LBSM Proces At014 en e

PlantPAx Logix Batch & Sequence Manager Application Techniques

FactoryTalk Batch, FactoryTalk View, FactoryTalk View Site Edition, FactoryTalk View SE, FactoryTalk View Studio, FactoryTalk View Studio Site

Edition, FactoryTalk Security, PhaseManager, Logix5000, RSLogix 5000, RSLinx Enterprise, Allen-Bradley, Rockwell Software, and TechConnect are

trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.


Contents Introduction ...................................................................................................................................................................5

Audience........................................................................................................................................................................5

Additional Resources.....................................................................................................................................................6

Requirements.................................................................................................................................................................6

Before You Begin..........................................................................................................................................................7

Install the Logix Infrastructure ......................................................................................................................................7

Logix Quick Start ..........................................................................................................................................................7

Incorporate the Logix Infrastructure into an Existing Logix Project .............................................................................8

Install the HMI Infrastructure......................................................................................................................................13

HMI Quick Start ..........................................................................................................................................................13

Incorporate the LBSM into an Existing HMI Application ..........................................................................................14

Set Up Security............................................................................................................................................................21

Modify Security Settings in an Existing HMI .............................................................................................................24

DLL Update.................................................................................................................................................................27

Configuration...............................................................................................................................................................28

Equipment Definition ..................................................................................................................................................28

Units ............................................................................................................................................................................28

Equipment Phases........................................................................................................................................................29

Example Equipment Definition ...................................................................................................................................30

Unit Configuration.......................................................................................................................................................31

Equipment Configuration ............................................................................................................................................32

Configure Master Sequences .......................................................................................................................................36

Edit Steps/Phases.........................................................................................................................................................38

Configure a Manual Phase...........................................................................................................................................40

Configure a Wait Phase ...............................................................................................................................................42

Insert and Delete Steps ................................................................................................................................................42

Connect to Equipment .................................................................................................................................................43


PhaseManager Interface ..............................................................................................................................................43

Bit Interface .................................................................................................................................................................48

Use the DN and State Bits ...........................................................................................................................................50

Runtime (operation).....................................................................................................................................................51

HMI Visualization and Navigation..............................................................................................................................51

Main Display ...............................................................................................................................................................51

Runtime Sequence Display..........................................................................................................................................52

Sequence Control.........................................................................................................................................................54

Operator Control..........................................................................................................................................................60

Phase Control...............................................................................................................................................................60

Equipment Control ......................................................................................................................................................64

Appendix A - Data Structure .......................................................................................................................................69

Appendix B - Bit Interface Examples..........................................................................................................................73


Introduction PlantPAx Logix Batch and Sequence Manager (LBSM) applications provide batch-process management

functionality, while requiring only a Logix controller and FactoryTalk View HMI for configuration and

execution. Although LBSM is best suited for single-unit systems with a finite number of recipes, the features

mirror those found in multi-unit, server-based systems, such as FactoryTalk Batch software. LBSM provides

recipe managements, manual/automated procedural control, and associated visualization.

The LBSM application’s ability to sequence equipment with or without Logix PhaseManager software

provides a platform that you can use in nearly any application, from process to packaging. Logix

PhaseManager software allows a seamless migration from LBSM to FactoryTalk Batch software.

Logix components include:

• user-defined data types (UDT).

• Add-On Instructions.

• tasks.

• tags.

HMT components include:

• displays.

• global objects.

• tags.

Audience You must be familiar with the ISA S88.01 Batch Control Standard. The LBSM is programmed in a way that is

similar to S88, by using equipment phases and a state model for your equipment.


Additional Resources These documents contain additional information concerning related Rockwell Automation products.

Resource Description

PhaseManager User Manual, publication LOGIX-UM001 Provides detailed information on how to define equipment phases.

FactoryTalk Batch PhaseManager User’s Guide, publication BATCHX-UM010

Provides information on how to develop a batch automation system with FactoryTalk Batch software and RSLogix 5000 software to develop phase logic for Logix5000 controllers.

Logix5000 Controllers General Instructions Reference Manual, publication 1756-RM003

Provides programmers with details about each available instruction for a Logix-based controller.

FactoryTalk View Site Edition User’s Guide, publication VIEWSE-UM006

Provides detailed information on how to use FactoryTalk View Site Edition software.

You can view or download publications at http://www.rockwellautomation.com/literature. To order paper

copies of technical documentation, contact your local Rockwell Automation distributor or sales

representative.

Requirements You need these components to use LBSM:

• Logix controller, firmware revision 17.0 or later

• RSLogix 5000 software, version 17.0 or later

• FactoryTalk View Site Edition software, version 5.1 or later


Before You Begin Extract the LBSM_Vx.x.zip file that was delivered with your LBSM application. This file includes these files.

Install the Logix Infrastructure The LBSM application is designed as a standalone starting point for projects and with add-on capability so

you can integrate it into your existing application. To integrate the LBSM application into your existing

application, depending on your project needs choose either the Quick Start option or the Incorporate into

Existing Logix Project option.

Logix Quick Start If you do not need to incorporate the LBSM application into an existing Logix project, you can begin with

one of the Logix projects provided with the LBSM application. The LBSM application provides these Logix

files:

• LBSM_Blank.acd contains the LBSM Logix components only.

• LBSM_Sample.acd contains the LBSM components along with preconfigured equipment and

sequences.


Incorporate the Logix Infrastructure into an Existing Logix Project Follow these steps if you incorporate the LBSM application into an existing Logix project.

1. Add the tasks, _PIs and _SQs, along with the program within the tasks, to your Logix project.

• The _PIs (procedural interfaces) task controls the execution of each phase.

• The _SQs (sequences) task controls the execution of each sequence.

• The routines within these tasks are written in structured text and the code is locked from the user.

a. In your Logix project, right-click the Tasks folder and choose New Task.

b. Create a new task called _PIs and set the configuration for the PI task to the following:

• Type = Periodic

• Period = 20…100ms (typical)

• Priority = Low (higher priority number)


c. Right-click the _PIs task and choose Import Program.

d. Browse for the PI.L5X file and click Import.


The Import Configuration dialog box appears.

e. Click OK.

f. Repeat the steps a through e for the _SQs task, using a period of 50…100 ms and the SQ.L5X

program file.

2. Import the EM_LBSM Add-On Instruction to your Logix project.

IMPORTANT: You must use the EM_LBSM Add-On Instruction in each equipment module that you create. This Add-On Instruction manages the equipment module modes and handshakes to the rest of the system. See the Configuration section for more information.

a) In your existing Logix project, right-click the Add-On Instructions folder and choose Import

Add-On Instruction.


b) Browse for and select the EM_LBSM.L5X Add-On Instruction and click Import.

The Import Configuration dialog box appears.

c) Click OK.


The controller scope tags in the Controller Scope Tags table are added to your Logix project. By default, these tags are available:

• One unit

• Ten equipment phases per unit

• Four master sequences per unit

Modify the array sizes, if necessary, to fit your needs. See the Configuration section for details on defining units, equipment phases, and sequences.

Controller Scope Tags

Name Data Type Array Size Array Description

_Equipment EQPI[x,y] x - max number of units

y - max number of phases

Stores equipment module and equipment phase details for each unit

_SQm SQConfig[x,y] x - max number of units

y - max number of master sequences

Stores master sequence details for each unit

_SQrt SQ[x] x - max number of units Stores run-time sequence details (one run-time sequence per unit)

_UN Unit[x] x - max number of units Stores unit details


Install the HMI Infrastructure The LBSM application is designed as a standalone starting point for projects and with add-on capability so

you can integrate it into your existing application. To integrate the LBSM application into your existing

application, depending on your project needs choose either the Quick Start option or the Incorporate into

Existing HMI Application option.

HMI Quick Start Use FactoryTalk View software if you do not need to incorporate LBSM into an existing HMI application.

1. To restore the LBSM.apa file with the FactoryTalk View Application Manager tool, choose

Start>Programs>Rockwell Software>FactoryTalk View>Tools>Application Manager.

2. Click Site Edition (Local), and then click Next.

3. Click Restore application, and then click Next.

4. Browse for and select the LBSM.apa file, and then click Next.


5. Type a name for the application, and then click Finish.

Incorporate the LBSM into an Existing HMI Application Follow these steps to incorporate the LBSM application into an existing FactoryTalk View SE application.

1. Add the global objects to your HMI application.

a) In FactoryTalk View Studio software, expand the Graphics folder in the Explorer window.

b) Right-click Global Objects and choose Add Component Into Application.


c) Browse for the three LBSM global objects as shown below.

d) Select all *.ggfx files and click Open.

2. Add the displays to your HMI application.

a) In FactoryTalk View Studio software, expand the Graphics folder in the Explorer window.

b) Right-click Global Objects and choose Add Component Into Application.


c) Browse for the LBSM displays as shown below.

d) Select all *.gfx files and click Open.

3. Add the HMI tags to your application.

a) In FactoryTalk View Studio software, from the Tools menu, choose Tag Import and Export Wizard.

b) From the Operation pull-down menu, choose Import FactoryTalk View tag CSV files.

c) Click Next.

d) From the Project type pull-down menu, choose Site Edition.


e) Browse for and select your FactoryTalk View SE project file, and then click Next.

f) Check Tags.

g) Browse for and select the LBSM-Tag Import File.csv file, and then click Next.

h) Click Skip existing (fastest), and then click Next.


4. Set up communication with your Logix controllers.

The LBSM application uses direct reference tags. A shortcut must exist in RSLinx Enterprise software

that is directed to the controller containing the LBSM tags. The default shortcut name used in the LBSM

application is LBSM_1. If you have installed the LBSM application in more than one controller, you need

to create a shortcut for each controller. This shortcut name is used as a parameter in several global

objects on the main display, as described in step 6 below.

5. Incorporate the LBSM main display into your application.

The main display is preconfigured with one ‘unit overview’ display. This unit overview display provides

runtime status for the unit, a button to call up the sequence control window, a button to call up the

runtime sequence detail, and buttons for configuring the unit name, the master sequences, and the

equipment. You can add additional overview objects if your application has more than one unit.

a) Resize the main display to meet your application’s full-size screen requirements.

This is the only graphic you need to resize. All other LBSM graphics are pop-up boxes that spawn

from this display or other global objects


b) Add navigation to the LBSM main display from an existing process screen or menu.

Each global object on the main display has two parameters; the first parameter is the shortcut name

and the second is the unit array position. The parameter values must be updated with the correct

shortcut name and unit index.

c) From FactoryTalk View Studio main display, right-click an object and choose Global Object

Parameter Values.

d) Replace parameter #101 with your shortcut name, if you used something other than LBSM_1, from

step 4 above.

e) Replace parameter #102 with the unit array position.


f) Repeat the steps a through f for all objects on the display.

There are six objects (shown below) in each unit overview ‘group’ that require this change.

6. Optionally, add a subset of LBSM buttons to your unit displays or overview graphics.

The main display is the home configuration for LBSM, but it is not intended to be the only link to LBSM.

For example, it may make sense for each unit graphic or overview graphic to contain the subset of

buttons below, providing sequence status and linking the unit to the runtime screens.


Set Up Security The LBSM application is preconfigured to use FactoryTalk Security codes (A through P). Global objects are

configured by using the PlantPAx HMI security standards shown in this table.

FactoryTalk View Security Codes (A through P)

Configuration

Nor

mal

Ope

ratio

n of

Dev

ices

Man

ual D

evic

e O

pera

tion

(n

on c

oord

inat

ed)

Equi

pmen

t Mai

nten

ance

Conf

igur

atio

n an

d Tu

ning

Mai

nten

ance

Engi

neer

ing

Conf

igur

atio

n

Ackn

owle

dge

Alar

ms

Supe

rvis

ory

Ope

ratio

ns

Disa

ble

Alar

ms

Byp

ass

Perm

issi

ves

and

Inte

rloc

ks

Spar

e

Nor

mal

Pro

duct

ion

(bat

ches

and

lots

)

Setp

oint

and

Par

amet

er O

verr

ide

Over

ride

/For

ce S

eque

nces

Proc

ess

Exce

ptio

n Ha

ndlin

g, A

dvan

ced

Prod

uctio

n

Nav

igat

e A

cros

s U

nits

/App

licat

ions

Shut

dow

n A

pplic

atio

n, O

pera

ting

Syst

em A

cces

s

Adm

in:

Secu

rity

, Use

rs, P

assw

ords

A B C D E F G H I J K L M N O P

Command equipment in Operator mode

X

Enter setpoints, control variables X Reset latched interlocks, restart equipment X

Add batch to batch list, run batches X Hold, restart batches, clear failures, bind, bind ack X

Acquire/lock and release equipment Operator mode X

Change Loop mode (manual, auto, cascade)

X

Acquire/release equipment Maintenance mode

X

Reset runtime accumulators X

Override inputs X

Bypass feedback X

Enable/disable device X Configuration (limits, constants, timers) X

Modify alarm delay times X

Tuning X

Change machine configuration X

Set up configuration (advanced) X Alarm configuration (ack required, reset required)

X

Put device in simulation X

Edit HMI application X


FactoryTalk View Security Codes (A through P)

Configuration

Nor

mal

Ope

ratio

n of

Dev

ices

Man

ual D

evic

e O

pera

tion

(n

on c

oord

inat

ed)

Equi

pmen

t Mai

nten

ance

Conf

igur

atio

n an

d Tu

ning

Mai

nten

ance

Engi

neer

ing

Conf

igur

atio

n

Ackn

owle

dge

Alar

ms

Supe

rvis

ory

Ope

ratio

ns

Disa

ble

Alar

ms

Byp

ass

Perm

issi

ves

and

Inte

rloc

ks

Spar

e

Nor

mal

Pro

duct

ion

(bat

ches

and

lots

)

Setp

oint

and

Par

amet

er O

verr

ide

Over

ride

/For

ce S

eque

nces

Proc

ess

Exce

ptio

n Ha

ndlin

g, A

dvan

ced

Prod

uctio

n

Nav

igat

e A

cros

s U

nits

/App

licat

ions

Shut

dow

n A

pplic

atio

n, O

pera

ting

Syst

em A

cces

s

Adm

in:

Secu

rity

, Use

rs, P

assw

ords


Acknowledge alarms X

Reset alarms X

Suppress alarms X

Disable alarms X

Modify alarm limits and deadbands X

Bypass permissives and interlocks X

Respond to prompt (level 1) X

Respond to prompt (level 2) X Exception processing (resume, manual, auto, semi-auto, pause, disconnect, release)

X

Exception processing (step change, parameter change, step, acquire, reorder, reactivate step)

X

Override downloaded setpoints X Override downloaded phase parameters X

Manual batch processing (stop, abort, reset phases) X

Manual supervisory EP/EM control X

Force steps/states X

Change inflights and preacts X

Force queue indexing X

Navigate to other units X

Shut down HMI application X Access Windows Start menu, Windows apps X

Change accounts/passwords X

Change security settings X


We recommend that you set up these security permissions for each group.

FactoryTalk View Security Codes (A

through P) Configuration

Nor

mal

Ope

ratio

n of

Dev

ices

Man

ual D

evic

e O

pera

tion

(n

on c

oord

inat

ed)

Equi

pmen

t Mai

nten

ance

Conf

igur

atio

n an

d Tu

ning

Mai

nten

ance

Engi

neer

ing

Conf

igur

atio

n

Ackn

owle

dge

Alar

ms

Supe

rvis

ory

Ope

ratio

ns

Disa

ble

Alar

ms

Byp

ass

Perm

issi

ves

and

Inte

rloc

ks

Spar

e

Nor

mal

Pro

duct

ion

(bat

ches

and

lots

)

Setp

oint

and

Par

amet

er O

verr

ide

Over

ride

/For

ce S

eque

nces

Proc

ess

Exce

ptio

n Ha

ndlin

g, A

dvan

ced

Prod

uctio

n

Nav

igat

e A

cros

s U

nits

/App

licat

ions

Shut

dow

n A

pplic

atio

n, O

pera

ting

Syst

em A

cces

s

Adm

in:

Secu

rity

, Use

rs, P

assw

ords


Typical Permissions

HMI operators X X X X HMI operating supervisor X X X X X

X X X X X

HMI maintenance X X X X X X X X X X X HMI maintenance supervisor X X X X X X X

X X X X X X

HMI manager X X X X X X X X X X X X X

HMI engineering X X X X X X X X X X X X X X

HMI admin X X X


Modify Security Settings in an Existing HMI There are two approaches to configuring runtime security settings in your HMI application.

• Security settings in your existing HMI application can be changed to match the table on page 19.

• LBSM global object-security configuration can be changed to match your existing application’s

security settings.

Follow these steps to change the runtime security settings in your existing application to match the table on

page 21.

1. In the FactoryTalk View Studio Explorer window, choose Runtime Security.

2. Click Security Accounts.

3. Expand the FactoryTalk View Security Codes and modify the settings for each user or user group.

Select the user.

Modify the permissions for that user.


Follow these steps to change the security settings, for multiple objects, to match your existing settings. Note that the visibility animation must be changed for the global objects. 1. In the FactoryTalk View Studio Explorer window, select a Global Object display.

2. Select all objects on the display and use tag substitution to change the security code.

Visibility animation is configured to use the built-in FactoryTalk View security function ‘CurrentUserHasCode(*)’, where ‘*’ represents the A-P security code. For example, the preconfigured security code for the advanced engineering configuration is ‘E’, per the table on page 19. If your HMI application uses security code ‘F’ for the advanced engineering configuration, replace ‘CurrentUserHasCode(E)’ with ‘CurrentUserHasCode(F)’.

3. Click Replace. 4. Repeat steps 2 and 3 for all three global object displays.


Follow these steps to modify the security settings for a single object. 1. Right-click the global object display and choose Animation. 2. Click the Visibility tab to open the Animation dialog box. 3. Right-click the object display and choose Object Explorer.

Use the Object Explorer to find the visibility animation for the object containing ‘CurrentUserHasCode(*)’.

4. Change the security code to match your application.

For more information about FactoryTalk Security software, including detailed set-up instructions, see the FactoryTalk Security Quick Start Guide, publication FTSEC-QS001.


DLL Update If you see gray hash boxes in the numeric entry faceplate, you need to update the FM20.dll file. Replace your

existing file located in C:\WINDOWS\system32 with the one included in the LBSM.zip file.


Configuration

Equipment Definition This equipment definition section offers guidance for system design and explains how the equipment in your

system correlates to the LBSM infrastructure.

Units The first step in configuring the LBSM application is to identify the units in your application. A unit is a

group of equipment that works together to perform a major processing activity, such as combining

ingredients. For example, a LBSM unit could be a mixer, blender, reactor, process skid, or continuous process

equipment. LBSM is configured by default for a single unit, but can be modified to accommodate additional

independent units per controller.

1. Identify the units in your application.

2. If more than one unit resides in a controller, assign each unit a unique index number, starting with

zero.

This number correlates your equipment with a specific array memory location in the controller.

3. If more than one unit is required, modify the array sizes for the LBSM controller tags by referring to

this table (where x represents the number of units).

Controller Scope Tags

Name Data Type Array Size Array Description

_Equipment EQPI[x,y] x - max number of units

y - max number of phases

Stores equipment module and equipment phase details for each unit

_SQm SQConfig[x,y] x - max number of units

y - max number of master sequences

Stores master sequence details for each unit

_SQrt SQ[x] x - max number of units Stores run-time sequence details (one run-time sequence per unit)

_UN Unit[x] x - max number of units Stores unit details


Equipment Phases The next step is to define the equipment phases in your application. An equipment phase commands the

equipment in a unit to perform a specific action. For example, add ingredient A, add ingredient B, and

dispense might be equipment phases for a mixing tank. The LBSM application is preconfigured to include up

to 10 equipment phases per unit, but can be modified to accommodate additional equipment phases.

IMPORTANT: Expanding the number of equipment phases applies to all units in the system. It is not on a per unit basis.

1. Identify the equipment phases required for each unit in your application.

2. Assign a unique index number to each equipment phase within the unit, starting with zero.

3. If more than 10 phases are required for a unit, modify the array size for the LBSM controller tag,

_Equipment, per the table on page 26 (where y represents the number of equipment phases).

4. Determine what sequence data for each equipment phase, if any, needs to be passed from the sequence

to the equipment or vice versa. The LBSM application allows for these types of data to be passed to and

from equipment:

• Command (data type Boolean) – Use the command to tell the equipment to perform its action.

IMPORTANT: The LBSM application uses one command per equipment. This is not user configurable.

• Real Parameters (data type real) – Use real parameters if the equipment phase needs to send a real

parameter value to the equipment, such as a setpoint. For each real parameter required for the phase,

assign a unique index number, starting with zero.

IMPORTANT: The LBSM application supports up to four real parameters per phase. This is not user configurable.

• Boolean Parameters (data type Boolean)– Use Boolean parameters if the equipment phase needs to

send a Boolean parameter value to the equipment, such as a mode selection. For each Boolean

parameter required for the phase, assign a unique index number, starting with zero.

IMPORTANT: The LBSM application supports up to four Boolean parameters per phase. This is not user configurable.

• Reports (data type real) – Use reports if the equipment needs to receive actual feedback from the

equipment, such as a process variable. For each report required for the phase, assign a unique index

number, starting with zero.

IMPORTANT: The LBSM application supports up to two real report parameters per phase. This is not user configurable.


Example Equipment Definition This is an example of how the equipment might be defined for an application with two premix tanks.

Units Equipment Phases Equipment Phase Command

Equipment Phase Real Parameters

Equipment Phase Boolean Parameters

Equipment Phase Reports

0 = Agitate Mix 0 = Speed setpoint 0 = Mode 0 = Actual speed

1 = Add Ingredient A Add 0 = Setpoint in kilograms

1 = Flow rate in kilograms/second

N/A 0 = Actual kilograms

2 = Add Ingredient B Add 0 = Setpoint in buckets N/A 0 = Actual buckets

0 = Premix Tank A

3 = Dispense Dispense N/A N/A 0 = Final amount in gallons

0 = Agitate Mix 0 = Speed Setpoint 0 = Mode 0 = Actual speed

1 = Add Ingredient A Add 0 = Setpoint in liters N/A 0 = Actual liters

2 = Add Ingredient B Add 0 = Setpoint in kilograms

1 = Flow rate in kilograms/second

N/A 0 = Actual kilograms

3 = Heat Vessel Heat 0 = Temperature in °C N/A 0 = Actual temperature

1 = Premix Tank B

4 = Dispense Dispense N/A N/A 0 = Final amount in gallons


Unit Configuration

From the Main display, click the unit configuration icon to display the Unit Configuration dialog box.

You must be logged in as a user with engineering configuration rights to modify the unit configuration.

You can configure these items from the Unit Configuration dialog box.

Item Definition

The name of the unit.

The unit number, if applicable. This is the unit number used to identify the equipment in your facility, not the unit index used in the controller array.

The unique ID is incremented each time a sequence is started for the unit. You can reset or modify this number from this dialog box.

IMPORTANT: To accept the data, you must press Enter after all string data entry.


Equipment Configuration Configure the LBSM equipment phases by using the Equipment Configuration HMI display.

From the Main display, click the equipment configuration icon .

You must be logged in as a user with

engineering configuration rights to modify equipment.

Refer to the Equipment Configuration table on the next page.


Equipment Configuration

Item Definition

Equipment phases are listed vertically along the left side of the display. The number of equipment phase boxes shown on the screen is automatically adjusted to match the controller array size for up to 20 phases. If additional phases are required, you will need to modify the screen.

Phase boxes without names are unused placeholders.

Click the phase box to edit the phase. The blue triangle indicates the phase currently being configured.

The name of the equipment.

The name of the phase. This is often the same as the equipment name, but separate configurations have been provided if want a different name for the phase.

For future enhancement.

For future enhancement.

For future enhancement. Keep value at 1.

Equipment Module Command Commands the equipment to perform its action. The command name and logic state descriptors can be configured from this window.

The equipment module code must be configured to interface with the LBSM command. Refer to Connect the Equipment on page 43 and Appendix A on page 69 for more details.


Item Definition

Real Parameters Real parameters are values that the equipment phase sends to the equipment module, such as setpoints. Up to four real parameters can be configured per phase. You can configure these items for each parameter.

Parameters can belong to the phase, the equipment module, or both.

You can change phase parameters from the phase configuration or run-time phase windows.

Equipment module parameters can be changed only from the run-time equipment module window.

Typically, a parameter belongs to the phase and the equipment module. There may be some cases where the parameters need to be different.

For example, the mode selection for an agitator (fast/slow) might be a phase parameter, but the actual speed setpoint, may be an equipment module parameter because it is typically set by maintenance personnel.

The name of the parameter.

The engineering units for the parameter.

The operational limits for the parameter. The low and high values limit the operator entries when configuring a step or manually controlling the equipment.

For example, you may set the high limit for a mixer speed to 300 if the mixer should not run faster than 300 rpm.

If the Scaled checkbox is checked, the parameter value will be scaled up or down when the scale factor for the sequence is changed from 100%. If left unchecked, the parameter value will remain the same when the sequence is scaled.

Default values are constants that can be set when values are not expected to be used by an operator, maintenance personnel, sequence, or formulation.

For example, you could change the temperature value to accommodate the physical equipment when commissioning. Large vats might require 10 degrees while small vats would require 2 degrees.

A default value is not considered a phase or an equipment module parameter. Leave the Phase and EM boxes unchecked if configuring a default value.

If you use real parameters, the equipment module code must be configured to interface with these LBSM parameters. Refer to Connect the Equipment on page 43 and Appendix A on page 69 for more details.


Item Definition

Boolean Parameters Boolean parameters are discrete values that the equipment phase sends to the equipment module, such as a mode selection. Up to four Boolean parameters can be configured per phase. You can configure these items for each parameter.

Parameters can belong to the phase, the equipment module, or both.

Phase parameters can be changed from the phase configuration or run-time phase screens.

Equipment module parameters can be changed only from the run-time equipment module screen.

Typically, a parameter will belong to the phase and the equipment module. Using the agitator example as described in the Real Parameters row above, the mode selection (fast/slow) would be a Boolean parameter belonging to the phase.


The logic state descriptor for the Off state.

The logic state descriptor for the On state.

Default is used for configurations that do not need to be accessed from a run-time window. The configuration can default to either the Off or the On state. In this case, the parameter would not be considered a phase or equipment module parameter.

If Boolean parameters are used, the equipment module code must be configured to interface with these LBSM parameters. Refer to Connect the Equipment on page 43 and Appendix A on page 69 for more details.

Report Parameters Reports are values that the equipment phase receives from the equipment modules. For example, the final amount of a material added by the equipment. You can configure these items for each parameter.

Similar to Real and Boolean parameters, Report parameters can belong to the phase, the equipment module, or both.

Phase parameters are displayed on the run-time phase windows. Equipment module parameters are displayed on the run-time equipment module window.



If required by the equipment phase, the equipment module code must be configured to interface with these LBSM parameters. Refer to Connect the Equipment on page 43 and Appendix A on page 69 for more details.


Configure Master Sequences

From the Units Overview object on the Main display, click the master sequence edit icon . This window

automatically adjusts based on the number of sequences configured in the controller array. The default

window supports 12 sequences. If you need more sequences, you will need to modify this window.

Choose a master sequence from the list. The master sequence configuration window appears.

The master sequence configuration display automatically adjusts based on the number of phases and steps

configured in the controller. The default window supports 20 phases with 24 steps.

Refer to the Master Sequence Configuration table on the next page.


Master Sequence Configuration

Item Description

The name of the sequence.

Sequence steps are listed horizontally across the top.

Equipment phases are listed vertically along the left side.

For each step in a sequence, the phase can either be inactive, active, or owned.

Inactive means the phase does nothing in the step. This is indicated by a grey box.

Active means the phase is executed in the step. This is indicated by a green square.

Owned means the sequence will acquire ownership of the phase without executing it. This might be used to pre-allocate an ingredient, so it will be available in the next step. Owned is indicated by a cyan circle.

When you click a step or phase intersection, the phase configuration window appears. However, if you are in the quick configuration window, the phase toggles between inactive, active, and owned for that step.

Use the boxes between steps to configure allowable pause points. Pause points are preconfigured points in between sequence steps where you have the option to pause the sequence. Once paused, you then have the option of skipping to the previous pause point, skipping to the next pause point, or resuming the sequence.

When checked, the sequence holds when a fault occurs. Otherwise, the sequence continues to run on fault.

Displays the master sequence quick configuration window. From the quick configuration window, click the phase or step intersection to toggle the phase between inactive, active, and owned for that step, rather than open the phase configuration window.

When checked, the insert/delete step icons are displayed. Refer to Inserting and Deleting Steps on page 42.


Edit Steps/Phases To modify a particular step in a sequence, click a phase or step intersection. The step edit/phase

configuration window then appears.

Refer to the Phase Configuration table on the next page.


Phase Configuration

Item Description

The step numbers are shown horizontally across the top of the window. The blue triangle indicates the step currently selected for configuration. Step numbers are highlighted in green if the phase currently selected for configuration is active in that step. Step numbers are highlighted in cyan if the phase currently selected for configuration is owned, but not active, in the step. To edit a different step, click the step number.

Equipment phases are listed vertically along the left side of the window. The number of equipment phase boxes shown is automatically adjusted to match the controller array size for up to 20 phases. If you need additional phases, you need to modify the window.

Phase boxes without names are unused placeholders.

Manual and Wait phases are preconfigured.

Click the phase box to edit the phase. The blue triangle indicates the phase currently selected for configuration.

Phases are highlighted in green if they are active for the step currently being configured. Phases are highlighted in cyan if they are owned by the step, but not active.

Enter a name for the step. The step name appears on the run-time sequence display when the step is active.

The amount of time allowed for a step to complete before a fault is issued.

If the sequence is held, the step timeout timer will be reset if this box is checked.

If the sequence can be paused during the step, check Step is Pausable.

A check in the Active checkbox indicates that the phase is active in that step. The Owned box is automatically checked when the Active box is checked because a phase cannot be active unless it is owned. If the phase is owned but not active in the step, clear the Active checkbox, and only check Owned.

The parameters in the working area of the window are configurations for that phase instance. You can change the value of the parameter by clicking the box containing the value, which opens the numeric keypad. Enter the new value and click OK.


Configure a Manual Phase In manual phase, you can preconfigure the LBSM application to prompt the operator and then wait for

operator input before processing the sequence. You can configure each instance of the manual phase to

include instructions for the operator, expected or desired values for selected parameters, and operator input.

Refer to the Manual Phase table on the next page.


Manual Phase

Item Description

Check Active to activate the manual phase for the step.

This message appears in the operator prompt.

Parameters Use parameters for listing expected or desired values in the operator prompt. Up to four parameters can be configured for each manual phase instance. You can configure these items for each parameter.

Check Enabled to make the parameter visible on the operator prompt.


The desired value for the parameter.


If you check Scaled, the parameter value is scaled up or down when the scale factor for the sequence is changed from 100%. If left unchecked, the parameter value remains the same when the sequence is scaled.

Operator Input Use the operator input when the operator needs to enter a response to the operator action.

Check Enabled to make the operator input visible on the operator prompt.

The name for the operator input.

If you check Required, the operator must enter a response before proceeding. If left unchecked, the operator chooses whether to enter a response before proceeding.


Configure a Wait Phase Use the preconfigured wait phase to force the sequence to stay in a step for a preset amount of time. For each

instance of the wait phase, you can configure a timer preset value. The wait timer counts down from the

preset value as soon as the step becomes active. You can also configure the timer to reset on hold, if desired.

Insert and Delete Steps To add or remove a step in a sequence, from the Master Sequence Configuration display, check Insert/Delete

Step Mode to reveal the insert/delete step icons. Click a + icon to insert a step between two existing steps.

Click a – icon to delete the existing step.


Connect to Equipment The LBSM application supports two equipment interfaces: a PhaseManager interface and a bit interface.

Depending on your equipment need, choose the appropriate interface. You can use either one or both in any

application.

PhaseManager Interface When using the PhaseManager interface, an interface routine must be added to each PhaseManager phase.

This interface routine translates general LBSM commands to PhaseManager commands. Repeat these steps

for each PhaseManager phase.

1. Right-click your Phase and choose Import Routine.

2. Browse for the LBSMIntfc.L5X file and click Import.


3. In the Import Configuration dialog box, select Tags.

4. Change the alias for ‘ThisPhase’ to the name of your PhaseManager phase.

5. From the Your_Phase_Name_Here Operation pull-down menu, choose Discard.

6. From the EP Alias For pull-down menu, choose the array element of the ‘_Equipment’ array that

corresponds to the unit and equipment phase instance for your phase.


7. Select Other Components and replace the Final Name with your PhaseManager phase name.

8. Click OK to import the configuration.

9. Configure the execution of the LBSM interface routine.

a) If your phase uses a Prestate routine, use JSR to the interface routine from the Prestate routine so

that it is executed every scan of the phase and prior to actual phase state execution.

b) If a separate Prestate routine is not needed, configure the interface routine as the Prestate routine in

the phase configuration.


I. Right-click your phase and choose Properties.

II. Click the Configuration tab.

III. From the Prestate pull-down menu, choose LBSMIntfc as the assigned Prestate routine.

The LBSM application allows both LBSM and FactoryTalk Batch applications to leverage the same

PhaseManager phase. Therefore, if inputs and/or outputs are used in your PhaseManager routines, they must

be mapped to corresponding LBSM parameters/reports.

These are the two methods for mapping PhaseManager inputs and/or outputs to the LBSM application:

• Direct Tag Aliasing

• Coded Mapping


Direct Tag Aliasing

The Direct Tag Aliasing method keeps a one-to-one relationship between the PhaseManager inputs and/or

outputs and the corresponding LBSM tags. However, this method requires that the PhaseManager input

and/or output data types match those of LBSM exactly. Alias input and/or output phase tags to the

corresponding _Equipment array data.

Existing Tag Data Type Alias for Description

YourInputTag_Bool BOOL _Equipment[x,y].PI.Parameters.Bools.# Map any Boolean input parameters to the LBSM Boolean parameters tag, where x=unit instance y=equipment phase instance #=Boolean parameter instance(0-3)

YourInputTag_Real REAL _Equipment[x,y].PI.Reals[#] Map any real input parameters to the LBSM real parameters tag, where x=unit instance y=equipment phase instance #=Real parameter instance(0-3)

YourOutputTag_Real REAL _Equipment[x,y].EQ.Actual.Reals[#] Map any output parameters to the LBSM output parameters tag, where x=unit instance y=equipment phase instance #=Actual report instance(0-1)

Coded Mapping

The Coded Mapping method allows separation between PhaseManager input and/or output tags and the

corresponding LBSM tags. You can match different data types, for example map a Real LBSM parameter tag

to a DINT PhaseManager input tag. This method also provides a mechanism to leverage the LBSM Boolean

tags for decisions on mapping to input and/or output tags. Map the input and/or output phase tags in the

first rung of the LBSMIntfc routine. In the first branch, replace the destination tags in the move instructions

with your phase input tags. In the second branch, replace the source tags in the move instructions with your

phase output tags.

IMPORTANT: Inputs are aliased to the .PI structure and outputs are aliased to the .EQ structure.


Bit Interface

The Equipment Bit Interface consists of a number of inputs and/or outputs used to control and monitor

your equipment when you’re not using PhaseManager software. In this equipment, lower level devices (such

as control modules) are configured to perform some predefined function as one piece of equipment, or

equipment module. This predefined Equipment Bit Interface provides a consistent way to connect custom

user-coded equipment to the LBSM application.

These are the LBSM bits used by the interface.

1. To begin using this interface, create a tag of type EM_Composite for each equipment module.

The tag naming convention is up to you.

2. Alias the equipment tag to the corresponding LBSM equipment tags at the controller scope.

Using the example from the Equipment Definition section, the Equipment tag name PremixA_Agitate is

aliased to _Equipment[0,0]. Refer to this table.

Unit Equipment Phase Alias

0=Agitate _Equipment[0,0].EQ

1=Add Ingredient A _Equipment[0,1].EQ

2=Add Ingredient B _Equipment[0,2].EQ

0=Premix Tank A

3=Dispense _Equipment[0,3].EQ

0=Agitate _Equipment[1,0].EQ

1=Add Ingredient A _Equipment[1,1].EQ

2=Add Ingredient B _Equipment[1,2].EQ

3=Heat Vessel _Equipment[1,3].EQ

1=Premix Tank B

4=Dispense _Equipment[1,4].EQ


3. Use the equipment tags created in step 1 to program each equipment module interface with these bits.

Member Data Type Notes Cmnd BOOL Boolean input that commands the EM to perform its primary

function. ParameterValues ParameterValues Inputs to the EM that can be modified from the HMI. For example,

setpoints. You can use a maximum of 4 real and 4 Boolean parameters.

HoldReq BOOL Boolean input that requests the EM to perform its Hold function. This could be to go to a known state or just stay where it is (do nothing).

ResetReq BOOL Boolean input that requests the EM to reset; put the EM into a known initial state, ready to run again.

State BOOL Boolean output that indicates that the EM is Off (0) or On (1). DN BOOL Boolean output that indicates that the EM has achieved its final

state. User program must always set this tag at some point in the operation of the EM.

Actual ActualValues Outputs from the EM that are used by the phase. For example, a control variable, such as temperature or speed. You can use a maximum of 2 real actual values.

ResetDN BOOL Boolean output that indicates that the EM has been reset caused by the setting of the ResetReq input.

Held BOOL Boolean output that indicates that the EM is in a state caused by the setting of the HoldReq input.

Fault BOOL Indicates an EM fault. Could be the OR’ed composite of all EM component faults.

Health BOOL Indicates bad EM health. Could be the OR’ed composite of all EM component health bits (like CM IO health bits).

IMPORTANT: Refer to Appendix A for details of the EM_Composite data type. Refer to Appendix B for several example applications.

4. Add an instance of the EM_LBSM Add-On Instruction to each equipment module.

The EM_LBSM Add-On Instruction manages the equipment module modes and handshakes to the rest

of the system. You must use this in each equipment module that you create.


Use the DN and State Bits The relationship between the DN and State bits is critical for the appropriate behavior of procedural handling

of equipment entities. There are two distinct behaviors that can occur: the equipment can complete (finish

and be released) or it can do what was asked of it and keep running.

Resolution is determined at the time that EM.DN=1; if EM.State=0 then complete, if EM.State=1 then

continue operation.

• Completion - The equipment accomplishes what was requested and completes the procedural manager.

When the EM.DN bit goes high, the EM.State bit is low. This combination of bits tells the engine that the equipment has finished what was requested (EM.DN=1) and is in a low state or de-energized (EM.State=0). Example: Ingredient Addition The equipment is to add a specified amount of an ingredient. EM.Cmnd=1 tells the equipment to perform its function. EM.State=1 to indicate that it is adding material. EM.State=0 to indicate that it is no longer adding material. EM.DN=1 to indicate that it is done (has added the requested amount and turned off).

• Finish action but keep running - The equipment accomplishes what has been requested but remains running. When the EM.DN bit goes high, the EM.State bit is high. This combination of bits tells the engine that the equipment has finished what was requested (EM.DN=1) and is in a high state or energized (EM.State=1). Example: Simple Agitation The equipment is to maintain an agitator at a specified speed. EM.Cmnd=1 tells the equipment to perform its function. EM.State=1 to indicate that it is running. EM.DN=1 to indicate that it is done (has attained the desired speed).


Note that user programming for a piece of equipment could change the behavior of the EM.State bit depending on its mode of operation. In this way the equipment could behave as one in a particular step, but as the other in another step.

Example: A Timed Agitator In one step it is desirable to use as a free running agitator that is stopped at the end of the step. In another step, it could be used in conjunction with a timer in the equipment to perform a precision timed agitation that would shutdown and complete when it was finished. In each case, the programming to set the EM.State bit would be different.

Runtime (operation)

HMI Visualization and Navigation

Main Display The LBSM main display provides sequence status, access to the sequence control window and the runtime

sequence display. You can access the unit, master sequence, and equipment configuration windows, but you

will not have permission to modify the configuration.

Item Description

Displays the unit name.

Identifies the sequence and step that is currently active for the unit along with its status (status indicators are shown to the right). Click this button to navigate to the sequence control window.

Navigates to the runtime sequence window.

Navigates to the unit configuration window.

Navigates to the master sequence edit selection window.

Navigates to the equipment configuration display.


Runtime Sequence Display

Click the magnifying glass icon from the main display to navigate to that unit’s detailed runtime

sequence display. Use the sequence display, shown below, to control the sequence, display the sequence

runtime activity, and display the sequence step configuration.

Item Description

Indicates the current sequence state. Click this button to call up the sequence state diagram, which also provides a key to the status indicators.

Saves the current sequence as master sequence.

Click this button to edit the currently running sequence.

Current sequence selected.


Item Description

Calls up the LBSM Runtime Help window, which provides details on the operations, commands, sequence state indicators, and equipment phase indicators.

Operation and Command Buttons

By default, sequences run at 100%. The scale factor lets you scale designated sequence parameters up or down.

The vertical axis displays the configured equipment and current phase status.

The horizontal axis displays steps. The sequence progresses sequentially through the steps, starting at the left with step 0 and working to the right.


Item Description

Double marks between the steps indicate allowable pause points, which are configured as part of the sequence.

Sequence Control You can control a sequence from the runtime sequence display as shown above or from the sequence control

window. Click the button below from the main display to navigate to that unit’s sequence control window.

Load a Sequence

To load a sequence, click the selection list icon

and then choose a sequence from the list of master

sequences. Once you load a sequence, it can be started many times and remain the runtime sequence until you

choose a new master sequence.


Start a Sequence

Click the start sequence icon to transition the sequence to the running state. You can only start a

sequence when it is in the Idle state. Each time a sequence is started, the unit’s unique ID is incremented.

When a sequence is started, the sequence display shows you a significant amount of information.

Click the sequence state for a key to these indicators:

• A rectangular outline highlights the current step.

• A green box indicates that the phase, in that step, is active.

• A black dot indicates that the phase, in that step, is complete.

• A green box with a black dot indicates that the phase has completed its actions but is still active.

Typically, this is for phases that are active across several steps, such as agitation.

• The indicators at the far left display the current phase state.


Hold a Sequence

When a sequence is running, the hold sequence icon is active. When you click this hold sequence icon,

all active phases are commanded to their respective hold states. The sequence can then be restarted, stopped,

or aborted.

Restart a Sequence

When a sequence is in the hold state, the restart sequence icon is active. Click this restart sequency icon

to restart the sequence from the step that was active at the time the hold was initiated.

Stop a Sequence

Click the stop sequence icon to perform an orderly shutdown of the sequence. This request must be

confirmed before the sequence will stop. Click Yes from the Confirm Operation dialog box shown below, to

shutdown the sequence. The sequence transitions to the Stopped state, which then commands each active

phase/equipment to its respective hold state. Click No to cancel the shutdown request.

Once stopped, click the reset icon to return the sequence to the Idle state.

Abort a Sequence

Click the abort sequence icon to perform an immediate shutdown of the sequence. This request must

be confirmed before the sequence will abort. Click Yes from the Confirm Operation dialog box shown

below, to abort the sequence. The sequence transitions to the Aborted state, which then commands each

active phase/equipment to its respective hold state. Click No to cancel the abort request.

Once aborted, click the reset icon to return the sequence to the Idle state.


Reset a Sequence

Once the sequence is complete, stopped, or aborted, the reset icon becomes active and the sequence

can be reset. Resetting the sequence returns the sequence to the Idle state.

Pause and Skip If you have configured allowable pause points for the sequence, they are indicated as shown below.

Click the pause request icon to request the sequence to stop at the next configured pause point.

When the sequence reaches the next configured pause point, the sequence pauses, and the step control icons

become active.


At this point, you can:

• click to skip to the previous pause point.

• click to skip to the next pause point.

• click to resume the sequence.

Once the sequence is resumed, it will not pause at a configured pause point until another pause request is

issued, or an auto pause is requested.

Click the auto pause request icon to request the sequence to stop at every configured pause point.

Click the cancel pause request icon to cancel the pause or auto pause request.

Manual Prompt If you have configured a Manual Phase in the sequence, the manual prompt request icon becomes active

during that step. The Manual Phase indicator blinks orange and the status indicator is orange with an

exclamation point, indicating that operator attention is required.


Click Manual or the respond to manual prompt request icon to display the

Prompt dialog box.

After reading and performing the actions indicated in the Prompt dialog box, click the checkmark icon

to acknowledge the prompt.

Wait Timer If you configured a Wait Phase in the sequence, the wait timer starts timing when the step becomes active.

The timer counts down from preset. The remaining wait time is displayed in seconds.


Operator Control The LBSM application provides operator control in a runtime environment to users with manual operation

security privileges.

Phase Control Authorized users can take control of a phase by clicking the equipment box, which will open the Phase

Control dialog box.

Item Description

Indicates the current state of the phase.

Click the release equipment icon to release the phase from operator control.

Click the acquire equipment icon to take ownership of the phase.

Command Buttons

Click the motor icon to open the equipment module control dialog box.

Indicates the system health for the phase (I/O fault indication).

Phase output parameters and their current values are displayed in this section.

Phase input parameters and their current values are displayed in this section.


Acquire a Phase

Click the acquire equipment icon to let authorized users take ownership of the phase. Once ownership is

acquired, the phase control icons become active and the input parameters are available for modification (as

indicated by a white background).

Modify Phase Parameters To modify an input parameter, click the parameter value to open the keypad entry dialog box. Enter a new

value and click OK.


Run a Phase

Click the start phase icon to transition the phase to the running state.

Hold a Phase

When a phase is running, the hold phase icon is active. When you click the hold phase icon, the phase

enters its hold state. The phase can then be restarted, stopped, or aborted.

Resume a Phase

When a phase is being held, the resume phase icon is active. Click the resume phase icon to restart the

phase.

Stop a Phase

Click the stop phase icon to perform an orderly termination of the phase. Click Press RESET to return

the phase to the Idle state.

Abort a Phase

Click the abort phase icon to perform an immediate termination of the phase. Click RESET to return

the phase to the Idle state.


Reset a Phase

Once the phase is complete, stopped, or aborted, the reset icon becomes active and the phase can be

reset. Resetting the phase returns the phase to the Idle state.

Release a Phase

Click the release equipment icon to release the phase from operator control.


Equipment Control Click the motor icon on the phase control dialog box to let authorized users take control of equipment. Once you have

control of the equipment, the Equipment Module dialog box opens.

Item Description

Equipment Module on/off indication.

Indicates when the Equipment Module is done.

Click the release equipment icon to release the equipment from operator control.

Click the acquire equipment icon to take ownership of the equipment.

Command Buttons

Equipment output parameters and their current values are displayed in this section.

Equipment input parameters and their current values are displayed in this section.

Indicates the system health for the equipment (I/O fault indication).

Indicates the current state of the equipment.


Acquire Equipment

Click the acquire equipment icon to let authorized users take ownership of the equipment. Once

ownership is acquired, the equipment control icons become active and the input parameters are available for

modification (as indicated by a white background).

Modify Equipment Parameters To modify an input parameter, click the parameter value to open the keypad entry dialog box. Enter a new

value and click OK.

Run the Equipment

Click the start icon to run the equipment module. You cannot modify input parameters while the

equipment module is running.

Stop the Equipment

Click the stop icon to stop the equipment module.


Hold the Equipment

When the equipment module is running, the hold equipment icon is active. Click the hold icon to hold

the equipment. The dialog box indicates that the equipment is being Held. The equipment module can then

be restarted, stopped, or reset.

Reset the Equipment

Click the reset icon to reset the equipment module.

Release the Equipment

Click the release equipment icon to release the equipment from operator control.


Configure Runtime Sequences You can modify runtime sequences in the same manner as described in the Configure Master Sequence

section. There are two main differences between configuring a master sequence and configuring a runtime

sequence.

• You can insert and delete steps only when the sequence is in the Idle state.

• Changes applied to the runtime sequence are not applied to the master sequence unless they are

saved to the master sequence.

To save the runtime sequence as the master sequence, click the save icon and then choose a

master sequence to replace with the current running sequence.


Notes:


Appendix A - Data Structure The LBSM application interfaces to your equipment through a tag named _Equipment. This tag is an array

composed of two data types, EM_Composite and PIDefinition. These data types store the configuration for

your equipment phase instances. The objects on the Equipment Configuration dialog box align with the

members of this array. For example, the equipment phases for the first unit (unit 0) would align with the

_Equipment array as indicated below.

Expanding _Equipment[0,0] reveals how the _Equipment array aligns with several other objects on the

Equipment Configuration dialog box for the first phase instance of the first unit instance [0,0].


The EM_Composite member of the _Equipment array provides the interface between the LBSM application

and your equipment. Your equipment module code must be configured to interface to these tags. The details

for each member of the EM_Composite data type are shown in the table below. Examples for programming

the interface are shown in Appendix B.

EM_Composite Data Types

Member Data Type Notes

EquipmentName Name Equipment name that is displayed on the HMI.

Display Name For future enhancement.

EMProgReq BOOL Boolean input that requests the Equipment Module go to Program mode. This input is used by the EM Add-On Instruction.

EMOperReq BOOL Boolean input that requests the Equipment Module go to Operator mode. This input is used by the EM Add-On Instruction.

CMReq BOOL Boolean input that requests the CMs go to Operator mode. This input is used by the EM Add-On Instruction.

Cmnd BOOL Boolean input that commands the EM to perform its primary function.

CmndName ParameterBool Name of the command issued by the phase for display on the HMI equipment.

ParameterEnable DINT Enabling a parameter makes it active for the equipment module. This corresponds to EM enable on the equipment configuration dialog box.

ParameterNamesReal ParameterReal[4] Names of the Real parameters for display on the HMI equipment.

ParameterNamesBool ParameterBool[4] Names of the Boolean parameters for display on the HMI equipment.

ParameterValues ParameterValues Inputs to the EM that can be modified from the HMI. For example, setpoints.

ActualEnable DINT Enabling an actual value (or report value) makes it active for the equipment module. This corresponds to EM enable on the equipment configuration dialog box.

ActualNamesReal ParameterReal[2] Names of the values reported to the phases for display on the HMI equipment.

Ownership Own For future enhancement.

HoldReq BOOL Boolean input that requests the EM to perform its Hold function. This could be to go to a known state or just stay where it is (or do nothing).

ResetReq BOOL Boolean input that requests the EM to reset; put the EM into a known initial state, ready to run again.



NewParms BOOL Set by a supervisory entity when new parameters are given to the EM. User program must always reset this tag (set to zero). * Used as a handshake for upper level supervisors (so they know the EM executed).

EMProg BOOL Boolean output that indicates the EM is in Program mode. * The EMProgReq/EMProg interaction is used by the Running routine of the phase to determine the appropriate EM access mode for operation.

EMOper BOOL Boolean output that indicates the EM is in Operator mode. * The EMOperReq/EMOper interaction is used by the Running routine of the phase to determine the appropriate EM access mode for operation.

EM BOOL Boolean output that indicates the EM is in the EM mode.

CM BOOL Boolean output that indicates the EM is in the CM mode.

State BOOL Boolean output that indicates that the EM is Off (0) or On (1). Indicates that the EM is performing its primary function as in response to a Cmnd=1. * Used by the Stopping routine in the phase to determine when the EM is in the user-definable Off or On state.

DN BOOL Boolean output indicates that the EM has achieved its final state. User program must always set this tag at some point in the operation of the EM. Every EM has a condition or state that is considered its final condition or state. You must define that condition for an individual EM and appropriately condition the DN bit. EMs that ‘Run til Done’ set the DN bit when its objective is achieved. For example, ‘automatically metered ingredient add’. EMs that ‘Run til Stop’ set the DN bit immediately or constantly. For example, ‘agitator’. EMs that ‘Run til Done, Continue til Stop’ set the DN bit when its objective is achieved. For example, ‘Slow reacting temperature loop’ (it is ‘DN’ when at SP but continues to regulate until told to stop). The DN must be reset whenever the Cmnd bit is low. The DN could go low as the result of receiving new parameters indicating a new objective, as defined by user logic. *The Cmnd/DN interaction tells a Phase that the EM has performed the requested action. The phase sets the Cmnd and waits to see a DN to know that the EM has performed the requested action.



Actual ActualValues Outputs from the EM that are used by the phase. For example, a control variable, such as temperature or speed.

ResetDN BOOL Boolean output that indicates that the EM has been reset. The ResetDN is reset whenever the ResetReq is low. * The ResetReq/ResetDN interaction is used by the Resetting routine of the phase to determine that the EM has been reset.

Held BOOL Boolean output that indicates that the EM is in a state caused by the setting of the HoldReq input. Held is reset whenever HoldReq is low and the EM has resumed normal operation. * The HoldReq/Held interaction is used by the Holding and Restarting routines of the phase to determine that the EM is in the correct states.

Fault BOOL Indicates an EM fault. Could be the OR’ed composite of all EM component faults.

Health BOOL Indicates bad EM health. Could be the OR’ed composite of all EM component health bits (like CM IO health bits).

MyIndex DINT Set automatically by the LBSM code.

MyUnit DINT Set automatically by the LBSM code.

AcquisitionTO FBD_TIMER This timer, which starts when ownership of the EM is requested, is used for acquiring ownership of the EM. If ownership is not confirmed within this amount of time, a fault is issued.

CmndTO FBD_TIMER This timer, which starts when the command is issued, is used for completion of a command. If the command is not completed within this amount of time, a fault is issued.


Appendix B - Bit Interface Examples The following examples illustrate the basic usage of the bit interface for a user not using PhaseManager

software.

‘Add Ingredient’ Example An ingredient addition function may be comprised of a single valve or the combination of a pump, valve, and

totalizer. Either way, you must define these functions:

• How much ingredient to add (ParameterValue)

• When to go (Cmnd=1)

• When to temporarily suspend its operation, if needed (HoldReq=1)

• When to stop (Cmnd=0)

• When to reset any persistent functionality (ResetReq=1)

You need to monitor these activities:

• The group is actively functioning or energized (State)

• The group accomplishes what you requested (DN)

• How much ingredient it actually adds (ActualValue)

• When it achieves a temporary suspension of activity (Held)

• When it resets its internal functions (ResetDn)

• Whether any device faults occur (Fault)


‘He Who Finishes’ Example This example uses a timer as the equipment.

The functionality of this piece of equipment is what would be required of any equipment that would run and

finish on its own (and ‘Complete’ a commanding phase). Usually this type of equipment is used in one step

and its functionality does not span contiguous steps, although it could span contiguous steps in non-

continuous operation.

This type of equipment must be reset before running again.

‘Ingredient Add’ is an example of this type of equipment.

This equipment has these specifications.

Input Time in milliseconds to run (timer.PRE)

Output Accumulated time (timer.ACC)

Runtime functionality When the Cmnd bit is set, run the time. Set the State bit while the timer is running (timer.ACC=1). Set the DN bit when the timer is done (timer.DN=1).

Hold functionality When the HoldReq bit is set, hold the timer where it is and set the Held bit.

Reset functionality When the ResetReq bit is set, reset the timer (and set the ResetDN.bit).

NewParms functionality Not used because the intent of this equipment functionality is to run once and complete (requiring a reset and another start to run again).

Function Block Cmnd/State/DN

Inputs/Outputs


ResetReq / ResetDN

HoldReq/Held

Ladder Logic Cmnd/State/DN


Inputs/Outputs


ResetReq/ResetDN


HoldReq/Held

Structured Text Cmnd/State/DN


Inputs/Outputs

ResetReq/ResetDN

HoldReq/Held


‘He Who Must Be Stopped’ Example This example uses a timer as the equipment.

The functionality of this piece of equipment is what would be required of any equipment that would run and

continue until commanded to stop (and would not ‘Complete’ the phase). This type of equipment can be

used in one or more steps and its functionality could span contiguous steps in an uninterrupted fashion.

This type of equipment does not need to be reset before running again.

Examples of this type of equipment include Continuous Agitation and Temperature Control.


Input Time in milliseconds to quality as DN (timer.PRE).

Output Accumulated time (timer.ACC).

Runtime functionality When the Cmnd bit is set, run the timer. Set the State bit while the Cmnd bit is set. Set the DN bit when the timer is done (timer.DN=1).

Hold functionality When the HoldReq bit is set, hold the timer where it is if it has not yet completed (and set the Held bit).

Reset functionality When the ResetReq bit is set, reset the timer (and set the ResetDN bit).

NewParms functionality When the NewParms bit is set, the timer should be reset. This is because in the course of automatic control with a phase, this type of equipment could be given new parameters in another step without stopping. NewParms tells the equipment that is has new parameters and must accommodate them. It is possible that the equipment can respond to the new parameters instantly. In this case, the NewParms bit is not needed.


Function Block

Ladder Logic


Structured Text


‘He Who Could Be Either’ Example This example uses a timer as the equipment.

The functionality of this piece of equipment is what would be required of any equipment that would execute

as either of the previous two, selected by a parameter. This type of equipment can be used in one or more

steps and its functionality could span multiple contiguous steps in an uninterrupted fashion.

This type of equipment may need to be reset before running again.

Examples of this type of equipment include Timed/Free Agitation.


Input Time in milliseconds to quality as DN (timer.PRE). The mode (0-Timed, 1-Free Running).

Output Accumulated time (timer.ACC).

Runtime functionality When the Cmnd bit is set, run the timer. Set the State bit while the Cmnd bit is set. Set the DN bit when the timer is done (timer.DN=1).

Hold functionality When the HoldReq bit is set, hold the timer where it is if it has not yet completed (and set the Held bit).

Reset functionality When the ResetReq bit is set, reset the timer (and set the ResetDN bit).

NewParms functionality This is not used because the intent of this equipment functionality is to run once and complete (requiring a reset and another start to run again). When the NewParms bit is set, the timer should be reset. This is because in the course of automatic control with a phase, this type of equipment could be given new parameters in another step without stopping. NewParms tells the equipment that is has new parameters and must accommodate them. It is possible that the equipment can respond to the new parameters instantly. In this case, the NewParms bit is not needed.


Function Block

Ladder Logic


Structured Text


Notes:

LBSM Proces At014 en e

Documents

Transcript of LBSM Proces At014 en e