RSTechED 2011

(PR07) PlantPAx - System Engineering

Copyright 2009 Rockwell Automation, Inc.

2 of 92

PR07 PlantPAx System Engineering

Contents
Before you begin ......................................................................................................................................... 5 About this lab ................................................................................................................................................ 5 Tools & prerequisites .................................................................................................................................... 5 The PlantPAx Automation System ............................................................................................................ 6 The PlantPAx Core ....................................................................................................................................... 7 Goals of this Class ........................................................................................................................................ 7 Format of this Class ...................................................................................................................................... 8 The Mix Application .................................................................................................................................... 9 Project Documents ...................................................................................................................................... 10 Lab Setup ................................................................................................................................................... 14 RSLogix Emulate5000 and the Logix Processors ...................................................................................... 14 The FTViewSE Operator Client window and process application .............................................................. 15 Security and User Logins ............................................................................................................................ 16 The Process Library.................................................................................................................................. 17 Controller Layout ......................................................................................................................................... 19 Adding a Control Valve (XV8000) to the Controller .................................................................................... 20 Adding XV8000 to the HMI.......................................................................................................................... 32 Interacting with XV8000 online ................................................................................................................... 39 Importing / Exporting Devices On the Fly ............................................................................................ 44 Exporting A Routine .................................................................................................................................... 44 Importing A Routine .................................................................................................................................... 46

3 of 92

Building Large Projects ............................................................................................................................ 49 Our Workflow .............................................................................................................................................. 49 Using Our Workflow .................................................................................................................................... 51 Adding Visualization .................................................................................................................................... 62 Building a System ..................................................................................................................................... 85 Interlocks and Permissives ......................................................................................................................... 85 Adding Interlocks and Permissives ............................................................................................................. 86 Customizing the System ............................................................................................................................. 92

Before you begin

About this lab

This class guides you through the steps involved in building a real world Process Control Application. We will focus on the PlantPAx Core Components. This lab takes approximately 100 minutes to complete.

Tools & prerequisites

Factory Talk View SE, V5.1 RSLogix 5000, V18 RSLogix Emulate 5000, V18

5 of 92

The PlantPAx Automation System

These system elements allow flexible and scalable system configurations to be created. These configurations can range from small unit, equipment or lab process applications to large plant wide and highly-distributed applications. In this class we will focus exclusively on the PlantPAx Core. Specifically we will focus on building and designing PlantPAx Core Systems.

The PlantPAx Core

The PlantPAx core is the heart of a PlantPAx System. Based on Integrated Architecture automation products, the core system can be extended through the addition of optional functions such as Batch, Historian, or Asset Management while providing the capability to meet critical process control, availability and safety requirements. The PlantPAx core system supports typical process control configurations based on the Purdue CIM model and ISA system standards (S88, S95, and S99). PlantPAx Core Functions Engineering Development Environment System Wide Visualization Process Control

PlantPAx Core Components CLX Controllers HMI Server FT Directory Services

The core itself is scalable and may consist of one HMI and Controller pair or multiple controllers. A basic system may only consist of core components.

Goals of this Class

This class will focus on the tasks involved in building a Process Control System using the Process Core. While a PlantPAx Core System will be sufficient for many applications, others will require the addition of additional PlantPAx modules to provide the required functionality. The important thing to note is that both the PlantPAx Core itself and a larger PlantPAx system can be scaled to your specific needs.
7 of 92

This class will illustrate how quickly a high quality Control Application can be developed using the PlantPAx Process Library.

Format of this Class

This class is broken into 4 Sections. In the first Module we will introduce the User to the PlantPAx System Core. In the subsequent sections, you will get to build control modules using the Process Library. We will then look at ways to streamline the development process

The Mix Application

This class guides the user through the steps involved in building a real world Process Control and Visualization Application. The Scenario An addition has been made to our plant. This addition will be known as the Mix Area and consists of 2 Mix Tanks and associated equipment.
FQ XV 8000 8000 XV 8001 F FIT8000

Material 1

FQ XV 8002 8001 XV 8003 F FIT8001 LT 8000 MTR8000 LI 8000

Material 2

LI 8100

TT 8000

TT 8100

MTR8100

LT 8100

PIC 8100
Mix Tank T8000 LSL 8000 Storage Tank T8100 LSL 8100 PT 8100 XV 8100 5 PMP8000

XV 8004

Plant
PMP8100 VLV8100

[NOTE There is a larger view on the Next Page]

As is customary, the design team has communicated these additions by issuing a P&ID Document along with electrical schematics. (see next page) In production, specific quantities of Material 1 and 2 will be mixed in T8000 and then transferred to Storage Tank T8100. From here, it is fed to the Plant. Using elements from the Process Library we will insert the controller code and Visual Elements needed to control the individual system elements. We will then add the safety interlocks and permissives to the system. Initially, this class will focus on making minor changes online (on the fly) without interrupting the operations of your plant. Later, we will demonstrate how efficiently a large scale system can be built. NOTE - All the code required to simulate this equipment has already been added to this application. The user only has to tie in the various modules to the Generic IO to implement the project.

9 of 92

Project Documents

FQ XV 8000 8000 XV 8001 F FIT8000

Material 1

FQ XV 8002 8001 XV 8003 F FIT8001 LT 8000 MTR8000 LI 8000

Material 2

LI 8100

TT 8000

TT 8100

MTR8100

LT 8100

PIC 8100
Mix Tank T8000 LSL 8000 Storage Tank T8100 LSL 8100 PT 8100 XV 8100 5 PMP8000

XV 8004

Plant
PMP8100 VLV8100

24V C

24V + IN0 IN0

XV8000

IN0

IN0

XV8000 CLOSED LS XV8000 OPENED LS XV8001 CLOSED LS XV8001 OPENED LS XV8002 CLOSED LS

IN1

XV8001

IN1

IN2

XV8002

IN2

IN3

XV8003

IN3

XV8004
IN4 IN4

XV8100
IN5 IN5

XV8002 OPENED LS XV8003 CLOSED LS

IN6

MTR8000 RUN
IN6

MTR8100 RUN
IN7 IN7

XV8003 OPENED LS

IN0

IN0

PMP8000 RUN
IN8 IN8

XV8004 CLOSED LS XV8004 OPENED LS XV8100 CLOSED LS XV8100 OPENED LS

PMP8100 RUN
IN9 IN9

SPARE
IN10 IN10

SPARE
IN11 IN11

SPARE
IN12 IN12

MTR8000 RUNNING MTR8100 RUNNING

IN13

IN13

SPARE

IN14

SPARE

PMP8000 RUNNING
IN14

PMP8100 RUNNING
IN15

SPARE

IN15

24V C IN0

24V +

[NOTE - These Electrical Schematics are deliberately generic]

11 of 92

FROM DRIVE
IN0 IN0 IN0 IN0

MTR8000 Speed
IN1 IN1

FT8001

FROM DRIVE

IN2

IN2

MTR8100 Speed
IN3 IN3

SPARE

IN4

IN4

TT8000
IN5 IN5

SPARE

IN6

IN6

TT8100
IN7 IN7

SPARE

IN8

PT8100

IN8

SPARE

IN9

IN9

IN10

LT8000

IN10

SPARE

IN11

IN11

IN12

LT8100

IN12

SPARE

IN13

IN13

IN14

FT8000

IN14

SPARE

IN15

IN15

24V +

[NOTE - These Electrical Schematics are deliberately generic]

Remote_08_01_O 0 XV8000 Open 1 XV8001 Open 2 XV8002 Open 3 XV8003 Open 4 XV8004 Open 5 XV8100 Open 6 MTR8000 Run 7 MTR8100 Run 8 PMP8000 Run 9 PMP8100 Run 10 Spare 11 Spare 12 Spare 13 Spare 14 Spare 15 Spare Remote_08_02_I 0 XV8000 Closed LS 1 XV8000 Opened LS 2 XV8001 Closed LS 3 XV8001 Opened LS 4 XV8002 Closed LS 5 XV8002 Opened LS 6 XV8003 Closed LS 7 XV8003 Opened LS 8 XV8004 Closed LS 9 XV8004 Opened LS 10 XV8100 Closed LS 11 XV8100 Opened LS 12 MTR8000 Running 13 MTR8100 Running 14 PMP8000 Running 15 PMP8100 Running

Remote_08_03_AI 0 MTR8000 Speed Feedback 1 MTR8100 Speed Feedback 2 TT8000 Sensor Reading 3 TT8100 Sensor Reading 4 PT8100 Sensor Reading 5 LT8000 Sensor Reading 6 LT8100 Sensor Reading 7 FT8000 Sensor Reading Remote_08_04_AI 0 FT8001 Sensor Reading 1 Spare 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare Remote_08_05_AO 0 MTR8000 Speed Reference 1 MTR8100 Speed Reference 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare

Remote_08_06_I 0 LSL8000 1 LSL8100 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 9 Spare 10 Spare 11 Spare 12 Spare 13 Spare 14 Spare 15 Spare

13 of 92

Lab Setup

Make sure you are on the Batch Management & Control image. You can confirm this by looking for the image name Batch Management & Control on the dropdown in the middle upper of the desktop.

If you need to switch images, select the Batch Management & Control tab.

Or use the blue-arrow button at the top of the screen.

RSLogix Emulate5000 and the Logix Processors

RSLogix Emulate5000 should already be running and contain two Logix processors. Click on the button in the Windows toolbar at the bottom of the screen to open and view the RSLogix Emulator chassis.

The controller files for the Batch Area and the Utilities Area have already been loaded into the two processor modules in slots 3 and 5 respectively. Make sure both the processor modules are in Run mode. If they are not then place them in Run mode by right-clicking on the module and using the pulldown menu.

14 of 92

NOTE: Throughout this lab if any processor seems to fail or lock-up, right-click on the processor and clear the Major Fault(s) and place it back into Run mode.

The FTViewSE Operator Client window and process application

The FactoryTalkViewSE Operator Client window should already be running. Click on the Windows toolbar button at the bottom to open the Operator Client window

The HMI will appear as follows after launching the SE Client. (Note: the initial screen might need to be refreshed. Refresh by clicking the button in the upper right of the display.

The process application consists of a Premix vessel, two Reactor Vessels and Storage Tanks with Batch control, and a Utilities area with two Utility Boilers, a Condensate area and Feed water system. You can

navigate to different areas of the plant using the navigation button bar and the pull-down menu buttons. This application has been built using the PlantPAx Process Library of pre-defined Faceplates and graphics Objects. The lab will focus on adding logic and graphic display elements for the Mix area.

15 of 92

Each PlantPAx Process Library element consists of an AOI (Add-On Instruction) which is embedded in the Control Logix application processors and a collection of associated graphics objects. The graphics objects, when placed in a HMI application, can be used to launch a faceplate. The faceplate provides an operator, maintenance technician, or engineer with all the functionality he will need to manipulate and configure the devices. If you have time, take a few minutes to browse the HMI application. In particular feel free to click on individual valves, pumps, and sensors and observe the faceplates and faceplate tabs.

Security and User Logins

Click on the security key in the top right corner of the screen to login as an Engineer.

On the login window enter eng for the User Name and engineer for the password. Click OK. You will now be logged in as an engineer (as indicated at the bottom right of the screen). Click on the Help button in the top right corner of the screen for a list of user ids and passwords. The Help button shows you all of the configured users and passwords in this lab application.

The device pop-up faceplates in this application have an Operator tab for device control (start/stop, open/close, modes, setpoints), a Maintenance tab for overiding of interlocks/ permissive and disabling the device, and an Engineering tab for device and alarm configuration. The features and buttons on the various tabs are only active with the proper user login. This lab will focus on the engineering functions available from the pop-ups. You are now ready to proceed with this Lab!

16 of 92

The Process Library

Throughout this Lab we will be using the Process Library. The Process Library consists of a collection of Ready to Use, Device Level Control Modules. These consist of Application Code developed within Add On Instructions (AOIs), Graphic Objects (which will be displayed on your HMI) and Faceplates for operator and/or engineering interface to the device logic.

Application Code

Contains the code which controls the associated device. This code is embedded in an AOI which can be instantiated multiple times in a given application. The Process Library AOIs can be found in the AOI Section of the Controller Tree.

Graphic Objects

The Graphic Objects are used to build HMI Displays. There is a selection of Global Objects available for each Process Library Element. These Global Objects can be imported into displays and provide visual feedback to the user. Clicking on these devices will launch the associated Faceplate. The Process Library Global Objects can be found under the Global Objects Tab of the FactoryTalk View Studio application.

17 of 92

Faceplates

Faceplates automatically launch when you click on the Graphic Object in a Display. They are used to display detailed information relating to a device. They provide the user with the ability to reconfigure the device. These faceplates incorporate security features which restrict a users ability to configure and manipulate devices. The Faceplates are associated with Graphic Objects and do not need to be individually configured.

The Process Library consists of the following, P_AIN P_AInAdv P_AInDual P_Alarm P_AOut P_Din P_DoseFM P_DoseWS P_Intlk P_Mode P_Motor2Speed P_Motor P_MotorHO P_MotorRev P_Perm P_Reset P_ResInh P_RunTime P_ValveHO P_ValveMO P_ValveSO P_VSD Analog Input Advanced Analog Input Dual Analog Input Alarm Analog Output Digital Input Flow Dosing Weigh Dosing Interlock Mode 2 Speed Motor Single Speed Motor Hand Operated Motor Reversing Motor Permissive Reset Reset Inhibit RunTime Hand Operated Valve Motor Operated Valve Solenoid Operated Valve Variable Speed Drive

This Lab will illustrate how easy it is to assemble Process Library Components into an Application. Each module can be replicated many times in your application. Each time you instantiate an object you inherit all the functionality associated with it. In addition, each instance of the modules can be configured for your particular needs.

18 of 92

Controller Layout
Throughout this Lab Section we will be working with RSLogix 5000 Software. This application will be open on your PC. Select this application and view the Project Tree along the left hand side. The application PlantPAx_Cont_Master should be open and online with the Emulator Controller. We have chosen to organize the application by Functional Areas (Tasks\Programs) and Devices (Routines). We have created the task _8000_Mix to contain the code that will control the Mix Area. This is an Event Task which is triggered from the MainTask every 250ms.

19 of 92

Adding a Control Valve (XV8000) to the Controller

In this section we will add a Control Valve to our application. We will make use of the P_ValveSO Device from the Process Library. Initially, we will insert the AOI in the Logix ACD file. Later, we will add the associated Visualization elements to the HMI. (Graphical Object and Faceplate) We have divided the Mix Area into 2 functional sub-areas, _8000_MixTank and _8100_StorageTank

We wish to add XV8000 to our application. This element will be added to the _8000_MixTank program. To do this, 1. Expand the _8000_Mix Task and the component Program _8000_MixTank. Right click on the Program icon and click on New Routine

2. The New Routine window will open. The new routine should be named XV8000 and should be of Type Function Block Diagram. Click on OK

20 of 92

3. The Routine XV8000 will now be created. Double click on the routine to open it.

4. Click on the Start Pending Routine Edits Button (at the top of the sheet) to enable edits. This is necessary as we are currently online with the controller in Run Mode.

5. Right Click on the Sheet to access the Edit Menu, Select Add Element

21 of 92

6. The Add FBD Element Popup will appear. Type in P_ValveSO as shown below. P_ValveSO is an element of the Process Library and is used to control a Solenoid Valve such as XV8000. Click OK.

7. A P_ValveSO instruction has now been placed in the FBD Sheet. To access its properties click the properties button.

Properties Button

22 of 92

8. We wish to make the PCmd_Acq, Cfg_UseClosedLS and Cfg_UseOpenLS visible so they can be manipulated by the program. Make these parameters visible by clicking the visibility checkbox associated with each parameter. Click on Apply and OK

[Note The parameters are listed in alphabetical order. Cfg_UseClosedLS and Cfg_UseOpenLS are located near the top of this list. PCmd_Acq is about half way down] 9. Map the instruction to the backing tag XV8000. Each specific instance of an AOI has a dedicated Backing Tag which is used to store data associated with the specific instance of the AOI. To map the tag, double click on the P_ValveSO_01 tag and type in XV8000and then hit the Enter key.

23 of 92

10. After the TAG has been entered, Right Click on the Tag (XV8000) to access the Edit Menu for the Tag. Select New XV8000 from the menu.

11. Use the New Tag pop-up window to create the backing tag for the AOI. Each AOI has an associated User Defined Tag Type that has been created to interface with the AOI logic and the HMI objects that will be added later in this lab. Verify the Type is Base, the Data Type is P_ValveSO, and the Scope is PlantPAxDemo_Cont_Master. Click OK after entering the Tag information.

[PLEASE VERIFY THAT THIS IS A CONTROLLER SCOPED TAG! FAILURE TO DO THIS WILL CAUSE PROBLEMS LATER IN THE LAB!]

24 of 92

12. Drag and drop 5 IREFs (input references) from the toolbar to the FBD Sheet as shown. To drag and drop hold the left mouse key down when over the IREF icon (see below) and move it over the Sheet. When you are happy with the location of the IREF release the mouse button

13. Now connect the IREFs to the instruction inputs as shown below. To do this click on the edge of the IREF instruction and with the mouse button still depressed, drag the connection line to the appropriate input pin on the Solenoid Operated Valve instruction.

25 of 92

14. We should now reference the Electrical Schematic and IO List to identify the correct IO to connect to this device.

15. Map the IREFs as shown below by double clicking in the IREF symbol and entering the associated tags. [Ask the instructor for assistance if needed] Please pay close attention to the input assignments as circled below.

26 of 92

. [Note - We are connecting a 1 to the PCmd_Acq input to ensure that the Valve will default to Program Mode any time that the operator does not request it from the associated HMI faceplate.] 16. In a similar fashion we can now add an OREF and connect it to the Out terminal as shown below:

27 of 92

17. One final thing, we must add instructions to insure that this routine is executed. We do this by adding a rung to the MainRoutine that calls this routine. 18. Open MainRoutine by double clicking on the icon in the Project Tree

19. Right Click on the highlighted area and select Add Ladder Element.

20. Type in JSR in the Add Ladder Element popup. Click OK

28 of 92

21. This inserts a JSR (Jump to Subroutine) instruction in the Rung. Double Click on the Routine Name Entry Box and type in XV8000. Hit Enter.

22. Now, Right Click Input Par and select Remove Instruction Parameter. Then Right Click on Return Par and select Remove Instruction Parameter for the Input Par and Return Par. This removes the unneeded instruction parameters.

23. We must now Finalize the edits by pressing the button at the top of the sheet. You will be asked if you want to Finalize All Edits in Program? Click Yes. The changes will now be downloaded to the controller. 24. You may want to Save your application by Pressing the Save icon in the top left corner of the Logix application. Click Yes to save all changes and Yes to upload the current tag values.

29 of 92

25. Now that the logic has been added to the controller, you may want to view the actual instance of the ladder logic for valve XV8000 and the tag data associated with it. In the Project Tree area on the left hand side of the RSLogix application, scroll down to the Add-On Instructions area. Expand the Add-On Instructions and expand the P_ValveSO selection, then double click Logic.

26. The logic file that opens is the base AOI logic but it is not connected to any tags so there is no live data. In order to view the logic with data for the XV8000 valve, you need to select the specific instance of the AOI. There is a pull-down window in the upper right corner of the logic display that selects each instance of the AOI within the controller. Use the pull-down window to select the XV8000 instance. Once selected, the logic will be shown for valve XV8000 with current data which can be used to monitor or trouble shoot the logic.

27. There is also parameter and local tag data associated with the instance of the AOI for valve XV8000 you may want to view or modify. In the Project Tree area on the left hand side of the RSLogix application, right click Parameters and Local Tags and then select Monitor Tags in the pop-up menu. This opens a generic tag window for the AOI. Use the pull-down window in the top left corner to select the XV8000 instance of the AOI to view specific data for the valve. Most of the data that needs to be modified by an engineer can be modified by HMI faceplate displays that will be added later in this lab, but this is where the data is stored in the controller if you want to view or modify it.

30 of 92

[Note If the Data Context field is not available for selection, please verify that the tag screen is set to Monitor and not Edit. Look at the bottom of the Tag Display and select Monitor Tags]

Congratulations! You have just added a fully functional Control Valve to our PlantPAx Application!

What Have We Learned in this Section? 1. The AOIs contained in the Process Library encapsulate all the functionality required to manage and control an individual device. 2. Adding these components to a PlantPAx System is simple. 3. Library instances can be added to your application without disrupting your existing plant operations.

31 of 92

Adding XV8000 to the HMI

The code to control XV8000 has now been added to our Logix Application. The next step is to add the Visualization Elements to our FactoryTalk View HMI. Using <Alt-Tab> keys, select the Plant PAx Demo Client. We have created a screen for the Mix Area. This screen can be accessed by clicking on the Mix Button and then selecting Mix Tank T8000. As you can see the current screen shows an outline for positioning the Graphic Displays.

Our task is to use the Process Library to animate this display. To do this we will need to use the FactoryTalk View Studio Application. 1. Using <Alt-Tab> select the FactoryTalk View Studio Application. 2. Open the Displays folder under the Graphics area in the Application Explorer (along the left hand side)

32 of 92

3. Double click on the _Mix_Tank display. (this can be found about half way down) The display will open. We wish to add XV8000 to this display in the location highlighted below

4. We must now select the Global Object to use to represent XV8000. Expand the Global Objects folder of the Application Explorer Window. (This can be found in the Graphics Folder)

33 of 92

5. Now double click on [RA-BAS] Process Graphics Library (highlighted above). This library contains graphic objects which have been built to work with the Process Library AOIs in the Logix controller. The Graphic objects will be linked to the backing tag assigned to the AOIs.

6. We must now select the graphical object (P_ValveSO) we wish to use. Click on the graphic object for the Solenoid Valve as shown below and press Ctrl-C. This will copy the graphic to our buffer.

Close the Global Object window. Say No to saving changes.

7. Now return to the _Mix_Tank display. Click on this display and press Ctrl-V. This will paste the global object into the display. You can now drag and drop the Global Object to the desired position. (In this case over the grayed outline) The Global Object should appear as shown below.

The graphic object for the Solenoid Valve has now been inserted in the Display. We now need to map this graphical object to the associated AOI logic in the controller that we created in the last section.

34 of 92

8. With the Global Object selected (as above), right click to launch the object menu. From this menu, click on Global Object Parameter Values as shown below.

9. The window below will be displayed. This window gives us the opportunity to map tags in the AOI to the graphic. In this case, we only want to map the P_ValveSO AOI instance as there will not be an associated P_Intlk or P_Perm. Click on the Tag Browser button to select the associated P_ValveSO from the controller. Tag Browser Button

35 of 92

10. Right-click the PlantPAx Demo folder and choose to Refresh All Folders. This ensures that the displayed tags are current and actually in the controllers Live Data. Expand the L63_Util (a Linx topic that points to our controller) and Online folders to view the Logix Controller Data Table.

11. Select XV8000 and click on OK

36 of 92

12. Now Click OK on the Global Objects Parameter Values Window

13. Now close the _Mix_Tank display by pressing the X icon in the top right hand corner of the Display.

14. Confirm the changes by clicking on Yes.

15. We have now added XV8000 to our HMI application.

In the next section we will verify that our XV8000 valve operates correctly.

37 of 92

What Have We Learned in this Section? 1. Visual Elements can be added to a FactoryTalk View application that are linked with the AOI code elements added in the last section. 2. The combination of these AOI instructions and Visual elements provide sophisticated control and superior visualization to our process device. 3. These elements can be added to an application in minutes without disrupting the operations of our plant!

38 of 92

Interacting with XV8000 online

1. Using <Alt-Tab> keys, select the Plant PAx Demo Client. 2. Navigate to the Mix Area [NOTE you may need to navigate away from this screen and then return in order to refresh the contents] The display _Mix_Tank will now be displayed.

3. This screen includes the valve XV8000 that we just added. Click on the XV8000 graphic to launch the associated faceplate.

Spend some time using the faceplate to interact with the valve logic in the controller. The valve can be transferred from Operator to Program mode (controlled by logic in PLC) by selecting the LOCK or UNLOCK button.

39 of 92

4. You can also perform Maintenance and Engineering functions related to the operation of the valve directly from the faceplates without having to modify the programming in the PLC. Open the Maintenance Tab as shown below to provide access to the following data:

Ability to Disable device to prevent Operator or Program movement of valve Ability to Bypass Interlocks and Permissives that are allowed to be bypassed (additional details on Permissive & Interlock configuration will be covered in the BUILDING A SYSTEM section of this lab) Option to Bypass Interlocks and Permissives when the Valve is in Override Mode Option to use Limit Switches to establish travel failure alarms Setting of alarm timers for valve failure alarms

40 of 92

5. Now click on the Engineering Tab. This tab allows you to insert labels which will be displayed on the screen with the graphic. Double click on the highlighted data entry field and insert the text XV8000. [NOTE after entering data be sure to hit the Enter key on your keyboard. This will ensure that the data is sent to the data table in the processor.]

The label XV8000 should now be displayed under the graphic on the Mix Display.

41 of 92

In addition to adding Labels to describe the valve on the HMI, the following functions can be performed from the Engineering Tab to modify the operation of the valve without requiring changes to the logic in the PLC:

Select Fail Open operation for the Valve. Select Interlock or Permissive requirements for the Valve (additional details on Permissive & Interlock configuration will be covered in the BUILDING A SYSTEM section of this lab) Define which limit switches are connected to the valve Define fault status when multiple limit switches are used Define time delay for Feedback simulation if no limit switches are used

6. Now click on the Alarm Configuration Tab. This tab allows the engineer to identify which alarms are active and to assign a priority level to each alarm.

6. To exit the Faceplate click on the

button in the top right corner.

42 of 92

What Have We Learned? 1. Pre-Built Graphical Objects can be inserted in our FTView Application which can then be used to display information and launch complex Faceplates. 2. These faceplates allow online configuration. Each object had different configuration and/or engineering parameters that can be modified from the faceplates with proper login access allowing changes to be made to the device operation and HMI appearance without having to modify the PLC or HMI programming 3. These objects can be added to your FTView application while clients are running.

43 of 92

Importing / Exporting Devices On the Fly

We have seen how easy it is to add a module to your PlantPAx System. This works very well if you are building a small system but for larger systems you will look for ways to limit the busy work involved in development. PlantPAx allows an Engineer to export routines to XML files. These files can then be re-imported into any ACD file. Later we will see how an Engineer can use these XML files as a storage location for generic device configurations or templates. These configurations can then be used as a starting point for new devices. Best of all, this can all be done without interrupting the operation of your plant! Before we can import a routine and experience the benefits of importing XML files we must generate the XML file by exporting it from our application.

Exporting A Routine
1. Return to the Logix 5000 application. Right Click on the Routine XV8000 and click on Export Routine.

44 of 92

2. Logix will prompt you to enter a File Name and Location for the exported XML file. In our case we selected the location C:\PlantPAxDemo\Modules for Import\Routines:

3. Now enter the File Name XV8000 for the Routine and click on Export. If asked to replace an existing file of that name click yes.

45 of 92

4. You will be asked if you want to upload the tags values from the controller. Click Yes

The XV8000 Routine has now been exported and is available for import. Now, how do we use this routine?

Importing A Routine
We would like to import the routine XV8000 to use as a template for building a new routine, XV8001. 1. Right Click on the program _8000_Mix_Tank and select Import Routine

2. Now select the Routine XV8000 that you exported in the previous step. Click Import.

46 of 92

3. After a delay, the following popup will appear.

As there is already a Routine with the current name in the project, Logix gives you the option to use this file. In this case, both files are identical so it will not matter if we choose Use Existing or Overwrite. You must specify the Final Name that you want this is the name of the new routine that will be created after the import. In this case we should enter XV8001 as our Routine Name. Now click OK. 4. Because this import is being performed online, the system asks us how we wish the logic to be imported. We will select Import Logic and Edits as Pending since we need to edit this module before compiling. Click on OK

47 of 92

5. The import will now take place. The routine called XV8001 will be created. The contents of this routine will be identical to the exported XV8000 module. 6. The Engineer would now edit this module to use the XV8001 tag and associated IO. He would then add a JSR to call this routine and add the appropriate graphics to the HMI Application. You will be editing the XV8001 Routine later in this lab, so you do not have to modify it now. You can open up the XV8001 Routine to view the contents and see that it is identical to the XV8000 Routine. 7. You may want to Save your application by Pressing the Save icon in the top left corner of the Logix application. Click Yes to upload the tag values.

48 of 92

Building Large Projects

When working with larger systems, the benefits of adopting a smart Work Flow will multiply. PlantPAx is a very flexible system and each engineer may develop a slightly different Work Flow to maximize productivity and quality. In this section, we will implement one Work Flow that an Engineer could use to develop a system.

Our Workflow
In designing a Workflow, it is important to identify common aspects of a system and then manage these accordingly. Our Work Flow is as follows: 1. Create Generic Template Files 2. Create Alias Tags for IO which are aligned with Templates. 3. Import Template Files 4. Search and Replace Generic Tags within each Template. We have already seen that individual routines can be exported from an ACD file and later imported back into an ACD file. This gives us the ability to manage device configurations external to the ACD file that can lead to significant efficiencies in building an application. To help you, we have created the following template files:

File Name AnalogSensor.L5X Dosing.L5X PID.L5X SingleSpeedMotor.L5X ValveSO.L5X VSD.L5X

Whats In It? P_AIn P_DoseFM PIDE Instruction P_Motor, P_Perm, P_Intlk, P_Reset, P_RunTime P_ValveSO, P_Perm and P_Intlk P_VSD, P_Perm, P_Intlk, P_Reset, P_RunTime Spread over multiple sheets for clarity

These can be found in the folder C:\PlantPAxDemo\Modules for Import\Routines

Alias tags are tags that reference memory defined by another tag. Anytime we reference an Alias Tag, we are really referencing the underlying tag.

49 of 92

We have completed the following tasks in preparation for this Lab. We started with the electrical drawings and IO list (below),

We used this information to populate rows in a spreadsheet. This spreadsheet was in a format that can be imported into RSLogix 5000. These rows contained the information required to create generic Alias Tags to actual IO tags. We ensured that the Alias Tag Names aligned with the IO tags used in the Template Files. (eg. The Template File uses Motor_Running, we created an Alias Tag MTR8000_Running)

We then imported the Tag spreadsheet into our application file (ACD). The Alias Tags now appear in the Project Data Table

Because we have been careful to align the Alias Tags with the Template File, we can now perform a simple Search and Replace on the Template File after it has been imported into the project as shown below for the (Variable Speed Drive ) VSD template.

50 of 92

By doing a search and replace on VSD, we can convert this generic module to a specific Motor.

Using Our Workflow

Now lets use this Work Flow. Initially we will import a VSD Module to our system. We will then use this template file as a starting point for configuring MTR8000 in our Mix Application.

1. At this time save the project. In order to quickly develop the application you will need to go offline. To do this, click on the controller icon in the top left hand corner and select Go Offline.

2.

As before, right click on the _8000_MixTank and select Import Routine.

51 of 92

3. Navigate to C:\PlantPAxDemo\Modules for Import\Routines and select the file VSD.L5X. Click on Import. Logix will start importing the module.

52 of 92

4. Now the Import Configuration Popup will appear. In this case we wish to create a Routine and designate the name MTR8000. Now click OK.

5. The routine MTR8000 has now been imported and will appear as shown below. Double click on the MTR8000 module to open it.

53 of 92

6. The Routine will appear as shown below

Note that we have split this template over multiple sheets. You can select the other sheets via the pull down menu located in the upper right edge of the sheet.

The decision to spread this configuration over multiple sheets was made to increase clarity. The functionality of the code is unaffected.

54 of 92

7. We now wish to find and replace all references to VSD with MTR8000. Hit Ctrl-F The Search Window will open. Click on the Replace button.

8. Enter VSD and MTR8000 as shown. Make sure you select Current Routine and verify the Wrap box is checked. Click the Replace All button.

9. Logix will now replace all references of VSD with MTR8000. This will align the template to the pre-loaded tags and aliases. Click Close. This routine is now ready to compile and download.

55 of 92

10. By repeating steps 2 9 we should be able to build the rest of the routines in the _8000_MixTank program. The following tables summarize the tasks to be completed. Please delete routines XV8000 and XV8001 before performing the imports listed below. First we will import the Template Files (steps 2 5),

IMPORT ROUTINE Dosing.L5X Dosing.L5X Din.L5X AnalogSensor.L5X AnalogSensor.L5X SingleSpeedMotor.L5X ValveSO.L5X ValveSO.L5X ValveSO.L5X ValveSO.L5X ValveSO.L5X

FINAL NAME FT8000 FT8001 LSL8000 LT8000 TT8000 PMP8000 XV8000 XV8001 XV8002 XV8003 XV8004

56 of 92

11. Next we need to perform a Search and Replace inside each routine (steps 6 9),

ROUTINE FT8000 FT8001 LSL8000 LT8000 TT8000 PMP8000 XV8000 XV8001 XV8002 XV8003 XV8004

FIND WHAT DosingAin DosingAin Din Ain Ain Motor ValveSO ValveSO ValveSO ValveSO ValveSO

REPLACE WITH FT8000 FT8001 LSL8000 LT8000 TT8000 PMP8000 XV8000 XV8001 XV8002 XV8003 XV8004

12. Finally we need to add JSRs to the MainRoutine to ensure that the Routines we have just imported are executed. Open the MainRoutine by double clicking on the Module in the Project Tree.

57 of 92

13. Click on the area to the left of the second rung. This selects the Rung. Now Press Ctrl-C to copy the Rung. Then press Ctrl-V to paste a copy of the rung into the routine.

[NOTE If you did not add the JSR for XV8001 earlier in the Lab, then there will only be one Rung here. Select Rung 0 and copy as described above.]

14. The result is the addition of a third rung. Now Rung 2 by double clicking on XV8001 and replacing it with XV8002.

15. In this manner we can add all the rungs necessary to call the routines in this program. When you are done, there should be a total of twelve (12) Rungs (last Rung is number 11), each with a JSR selecting a different Routine. 16. Next, we need to import the components that will be part of the _8100_StorageTank program. Rather than continue to import and edit the individual Routines we can speed the process by importing the entire _8100_StorageTank program. To do this, right click on the _8000_Mix Task and select Import Program.

58 of 92

17. The Import Program Popup will appear. This time, select C:\PlantPAx Demo\Modules For Import\Programs\_8100_StorageTank.L5X and click on Import.

18. After a brief delay the Import Configuration Popup will appear. In this case, we want to Overwrite the existing program so just click on OK.

59 of 92

19. You may want to Save your application by Pressing the Save icon in the top left corner of the Logix application

20. The final step is to download the code we have just developed to the Logix Controller. Click on the Controller menu in the top corner and select Download as shown below.

21. You will be asked to confirm the download task. Click Download. The download process will begin.

60 of 92

22. If the download does not complete try to debug using the messages in the lower pane. Please
notify your instructor if you need help.

23. If there are no errors in your code you will be notified that the Download has completed. The
controller will now be in Remote Program Mode. You should transition the controller to Run Mode using the Controller Menu.

We have now added the code to control and monitor all of the devices in the Mixing Area. We must now add the associated graphic objects to the HMI.

What Have We Learned? 1. Standard code modules can be imported into our application to speed up configuration time and reduce mistakes. 2. By aligning our alias tags and template modules we can quickly build our application. 3. This frees the Engineer to focus his efforts on the custom aspects of his application. The resulting application inherits sophisticated functionality from the Process Library.

61 of 92

Adding Visualization
We have just added 18 devices to our system in a very short time. You can see how quickly systems can be assembled! Now we want to add the corresponding Visualization elements to our FactoryTalk View Application. 1. Return to the FactoryTalk View Studio Application. 2. Reopen the _Mix_Tank display. This will appear as shown. [NOTE XV8001 may also be included depending on whether you completed the Optional Tasks above. If XV8001 has been added follow the same instructions for XV8002]

3. We must now select the Global Object to use to represent XV8001. Expand the Global Objects area of the Application Explorer Window.

62 of 92

4. Now double click on [RA-BAS] Process Graphics Library (highlighted above).This library contains graphics which have been built to work with the Process Library AOIs in the Logix controller. 5. We must now select the graphic we wish to use. Click on the highlighted graphic and press CtrlC. This will copy the graphic to our buffer.

Close the Global Object window. Say No to saving changes.

63 of 92

6. Now return to the _Mix_Tank display. Click on this display and press Ctrl-V. This will paste the global object into the display. You can now drag and drop the Global Object to the desired position. (In this case over the grayed outline)

The graphical object has now been inserted in the Display. We now need to map this graphical object to the code modules in the controller that we created in the last section.

7. With the Global Object selected (as above), right click to launch the object menu. From this menu click on Global Object Parameter Values as shown below.

64 of 92

8. The window below will be displayed. This window gives us the opportunity to map tags in the AOI to the graphic. In this case we want to map the Valve Tag, the Interlock Tag and the Permissive Tag. Tag Browser Button

9. Expand the L63_Util (a Linx topic that points to our controller) and Online folders to view the Logix Controller Data Table.

65 of 92

10. Select XV8001 and click on OK

11. Now click on the browse button for the Interlock Tag.

66 of 92

12. The Tag Browser will launch. Select XV8001_Intlk and Click OK

13. Now click on the browse button for the Permissive Tag.

67 of 92

14. The Tag Browser will launch. Select XV8001_Perm and Click OK

15. The Global Object Parameter window will display again. Click OK.

The Visualization for XV8001 has now been set up. We can speed up the set up of the rest of the discrete valves using copy and paste.

68 of 92

16. Select Valve XV8001 and press Ctrl-C. Then press Ctrl-V to paste the Global Object.

Drag and drop the new Global Object to the appropriate position on the screen. 17. Once in position Right Click on the Global Object and select Global Object Parameters from the menu.

69 of 92

18. The Global Object Parameter Values popup will appear. This box will still be populated with the values from XV8001. All you need to do to configure this Visual Element for XV8002 is double click on each parameter and edit the values to XV8002.

19. When you are done editing the values should appear as shown below. Click OK

70 of 92

20. Repeat Steps 17 20 for valve XV8003. The Display should now appear as shown.

21. We also need to add XV8004 and XV8100.

71 of 92

We will need to use a different graphic for these valves. This graphic can be found in the Solenoid Operated Valve (P_ValveSO) area of the [RA-BAS] Process Graphics Library located in the Global Objects folder and is shown below.

22. Next we need to add MTR8000 and MTR8100.

The appropriate Global Objects for these motors can be found in the P_VSD Graphics Library. Double click on this Library and select the circled graphic. Select this Global Object and press Ctrl-C to copy it to your buffer.

72 of 92

23. Return to the _MixTank Display and press Ctrl-V. 24. Drag and drop the device to the location shown below.

25. Right click and launch the Global Objects Parameter Values Window. As before you can browse and select the appropriate values.

73 of 92

26. You should select the following values. [NOTE - We do not use a Reverse Permissive Tag in this application. Click OK.]

27. Now copy and paste this Motor and drag and drop it to the correct location for MTR8100.

28. Right click on this device and select Global Object Parameter Values. Edit all references to MTR8000 to MTR8100 and click OK.

74 of 92

29. Next we will import PMP8000 and PMP8100.

The graphic for this P_Motor device can be found in the P_Motor Graphics Library and select the highlighted graphic.

75 of 92

30. Drop this Global Object in the _Mix_Tank Display and position as appropriate.

31. Right Click on the Graphic and open the Global Object Parameter Values. 32. Populate the Global Object Parameter Values as shown below and click OK.

33. Next copy this Global Object for Pump 8100 and edit the Global Parameters as shown below. Click OK

76 of 92

34. Next we will map the Dosing Modules.

The graphic for this P_DoseFM device can be found in the Process Graphics Library and select the highlighted graphic.

35. Drop this Global Object in the _Mix_Tank Display and position as appropriate.

77 of 92

36. Right Click on the Graphic and open the Global Object Parameter Values. Populate the Global Object Parameter Values as shown below and click OK.

37. Now copy and paste this Global Object and edit the Global Parameters for FT8001 as shown below. Click OK

38. Next we will add the Temperature and Level Sensors.

78 of 92

The graphic for this P_AIn device can be found in the Process Graphics Library and select the highlighted graphic.

39. Drop this Global Object in the _Mix_Tank Display and position as appropriate.

40. Right Click on the Graphic and open the Global Object Parameter Values. Populate the Global Object Parameter Values as shown below and click OK.

79 of 92

41. Copy and paste Global Objects for TT8100, LT8000 and LT8100. 42. We also wish to add the Tank Level Graphics to the application. These can be found in the Process Graphics Library as shown,

43. Drop this Global Object in the _Mix_Tank Display as shown,

44. Right Click on the Graphic and open the Global Object Parameter Values. Populate the Global Object Parameter Values as shown below and click OK.

80 of 92

45. Copy, Paste and edit Global Objects for LT8100 46. Now we wish to add the Level Switches to the application. These can be found in the Process Graphics Library as shown,

47. Drop this Global Object in the _Mix_Tank Display as shown,

48. Right Click on the Graphic and open the Global Object Parameter Values. Populate the Global Object Parameter Values as shown below and click OK.

81 of 92

49. Copy and paste Global Objects for LSL8100 50. Finally we need to add PIC8100.

The graphic can be found in the right side of the Process Graphics Library as shown,

51. Drop this Global Object in the _Mix_Tank Display as shown,

82 of 92

52. Right Click on the Graphic and open the Global Object Parameter Values. Populate the Global Object Parameter Values as shown below and click OK. Note, in this case, 2 of the parameters (Description and Engineering Units) are text strings which will appear on the screen. The strings tags can be typed into the Value box directly without using the Tag browse button.

53. If you have completed all these steps the _Mix_Tank Display should now appear as shown below

83 of 92

54. Now close the Display by pressing the X icon in the top right hand corner of the Display.

55. Confirm the changes by clicking on Yes. 56. Using <Alt-Tab> keys, select the Plant PAx Demo Client application. Navigate to the Mix Area and select Mix Tank T8000 to view the graphic created with live data. [NOTE you may need to navigate away from this screen and then return in order to refresh the contents 57. Spend some time clicking on the various types of devices on the screen and reviewing the functionality of the faceplates. The faceplates are designed to not only provide an operator interface to the system, but to provide the engineer access to configuration parameters that can modify the functionality of the device from the HMI with proper authorization without having to access the controller from a separate engineering computer.

84 of 92

Building a System
We have now added the basic control components for building an application. We think you will agree that this was a relatively painless task. In a matter of minutes we have added full functionality to control all the devices in the Mix Area and also added the associated graphics to the HMI. Now, we need to make these individual components work together as a cohesive system. The Process Library includes modules which aid in this task. The P_Perm and P_Intlk devices can be used to logically coordinate other library elements.

Interlocks and Permissives

The primary purpose of Interlocks and Permissives is to encode certain rules of operation for equipment. These operational rules protect the equipment from Operator errors and may often be safety related. Permissives are conditions that must be met for a device to be enabled. Interlocks are condition that will cause a running device to be stopped. Typically Permissives and Interlocks are used for handling exceptional cases. Your normal sequencing code should be used to define normal operational starting and stopping. Permissives and Interlocks can override requests from logic to start or stop equipment. For example, we would not want to run PMP8000 if XV8004 is not open or the Mix Tank 8000 is low level. Running this pump while either of these conditions exists could result in the pump being damaged. The following table summarizes the kind of conditions that might be added to our system. Interlocks And Permissives Table

Device XV8000 XV8001 XV8002 XV8003 MTR8000 XV8004 PMP8000

Interlock [T8000 High Level] [T8000 High Level] [T8000 High Level] [T8000 High Level] T8000 Level > 5%

Permissive

T8000 Level > 10%

[XV8004 Not Open] OR [T8000 Low Level] OR [T8100 High Level]

XV8004 Open

85 of 92

MTR8100 XV8100 PMP8100

T8100 Level > 5%

T8100 Level > 10%

Adding Interlocks and Permissives

Many of the Templates that we imported into the application in previous sections included P_Perm and P_Intlk blocks. These blocks will now be used to add Permissive and Interlock functionality. As an example we are going to configure the Interlocks and Permissives for PMP8000. Lets return to the RSLogix 5000 application. 1. Double click on the Routine PMP8000 to open it.

2. Click on the Start Pending Routine Edits Button (at the top of the sheet) to enable edits.

86 of 92

3. This Sheet includes PMP8000_Perm and PMP8000_Intlk. [NOTE When developing the template we only made 4 inputs visible for the Permissive and Interlock

4. We need to add conditions to the Inp_Intlk00, Inp_Intlk01, Inp_Intlk02 and Inp_Perm01 inputs. [NOTE Inp_Perm00 is already being used to tie in the Reset Inhibit functionality]

5. We wish to code the following configuration: Device PMP8000 Interlock [XV8004 Not Open] OR [T8000 Low Level] OR [T8100 High Level] Permissive XV8004 Open

87 of 92

6. We can code this configuration as shown below:

7. We must now Finalize these edits by pressing the button at the top of the sheet. You will be asked if you want to Finalize All Edits in Program? Click Yes. The changes will now be downloaded to the controller. 8. The rest of the required configuration can be done directly from the View SE Client Application.

88 of 92

9. Return to the Plant PAx Demo Client. Click on the PMP8000 Graphic to launch its Faceplate.

10. In order to access the Permissive and Interlock Faceplates we need to configure the system to recognize that there are Permissives and Interlocks associated with this pump. To do this click, on the Engineering Tab and set the checkboxes as shown. [NOTE You may also want to change the labels to PMP8000 if it is not already configured]

89 of 92

11. Now return to the Home Tab. You should now be able to launch the Interlock faceplate by clicking on the button indicated.

12. We can configure the Interlocks from the faceplate. Click on the Interlocks Faceplate and select the Engineering Tab. From here we can input descriptions that will be displayed.

90 of 92

13. Configure as shown below. When editing the text Descriptions, please hit the ENTER key after each entry to download the data to the processor. A 1 in the OK State indicates that the associated equipment will be allowed to run when this input is 1. In this case we want PMP8000 to run when XV8004 is opened but not when T8000 is low or T8100 is high.

14. Returning to the Interlock Home Tab you will see that the Pump is now Interlocked as XV8004 is not open. The yellow outline indicates that this was the first condition activate the Interlock.

[NOTE T8000 is not in Low Status as we have not set the Low Limit. As an exercise you may want to do this and then verify that the second Interlock condition will now be set. Time permitting you may also wish to open XV8004 and verify that the Interlock goes away]

91 of 92

Customizing the System

We have now built the basic framework for the Mix Application. The Engineer is now free to focus his energies on building the custom aspects of his application. To help him with this, PlantPAx offers 4 types of routines Ladder, Structured Text, Function Block Diagramming and Sequential Flow Charts. If required, the Engineer can also make use of Phase Manager. He can mix and match all of the above as required. PlantPAx allows the Engineer to build more elegant control system by allowing them to focus on the unique aspects of his Process.

THANK YOU FOR ATTENDING THIS CLASS!

92 of 92