Course T301, Engineering an 800xA System - Advanced

Exercise 8.2 Add a Two Direction SFC for controlling the plant

TABLE OF CONTENTS
Exercise 8.2 Add a Two Direction SFC for controlling the plant.............................................................................................. 8.2-1
8.2.1 General Information................................................................................................................................................... 8.2-3
8.2.1.1 Objectives............................................................................................................................................................ 8.2-3
8.2.2 Exercise Steps ............................................................................................................................................................ 8.2-4
8.2.2.1 Create a normal SFC ....................................................................................................................................... 8.2-4
8.2.2.2 Create the header control module....................................................................................................................... 8.2-5
8.2.2.3 Connect the header to the chain.......................................................................................................................... 8.2-5
8.2.2.4 Set the end transitions ......................................................................................................................................... 8.2-6
8.2.2.5 Stop the plant: Step S51_StopPlant.................................................................................................................... 8.2-6
8.2.2.6 Wait till the plant is stopped: Transition TR52.................................................................................................. 8.2-6
8.2.2.7 Set the controls to manual mode: S52_ControlsToManual ............................................................................... 8.2-7
8.2.2.8 Set the controls to auto mode: S01_ControlsToAuto ........................................................................................ 8.2-7
8.2.2.9 Start the plant: S02_StartPlant............................................................................................................................ 8.2-7
8.2.2.10 Link the SC1_Header into the Functional Structure........................................................................................ 8.2-7
8.2.2.11 Test the chain .................................................................................................................................................... 8.2-7
8.2.3 Additional Exercises .................................................................................................................................................. 8.2-8
8.2.3.1 Set all plant controls to manual mode ................................................................................................................ 8.2-8
8.2.3.2 Set all plant controls to auto mode ..................................................................................................................... 8.2-8
8.2.3.3 Expand the Graphic Display of Tank1 ............................................................................................................... 8.2-8

8.2-1

Course T301, Engineering an 800xA System - Advanced

8.2-2

Engineering an 800xA System - Advanced

8.2.1 General Information

In this exercise you will add a Two Direction Sequence Chain for controlling the
whole plant at a higher level.
We want to create a SFC with the shape as displayed in the picture below.

With the On path we want to prepare the plant, with the Off part we want to shutdown
the plant. This is controlled by the faceplate of the special control module type.
What the chain should do is

8.2.1.1 Objectives
You will:

Create a normal SFC

Expand the SFC to a Two Direction SFC which will prepare and shutdown your
plant

Test the Two Direction SFC with its faceplate and watch the sequence chain by
the SFC Viewer

8.2-3

Engineering an 800xA System - Advanced

Exercise 8.2 Add a Two Direction SFC for controlling the plant

8.2.2 Exercise Steps

8.2.2.1 Create a normal SFC
The first step is to create a normal SFC.
In the next steps this SFC should:

On path
o

Set all the controls to auto mode

Start the batch of product for the plant The plant is running.

Off path
o

Stop the batch of product for the plant

Set all the controls to manual mode

o
We want to create the normal SFC on a new code page for the program Control.
Please

8.2-4

Enable the library SeqStartLib for your project and for the application Tank1
as well. This library includes all the functionality for the advanced SFC.

Open the editor of the Control program and create a new code page of
language Sequential Function Chart. Please name the code page
SC1_Chain.

Create the SFC as displayed in the picture below. The right path is the path for
preparing the plant; the left path is for shutting down the plant. Do not forget
to set S0 as initial step.

Engineering an 800xA System - Advanced

8.2.2.2 Create the header control module

The next step is to create a new control module. This control module type is located in
the SeqStartLib as well and is named SFC2DHeader. The faceplate of this control
module will control the prepare functionality and the shutdown functionality of our
plant.
Please

Create a new control module for the application Tank1. Please use the type
SFC2DHeader and name it SC1_Header.

Assign the Name and the Description parameter of the SC1_Header control
module.
Name: SC1_Header
Description: Prepare and shutdown the plant

Create two global variables for controlling the chain. They are used for the
connection between the chain and the header.
Important is the nosort attribute because the two variables are working in a
kind of a loop.
Name
SC1_ToSFC
SC1_ToHeader

Data type
HeaderToSFC
SFCToHeader

Attribute
nosort
nosort

Connect the variables to the parameters of the SC1_Header control module.

Variable
SC1_ToSFC
SC1_ToHeader

Parameter
ToSFC
FromSFC

8.2.2.3 Connect the header to the chain

Right now the header control module SC1_Header is connected to two global
variables, SC1_ToSFC and SC1_ToHeader. The next step is to connect these variables
to the chain SC1 as well.
Because we have to do this connection with Structured Text language we need an
extra code page for this.
Please

Create a new code page for the Control program and name it SC1_Control.
Please set the language Structured Text for it.

The first step is to connect the Hold and the Reset parts of the chain
SC1_Chain to the header variable SC1_ToSFC. Please write structure text so
that the
SC1_Chain.Hold variable gets the value from the SC1_ToSFC.Hold
variable,
SC1_Chain.Reset variable gets the value from the SC1_ToSFC.Reset
variable.

The next step is to connect the last steps of the paths of the chain to the header
variable SC1_ToHeader. Please write structured text so that the

8.2-5

Engineering an 800xA System - Advanced

Exercise 8.2 Add a Two Direction SFC for controlling the plant

SC1_ToHeader.LastStepOffSeq gets the value from the

S52_ControlsToManual.X variable,
SC1_ToHeader.LastStepOnSeq gets the value from the S02_StartPlant.X
variable.

Connect the start transitions TR01 and TR51 to the header variable
SC1_ToSFC so that a start/stop command from the faceplate will start/stop the
chain path.

8.2.2.4 Set the end transitions

Because the two direction SFC chain should stop at the end of each path we have to
set both end transitions, TR_OFF_END and TR_ON_END. Please do this now.

8.2.2.5 Stop the plant: Step S51_StopPlant

This step should stop the plant. The global variable Run_batch starts and stops the
product of batch for the plant. Please set this variable to false in this step.

8.2.2.6 Wait till the plant is stopped: Transition TR52

The transition TR52 should wait till the plant is stopped. The Batch_of_Product chain
is stopped when the S0_Idle step is executed and so the internal variable of the
S0_Idle step (S0_Idle.X) is true.

Please

8.2-6

Edit the transition TR52 of the S1_Chain so, that an enabled S0_Idle step
(variable S0_Idle.X) will continuo the SC1_Chain.

Engineering an 800xA System - Advanced

8.2.2.7 Set the controls to manual mode: S52_ControlsToManual

This step will only deal with the M1 agitator type and will set this type from auto
mode to manual mode. At the end of this exercise there is an advanced exercise where
to set the controls of the whole plant to manual mode.
Please

Open the step S52_ControlsToManual of the S1_Chain and set the M1

agitator to manual mode. For this you have to deal with the Interaction
Parameter of the M1 agitator. Because this step is the final step of the off
sequence, you have to take the P1 tab card (for initializing).

8.2.2.8 Set the controls to auto mode: S01_ControlsToAuto

This step will only deal with the M1 agitator type and will set this type from manual
mode to auto mode. At the end of this exercise there is an advanced exercise where to
set the controls of the whole plant to auto mode.
Please

Open the step S01_ControlsToAuto of the S1_Chain and set the agitator M1
to auto mode.

Select the transition TR02. Write some code so that this transition is true when
the agitator M1 is in auto mode.

8.2.2.9 Start the plant: S02_StartPlant

The last step is to start the batch of product for the plant. Use for this the variable
Run_batch.

8.2.2.10 Link the SC1_Header into the Functional Structure

Browse into the Functional Structure and link the SC1_Header module as a child of
the Tank1 area object of our plant.

8.2.2.11 Test the chain

Please download your project and test the new chain functionality.

8.2-7

Engineering an 800xA System - Advanced

Exercise 8.2 Add a Two Direction SFC for controlling the plant

8.2.3 Additional Exercises

8.2.3.1 Set all plant controls to manual mode
In this exercise you should set all the plant controls to the manual mode. Please use for
this the step S52_ControlToManual.

8.2.3.2 Set all plant controls to auto mode

In this exercise you should set all the plant controls to the auto mode. Please use for
this the step S01_ControlToAuto. You have to modify the transition TR02 as well.
Please remember: The transition TR02 takes care that all the controls are really in auto
mode.

8.2.3.3 Expand the Graphic Display of Tank1

Expand the Graphic Display of Tank1 and create an aspect link for it. A click onto this
link should open the faceplate for the SC1_Header control module so that the operator
is able to prepare and shutdown his plant.

8.2-8