L25 - PlantPAx Process Application Development Lab I. For Classroom Use Only!

Transcription

1 L25 - PlantPAx Process Application Development Lab I For Classroom Use Only!

2 Important User Information This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation ) is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation should only be used as a learning tool by qualified professionals. The variety of uses for the hardware, software and firmware (hereinafter Products ) described in this Documentation, mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards in addition to any applicable technical documents. In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter Rockwell Automation ) be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of, or reliance on, this Documentation. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in the Documentation. Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for: properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell Automation or thirdparty provided instructions, warnings, recommendations and documentation; ensuring that only properly trained personnel use, operate and maintain the Products at all times; staying informed of all Product updates and alerts and implementing all updates and fixes; and all other factors affecting the Products that are outside of the direct control of Rockwell Automation. Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use the following notes to make you aware of safety considerations: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. Identifies information that is critical for successful application and understanding of the product. Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: identify a hazard avoid a hazard recognize the consequence Labels may be located on or inside the drive to alert people that dangerous voltage may be present. Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures. PlantPAx Process Application Development Lab I 2 of 132

3 PlantPAx Process Application Development Lab I PlantPAx Process Application Development Lab I... 3 Before you begin... 4 About this Lab... 4 Tools and Prerequisites... 4 PlantPAx: The Modern Distributed Control System... 5 Studio 5000 Architect... 5 The Rockwell Automation Library of Process Objects - Reducing Development Time... 6 Application Templates and Process Strategies - Reducing Engineering Time... 6 Where to Get the Rockwell Automation Library of Process Objects... 7 Starting the Lab... 8 Creating Your PlantPAx System Application... 8 Change Controller Properties Configuring Controller and Strategies Configuring an HMI Project Testing the Code and HMI Application Re-Use Code Easily using Logical Organizer Commissioning the Device Faceplates Configuring Alarms Lab Summary Optional Lab Sections Configuring a Control Loop PlantPAx Process Application Development Lab I 3 of 132

4 Before you begin About this Lab This lab will familiarize the user with the steps necessary to start development of a PlantPAx DCS using Studio 5000 Architect and the Rockwell Automation Library of Process Objects. The user will define system controllers and servers and configure a control application with pre-defined library objects for common functions helping to reduce engineering time. Templates are included in the library for both controller applications and HMI applications to provide a consistent starting point for system implementation. In this lab we will cover the following subjects: Use the Studio 5000 Architect Application and templates to develop a PlantPAx application Leverage Process Strategies for level control using a tank with a pump and level indicator as an example Configure an HMI display to include pump and level objects Test the controller program and HMI functionality by creating and using an HMI client Leverage the Logical Organizer to take advantage of past engineering efforts to save time and reduce errors Configure alarms From this lab, the user will become familiar with: Studio 5000 Architect The Controller Application templates The HMI Application templates Process Strategies from the Rockwell Automation Library of Process Objects The Logical Organizer feature of Studio 5000 Logix Designer Symbol Factory, an HMI library of graphic symbols Tools and Prerequisites This lab is conducted using a VMWare Workstation virtualized environment that allows the ability to process one or more guest computer images on one host computer. All the software tools required for this lab are installed within this image running on your lab PC. These tools include: VMWare Workstation v10 (to run the Lab PC image) Studio 5000 Architect Application V1.0 Studio 5000 Logix Designer Application V24 FactoryTalk View Studio Software V8.1 FactoryTalk View SE Client Application V8.1 Rockwell Automation Library of Process Objects V3.5 RSLogix Emulate 5000 Software V24 All required files are contained on the VMWare image. They are located in folders: C:\Lab Files PlantPAx Process Application Development Lab I 4 of 132

5 PlantPAx: The Modern Distributed Control System PlantPAx is the modern Distributed Control System (DCS) from Rockwell Automation with all the core capabilities expected from a world-class DCS. The system is built on a standard-based architecture using Integrated Architecture components that enable multi-disciplined control and Premier Integration with the Rockwell Automation Intelligent Motor Control portfolio. A traditional distributed control system (DCS) is built for only one purpose process control. But in today s competitive economy, you need to consider forward-thinking possibilities and utilize technology and innovation to your advantage. It s time to rethink what to expect from a DCS. In order to drive productivity, increase efficiencies and reduce costs you need to integrate all of your automation operations to achieve The Connected Enterprise. The only way to do that is through the technology offered by the modern DCS the PlantPAx system. The PlantPAx modern distributed control system offers process control and more: Plant-wide control and optimization for dynamic, demand-driven business decisions Scalable and modular system architectures to meet your exact needs Open, secure and information-enabled networking capabilities Flexible delivery and support options Studio 5000 The Studio 5000 environment combines engineering and design elements into one standard framework that enables optimized productivity and reduced commissioning time. With the Studio 5000 environment, you can respond more quickly to changing market and business needs, while reducing total costs of ownership, including maintenance and training. The environment is the one place for engineers to develop all elements of their control system for operation and maintenance. Studio 5000 extends beyond one controller to be a system-wide development and design tool. Studio 5000 Architect Studio 5000 Architect provides an integrated environment that contains Logix devices, FactoryTalk View Servers, PanelView Plus terminals, and Stratix Network Switches. Additonal features of Studio 5000 Architect include: Graphical Layout of System Create a graphical representation of your system for easier system modifications Initial Architecture and Project Configuration Bulid Logix and FactoryTalk View projects from an integrated environment Re-Use of project content Re-use Logix and FactoryTalk View content as well as use content from the Rockwell Automation Library of process objects Data exchange wtih engineering tools - Exchange hardware configuration data with tools like EPLAN PlantPAx Process Application Development Lab I 5 of 132

6 The Rockwell Automation Library of Process Objects - Reducing Development Time The RA Library of Process Objects is a predefined library of Application Code, Graphic Objects, Faceplates, and Process Strategies that let you quickly assemble large applications with proven strategies, rich functionality, and known performance. The Application code contains the code which controls the associated device. This code is embedded in an Add-On Instruction (AOI) which can be instantiated multiple times in a given application. 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. Add-On Instructions Each object is provided as an importable Add-On Instruction and then becomes a native instruction in the application development environment. The Add-On Instructions can be utilized with any CompactLogix or ControlLogix programmable automation controller. Global Objects For rapid development of information-rich operator displays, the Rockwell Automation Library of Process Objects provides a collection of display objects that are linked to the Add-On Instructions with a drag and drop wizard. This allows rapid development of main plant display graphics. Faceplates All global objects have an associated faceplate which appears when the global object is clicked. These faceplates require no additional configuration. When an object has additional support functions linked, such as Run Time Monitor, Interlock Block, or others, the faceplate for these extended functions will also be accessible from the faceplate. Application Templates and Process Strategies - Reducing Engineering Time Application templates are included in the RA Library of Process Objects for both controller applications (Logix Controller Templates) and HMI applications (HMI Project Templates) to provide a consistent starting point for system implementation. As part of the future PlantPAx v4.0 System Release, process strategies will also be provided with the library as sample code (Process Strategies from the RA Library of Process Objects). PlantPAx Process Application Development Lab I 6 of 132

7 Where to Get the Rockwell Automation Library of Process Objects The current release of the library, v3.5, supports Studio5000 Application version 24 and later. The Rockwell Automation Library of Process Objects can be downloaded free from the Product Compatibility Download Center at: PlantPAx Process Application Development Lab I 7 of 132

8 Starting the Lab Creating Your PlantPAx System Application Double-Click the Studio 5000 V24 icon on the desktop to open Studio The Studio 5000 Common Launcher appears. Under Create, click New Project. In the project pane, select Architect as the Project Type. Note: The Common Launcher dialog box is used for all products in Studio 5000 software. The product types that appear in the project pane depend on the products that are installed on your workstation. PlantPAx Process Application Development Lab I 8 of 132

9 There are four system templates available for use within the Studio 5000 Architect that contain prebuilt logical and graphical elements that follow PlantPAx system guidelines. The four templates include the following: Distributed Architecture Connected Enterprise: Contains one Server for FactoryTalk Alarm and Events, Distributed HMI applications and Production Data, multiple controllers, and multiple Electronic Operator Interfaces Distributed Architecture Multiple Process Servers: Contains two PASS servers; multiple Operator Workstations (OWSs), Engineering Workstations (EWSs), I/O modules, and controllers. Distributed Architecture Single Process Server: Contains one PASS server; multiple OWSs, EWSs, I/O modules, and five controllers. Process Skid with Logix Batch Sequence Manager: Skid-based equipment to be integrated into overall system, including three CompactLogix controllers and PanelView. Select the Distributed Architecture Single Process Server template. Enter Lab as the project name and click Finish. Please wait while the architect project is created. This may take a few minutes. PlantPAx Process Application Development Lab I 9 of 132

10 The Architect palette appears with a layout of the architecture and pre-defined controllers for the selected template. As a starting point, the layout pages in the Architect software let you draw and connect your components. Each system template has pre-defined layout pages that show your control hardware layout the chassis, controllers, communication modules, I/O modules, HMI servers, PanelView terminals, and network switches. Servers, terminals, and communication modules are connected to network trunks. This template is preconfigured with five controllers. For lab purposes, let s suppose we do not need controllers LGXC04 and LGXC05. Hold the cursor down and draw a rectangle around the controllers to highlight them and then click the Delete button. PlantPAx Process Application Development Lab I 10 of 132

11 Notice the controllers were removed from the hardware diagram as well as the list of projects in the explorer pane. We can also import an existing controller project into our Architect project. Prior to the lab, we created a Logix controller file using the Basic Library template, which includes a subset of the Rockwell Automation Process Library Add-on instructions. For lab purposes we have also added code for process and I/O simulation. To import this existing project, right click on Projects, select Add, and Existing Project. PlantPAx Process Application Development Lab I 11 of 132

12 Click Browse. Select the PAC01.acd file from the Lab Files\Logix5000 folder. (PAC stands for Process Area Controller). Click Open. Click OK. Wait for the controller to import. This may take a few minutes. PlantPAx Process Application Development Lab I 12 of 132

13 Click OK to Confirm Synchronization changes. Click OK when the Ethernet Configuration dialog box appears. PlantPAx Process Application Development Lab I 13 of 132

14 Wait and the new controller will appear in the hardware diagram. Hold the cursor down and draw a rectangle around the new controller rack to highlight it and then drag it to the lower right corner of the diagram. Your hardware diagram should now look like the following: PlantPAx Process Application Development Lab I 14 of 132

15 Connect the new controller to the switch by clicking on any open port on the switch and dragging the connection to the communication module on the new controller rack. (Connect green dot to green dot). Change Controller Properties Controller Properties can be modified using Logix Designer from within the Architect application. Open Logix Designer by right-clicking on the PAC01 controller in the Project Explorer pane. Select Open Project in Designer. Wait a short time while Studio 5000 Logix Designer opens. PlantPAx Process Application Development Lab I 15 of 132

16 Changes can be made to the controller from within Logix Designer and then those changes can be synchronized with Architect. As an example, let s change the controller type in the PAC01 controller. Click on the Controller Properties button to launch the Controller Properties window. Click Change Controller. Change the controller from an L75 to an L74 by selecting 1756-L74 from the controller type dropdown menu. Click OK. PlantPAx Process Application Development Lab I 16 of 132

17 Click Yes to confirm the new controller type. When the controller change is complete. Save the controller. Maximize the Studio 5000 Architect window. In the Project Explorer, right click on the PAC01 project and select Synchronize Project. PlantPAx Process Application Development Lab I 17 of 132

18 Wait for the Synchronize Summary window to appear. Click OK to continue with the synchronization. Click OK to accept the current Ethernet Configuration. PlantPAx Process Application Development Lab I 18 of 132

19 A message will appear in the results pane indicating that synch is complete. Mouse over the controller in the hardware diagram to confirm that the controller type was updated to 1756-L74. Section Summary The Studio 5000 Architect application can be used to quickly define the controllers and servers that comprise a PlantPAx Distributed Control System. It can help reduce the engineering time to assemble your integrated architecture and process application PlantPAx Process Application Development Lab I 19 of 132

20 Configuring Controller and Strategies In this section of the lab, you will learn how to configure your controller using pre-configured process strategies that are imported as routines into a controller application. Maximize the Logix Designer window. Controller organization by Execution Tasks The controller is separated into Tasks that run at different execution speeds from a fast 50ms to as slow as 10sec. These Tasks are named A through H. The tasks allow us to make the best utilization of the processor in terms of execution time. The traditional Controller Organizer window is used to view the controller from an execution and utilization perspective. Using the Controller Organizer window, note that the Basic Library template includes pre-configured MainPrograms within each Task to be used as organizational containers to speed up engineering time. PlantPAx Process Application Development Lab I 20 of 132

21 The Logical Organizer a new feature in V24 Whereas the traditional Controller Organizer is used to view and configure the controller from an execution time and utilization perspective (Tasks), the new Logical Organizer provides a way to view and create an organizational model of the system (Programs and Routines). This allows operators and maintenance to troubleshoot the system more quickly while new features such as Selecting Multiple project components like AOI's, UDT's, Programs, and then copy/paste, drag/drop, export/ import them as one to reduce engineering time. For this lab we will work in the new Logical Organizer window. Click the Logical Organizer. Notice that a Diagnostics task is included in all controller templates. This task allows for troubleshooting, reporting and alarming of controller status and utilization. Note that there is pre-configured code for the lab simulation in Task C running at 250ms. Since we are in a lab setting and are not connected to real I/O, simulated I/O has been added to this template. In this section of the lab, we will add new code for a tank (including a pump and a level transmitter) to Task D running at 500ms. PlantPAx Process Application Development Lab I 21 of 132

22 We will now rename the main program in Task D from Task_D_MainProgram to Tank1. Double-click on Task_D_MainProgram to open the Program Properties window. Change the Name of the program to Tank1 and click OK. PlantPAx Process Application Development Lab I 22 of 132

23 Engineering the Controller using Process Strategy Routines Process Strategies from the RA Library of Process Objects support the concept of Re-use engineering to save time. Starting from pre-configured and tested control strategies that are imported as routines into a controller application we save engineering time. By organizing a controller into Programs (for example each Tank is a Program) and Routines (levels, pumps, valves) we simplify the location of a desired piece of code, and can Re-use code in line with best practices and standards management. Later in the lab, because we organized the controller by Tasks, Programs and Routines, we can easily copy the code for a complete tank (a Program), including all components like AOI's, UDT's, Routines, Tags, and then paste it, as one, to create more tanks to reduce engineering time. Importing a Process Strategy Routine for a Pump In this section, we will import a pre-configured Process Strategy routine for a motor (PS_Motor) into the program named Tank1. A motor can drive a blower, conveyor, mixer, agitator or a pump. We are configuring a drain pump to empty the tank. Right-click on the program named Tank1. From the menus select Add and then Import Routine. Browse to the Process Strategies folder and select the file for a motor, (RA-LIB)PS_Motor_3_5-00_ROUTINE.L5X, and click Open. PlantPAx Process Application Development Lab I 23 of 132

24 The Import Configuration window will open. From this window we can configure the new routine during the import process. Change the Final Name for the routine from MT100 to Pump. Do not click OK. In the Import Content area of the configuration window, click on the Tags folder to view all the tags that will be imported. We want to modify the tagnames by replacing the generic MT motor designator with PMP during the routine import. The MT is a default tag designator for any type of motor. A motor can drive a blower, conveyor, mixer, agitator or a pump. In this case we are designating a pump using PMP in the tagnames. Click on the Find/Replace button. PlantPAx Process Application Development Lab I 24 of 132

25 Find all the instances of MT in the tag references and replace with PMP. Confirm that only Final Name is checked in the Find Within options. Then click the Replace All button. Now click OK. PlantPAx Process Application Development Lab I 25 of 132

26 Wait for the import to complete. Once the import completes, a new routine named Pump is added to the Tank1 program. Double-click on the Pump routine to open the function-block editor and view the new code. Notice that all the instances of MT have been replaced with PMP in the tagnames and input/output reference connectors. The pump control routine is complete. PlantPAx Process Application Development Lab I 26 of 132

27 Importing a New Routine for Level Indication Next is to import a new routine that will contain the code for an analog input for tank Level indication. Rightclick on the program named Tank1. From the drop-down menus select Add and then Import Routine. For the tank level transmitter we will import a generic Process Strategy template for an analog input. Select the Process Strategy (RA-LIB)PS_AIn_3_5-00_ROUTINE.L5X import file and click Open. Wait for the Import Configuration window to open. PlantPAx Process Application Development Lab I 27 of 132

28 Change the Final Name of the new routine to Level. Do not click OK yet. Click on the Tags folder in the Import Content area of the window. Notice that tag references in the Process Strategy are prefixed with a generic XT designator (X is for the type and T stands for Transmitter). During the import we will find and replace the XT with LT for all tags. LT designates a Level TransmXTitter. Click on the Find/Replace button. PlantPAx Process Application Development Lab I 28 of 132

29 Find all instances of XT and replace with LT. Confirm that only Final Name is checked in the Find Within options. Then click the Replace All button. Now click OK. Wait for the import to complete. A new routine named Level has been added. Double-click on the Level routine to view the code. PlantPAx Process Application Development Lab I 29 of 132

30 Notice that all the tag names and references have been changed to LT100. The routine for the tank level is now complete. Next we need to add instructions to execute the new routines. We will do this by adding rungs to the MainRoutine that include Jump to Subroutine (JSR) instructions. The Jump to Subroutine (JSR) instructions will execute the Pump and Level subroutines. Double-click the MainRoutine for Tank1. PlantPAx Process Application Development Lab I 30 of 132

31 The ladder Code Editor will open since the Tank1 MainRoutine is ladder logic code. The MainRoutine is a continuous routine that always runs. It is used to monitor and alarm the Task s execution time and to execute other routines. Click on Rung 0 to select the rung (indicated by a blue box) and then right-click and select ADD Rung. A new rung has been added to the bottom. The e s in the blue box indicate that Rung 1 has an error. The error is because the rung is empty. We need to add an instruction to the rung. PlantPAx Process Application Development Lab I 31 of 132

32 The ladder code editor in LogixDesigner 5000 has various ways to add instructions to rungs. The easiest being if you already know the instruction name, such as JSR. To add a Jump to Subroutine (JSR) instruction to Rung 1, put the cursor on the rung and type JSR and click the Enter key. For reference only: Another way to add instructions is to right-click on the rung and select Add Ladder Element (Alt+Ins) from the selection window. An Add Ladder Element window opens to display all the available instructions sorted by groups or alphabetically. After adding the JSR to the rung it is still in error because the JSR instruction needs to have the Routine Name parameter filled in. Double-click the question mark, click on the down-arrow, and double-click the routine named Pump. PlantPAx Process Application Development Lab I 32 of 132

33 The error on Rung 1 will clear and the coding for the JSR for the Pump routine is complete. Now we need to add another rung for the JSR that will execute the Level routine. We will do this by copying Rung 1. Click on Rung 1 to select the rung (indicated by the blue box) and then right-click and select Copy Rung from the menu. Click on the bottom rung (End) to select the rung (indicated by a blue box) and then right-click and select Paste from the selection window. PlantPAx Process Application Development Lab I 33 of 132

34 Rung 2 has been added but we need to change the JSR instruction Routine Name parameter from Pump to Level to execute the Level routine. On Rung 2, double-click the Routine Name Pump in the JSR, and click on the down-arrow, and double-click the routine named Level. The JSR on Rung 2 for the Level routine is complete. The coding for Tank1 is complete and ready to download to the controller. In the upper left of the Logix Designer window click the Save button. Click on the Controller Status button and select Download. PlantPAx Process Application Development Lab I 34 of 132

35 In this lab we will be using RSLogix Emulate 5000 software to emulate a physical Logix controller. Click Change Type to change the controller type in the project from 1756-L74 to Emulator. Click Yes to confirm the controller change. Wait for the controller project to update. This may take a few minutes. Note: From this point forward in the lab we will no longer be able to synchronize this project with Architect, since Emulator is not a supported controller type in Architect. Click Download again to start the download. While waiting for the emulated controller download to complete, read about RSLogix Emulate PlantPAx Process Application Development Lab I 35 of 132

36 RSLogix Emulate 5000 software is an engineering tool that is capable of emulating a Logix controller. It can be used in conjunction with Logix Designer 5000 and FTView Studio SE to write and test application code and HMI displays without the need to connect to a physical Logix controller. For this lab, RSLogix Emulate 5000 software is already running and the chassis has a controller configured in slot 2. Click Yes to change the controller back to Remote Run mode. The controller status button is green to indicate in Remote Run mode. Minimize the Logix Designer window. Section Summary The new Logical Organizer provides a way to view and create an organizational model of the system. Application Controller Templates are available with pre-loaded library content to start your Logix project. Process Strategies were used to quickly add pump control and level indication code to the project, supporting the concept of Re-use engineering to save time. PlantPAx Process Application Development Lab I 36 of 132

37 Configuring an HMI Project In this section of the lab, you will learn how to create and configure your logical servers (data, HMI, and alarms). All of these software components are assigned to a PASS server. You will also use FactoryTalk View Studio software and an HMI Project Template to provide a starting point for your HMI project. You will then create a graphic screen containing a pump object and a tank level object, which will be used to test our controller code. Choose an HMI Template Application templates are included in the RA Library of Process Objects for HMI applications. Three HMI Project templates are available each of which supports a different display resolution: - FTVSE_7_P1FHD_3_1_00.apa 1920 x 1080 Full HD - FTVSE_7_P1SXGA_3_1_00.apa 1280 x 1024 SXGA - FTVSE_7_P1WXGA_3_1_00.apa 1366 x 768 WXGA All of the above HMI templates include the following attributes: Basic display layout, Navigation, and Alarm displays. However, the HMI templates do not include Library objects; the Library objects must be imported into the templates. In the following lab section, we will build HMI objects and displays through drag and drop procedures in Studio Architect. Return to Studio Architect. In the Library Management pane on the right, expand the Libraries\Process Library (v3.5)\templates\factorytalk View SE folders. PlantPAx Process Application Development Lab I 37 of 132

38 In the Project Explorer pane, expand the Lab\Projects\PlantPAx\Area folders. Drag the P1fTemplate (1920 x 1080 Full HD) folder from the Library Management pane and drop it into the PlantPAx_HMI folder in the Project Explorer pane. PlantPAx Process Application Development Lab I 38 of 132

39 In the Library Management pane, expand the Libraries\Process Library (v3.5)\process Objects folders. Drag-and-drop the FactoryTalk View SE folder from the Library Management Pane to the PlantPAx_HMI folder in the Project Explorer pane. When you are alerted that a component already exists, click Yes repeatedly to replace the existing components. (This warning will appear many times, since the template and the process objects use many of the same images.) The Displays, Global Objects, Images, and Macros from the HMI template and the process object library have now been added to the View project in your Architect application. PlantPAx Process Application Development Lab I 39 of 132

40 Define the PASS Server Scroll to the bottom in the Project Explorer and Click + to expand Hardware Diagrams and then expand the Process Area. Right-click on PASS01 and then click Properties. The Computer Graphic Properties dialog box will open. On the general tab, leave the graphic name as PASS01. In the Device tab, type the computer name that hosts the PASS. In this lab, the computer name is ASEWS01. Type the computer name, ASEWS01 and click OK. PlantPAx Process Application Development Lab I 40 of 132

41 Configure a Data Server In this section, we will create a shortcut on the data servers to connect our controller. Observe the communication pane (bottom, left corner). Notice that currently there is no controller connection configured. We will now configure the controller connection. On the process area hardware diagram, drag the communication module from the PAC01 chassis and drop it into the PASS01 server. When the communication module is dropped onto the PASS server, the Configure Module dialog box appears. Leave the defaults and click OK. PlantPAx Process Application Development Lab I 41 of 132

42 Notice that the communication shortcut is updated with the communication module name. Drag the controller from the PAC01 chassis and drop it into the PASS01 server. PlantPAx Process Application Development Lab I 42 of 132

43 The Add New or Modify Existing Shortcut dialog box appears. Leave the default values and click OK. Notice that the controller shortcut now appears in the communications pane. Note: we will modify this shortcut later in the lab to point to the emulate controller. Save your Studio Architect project. PlantPAx Process Application Development Lab I 43 of 132

44 Configure an Alarm and Event Server In the Project Explorer, expand the Lab\Projects\PlantPAx\Area\Alarm folders. Right click on PlantPAx_AE and select Properties. The Tag Alarm and Event Server Properties dialog box appears. Studio Architect defaults the alarm name and host computer. In the General tab, type a Description, such as Lab AE Server. PlantPAx Process Application Development Lab I 44 of 132

45 In the Priorities tab, confirm that the server-assigned priorities are enabled. Click OK. In the Project Explorer, right-click PlantPAx and choose Commit Project. Committing a project pushes all changes made to it in Architect into the associated Logix Designer or FactoryTalk View project file. Any differences in the project file are overwritten. Architect creates a new project file if one does not exist. PlantPAx Process Application Development Lab I 45 of 132

46 Click OK on the Commit Summary dialog box. Committing a project pushes all changes made to it in Architect into the associated Logix Designer or FactoryTalk View project file. Any differences in the project file are overwritten. Architect creates a new project file if one does not exist. Wait for the project to commit. This may take a couple minutes. When finished, close the Commit dialog box to complete the configuration of the servers. PlantPAx Process Application Development Lab I 46 of 132

47 View and Modify HMI Objects In the Project Explorer of Studio Architect, right-click PlantPAx and choose Open Project in Designer. This will open the FactotyTalk View Studio application. Wait a short time while the FactoryTalk View Studio application opens. FactoryTalk View Studio FactoryTalk View Studio is configuration software for developing and testing PlantPAx HMI applications. With FactoryTalk View Studio, you can: Configure a single operator station or configure an entire distributed application from one location Access tags via a tag browser that presents direct PLC tags and HMI tags in a logical hierarchy Remotely configure FactoryTalk View Site Edition servers Create displays and faceplates using a full-featured graphics editor When FactoryTalk View Studio is completely open, expand the PlantPAx\Area\Data\PlantPAX_DAT folders and then double click on Communication Setup. The PAC01 controller shortcut is currently directed to the 1756-L74 controller that we configured in Architect. Since we are using the emulator in the lab, we need to re-direct the controller shortcut to the Emulator. PlantPAx Process Application Development Lab I 47 of 132

48 With the PAC01 shortcut selected, expand the virtual backplane, 1789-A17 and select the RSLogix 5000 Emulator in slot 2. Click Apply. Click Yes to confirm the change to the shortcut. Click OK. Note: The communication setup can typically be configured within the Studio Architect software, but in the lab setting, we are using Emulator, which is not a supported controller type in Studio Architect. PlantPAx Process Application Development Lab I 48 of 132

49 View and Modify HMI Objects Expand the Displays folder and scroll down (to near the bottom of the list of displays) until you find the display named P1f Home (where the P1 stands for Process Area 1 and the f means this graphic is configured for full 1920x1080 resolution screens). Double-click on the display named P1f Home to open the display editor. This is the blank P1f Home display. We will start with this display because navigation to it is already configured on the template button bars. The next step will be to add a pump and level object for Tank1 to the display and then link the objects to tags in the controller. The easiest way to do this will be to use Global Objects. PlantPAx Process Application Development Lab I 49 of 132

50 Global Objects A global object is an HMI display element that is created once and referenced multiple times on multiple displays in an application. When changes are made to the original (base) object, the instantiated copies are automatically updated. In the Explorer window, expand the Global Objects folder. Scroll down until you find the global object named (RA-BAS) P_Motor Graphics Library. The RA-BAS stands for Rockwell Automation Base library and the P_Motor means this screen contains motor objects for process control. Double-click on the Global Object (RA-BAS) P_Motor Graphics Library to open the display editor. For rapid development of information-rich operator displays, the Rockwell Automation Library of Process Objects provides a collection of Global Objects that are linked to the Add-On Instructions with a drag and drop wizard. Display elements include motors, valves, analog and digital indicators and even a sequencer. Together with the HMI Project Templates they allow for rapid development of display graphics. PlantPAx Process Application Development Lab I 50 of 132

51 Drag-and-Drop a Pump object from the Global Objects display to the blank P1f Home graphic. In the Explorer window, search the Global Objects folder, scrolling until you find the global object named (RA-BAS) P_AIn Graphics Library. The RA-BAS stands for Rockwell Automation Base library and the P_AIn means this screen contains analog input objects for process control. Double-click on the Global Object (RA-BAS) P_AIn Graphics Library) to open the display editor. PlantPAx Process Application Development Lab I 51 of 132

52 Drag-and-Drop an Analog Input object from the Global Objects display above the pump on the P1f Home graphic. Right-click on the new pump object in the Main graphic window and select Global Object Parameter Values from the selection menu. The Global Object Parameter Values window opens. We need to enter the tag Value for the Motor into parameter 1. This parameter links the tag PMP100 (that we created earlier in the Logix code) to this instance of the pump object. For parameter 1, click on the ellipsis button in the column named Tag to open a Tag Browser window. PlantPAx Process Application Development Lab I 52 of 132

53 The Tag Browser window allows you to access controller tags via a browser window that presents the controller tags in a logical hierarchy. Click the Refresh All Folders button. Expand the directory named PlantPAX/Area/Data/PAC01 ( PAC01 is the data server shortcut name for the controller in slot 2 in the Emulator). Then expand the subdirectory named Online. Scroll-down the list and select the tag PMP100. Verify that the Selected Tag is /Area/Data::[PAC01]PMP100. Click OK. PlantPAx Process Application Development Lab I 53 of 132

54 Click OK once more to accept the updated parameter. Right-click on the new Analog Input object and select Global Object Parameter Values from the selection menu. The Global Object Parameter Values window opens. We need to enter the tag Value for the Level into parameter 1. Type {/Area/Data::[PAC01]LT100} or click the ellipsis button and select {/Area/Data::[PAC01]LT100}. Click OK to accept the updated parameter. PlantPAx Process Application Development Lab I 54 of 132

55 Click on the Save button to save the updates to the P1f Home display. The display is complete and functional but can be customized with tanks, piping, and more. The following section introduces and uses the Symbol Factory HMI library to add a tank symbol to the display. PlantPAx Process Application Development Lab I 55 of 132

56 Using the Symbol Factory HMI Library The Symbol Factory is an HMI library of over 5,000 graphics symbols for use in process HMI applications. Symbols include pumps, pipes, valves, tanks, mixers, motors, ducts, electrical symbols, flow meters, material handling, sensors, PLCs, transmitters, and ISA symbols. You can use drag-and-drop to transfer symbols from the Symbol Factory into an HMI display. Double-click the Symbol Factory folder in the Explorer window. Wait for the Symbol Factory window to open. Drag-and-drop a tank symbol from the Symbol Factory to the P1f_Home display. Categories include: pumps pipes valves tanks mixers motors ducts electrical symbols flow meters material handling sensors Transmitters and more Close the Symbol Factory window. PlantPAx Process Application Development Lab I 56 of 132

57 On the P1f Home display, place the cursor on the upper-right corner of the new tank and click-and-drag to enlarge the tank and cover the pump and level objects. Then, right-click on the tank, select Arrange. Click on Send to Back from the selection menu to place the tank behind the pump and level objects. To make the testing more interesting for the lab, code has been preconfigured in the PAC01 controller to simulate a decrease in tank level when the pump is running. This simulation includes code for resetting the tank level. We will add a button to this display, which will be used for setting the reset bit in the simulation code. From the FactoryTalk View Studio Objects menu, select Push Button, and then Button. PlantPAx Process Application Development Lab I 57 of 132

58 Draw a rectangle in the upper left portion of the display. The Button Properties dialog box will appear. On the Action tab, type (or copy and paste from below) the following for the Release action: &Set /Area/Data::[PAC01]HMI_Reset_System 1 PlantPAx Process Application Development Lab I 58 of 132

59 On the Up Appearance tab, type Reset Tank Levels as the Caption. Click OK. The P1f Home display should look like this. Click on the Save button to save the updates to the P1f Home display. PlantPAx Process Application Development Lab I 59 of 132

60 Section Summary: For rapid development of operator displays, the Rockwell Automation Library of Process Objects provides a collection of Global Objects that are linked to the Add-On Instructions with a drag and drop wizard. Together with the HMI Project Templates they allow for rapid development of display graphics. PlantPAx Process Application Development Lab I 60 of 132

61 Testing the Code and HMI Application The application (code and HMI) is finished; test it by running the FactoryTalk ViewSE Client. Create and Run an OWS Client File FactoryTalk View SE Client is software for viewing and interacting with the FactoryTalk View SE application at run time. Operators can use the client to view and interact with multiple graphic displays, manage alarms, view trends and adjust set points. From the FactoryTalk View Studio software Tools menu, choose Launch SE Client. To create a new client file, click New. PlantPAx Process Application Development Lab I 61 of 132

62 Type Lab as the name for the new configuration file. Click Next. Select Network Distributed and click Next. PlantPAx Process Application Development Lab I 62 of 132

63 From the pull-down menu, choose PlantPAx as the application. Click Next. Click the ellipsis button to select an Area name. Choose PlantPAX/Area in the browser and click OK. PlantPAx Process Application Development Lab I 63 of 132

64 From the Startup macro pull-down menu, choose P1f_Client as the startup macro. The startup macro launches the initial displays and docks the navigation and alarm tool bars. Click next. Uncheck Show Diagnostics List and click Next. PlantPAx Process Application Development Lab I 64 of 132

65 Click Next. Click Finish. Wait for the project to load and the client window to open. PlantPAx Process Application Development Lab I 65 of 132

66 When the client file opens, your application window appears with the layout of the selected template. Notice the docked Header and Footer displays. They are part of the Framework displays contained in the HMI template that also includes button bars and alarm history and help displays. The template Header graphic is used to display information that will always be visible to the operator, such as the current date and time, name of the current area, general alarm and system status and navigation buttons. Click on the Reset Tank Levels button on the display. Wait for the tank level to fill to 60%. PlantPAx Process Application Development Lab I 66 of 132

67 We are now ready to test our application. We can now start the pump and empty the tank. Click on the pump object to open the operator faceplate. From the operator faceplate, click on the green start button to start the pump. The pump will start running and the tank empties. Minimize the Client window. The lab section is complete. PlantPAx Process Application Development Lab I 67 of 132

68 Re-Use Code Easily using Logical Organizer The new Logical Organizer provides a way to view an organizational model of the system. This allows engineers to modify the system more quickly. New features such as Selecting Multiple project components like AOI's, UDT's, Programs, and then copy/paste, drag/drop, export/ import them as one to reduce engineering time. In this section of the lab we will be doing a copy/paste of program Tank1 to a new tank program Tank2. For this part of the lab we will work in the new Logical Organizer window. Maximize the Logix Designer window. In the previous section of the lab we made Logix code additions offline and then loaded the controller. In this section we will be making code changes online to the running controller to demonstrate how code can be added without interrupting the operations of a running plant. In the Logical Organizer window, Right-click the program Tank1 and click Copy. PlantPAx Process Application Development Lab I 68 of 132

69 Right-click on the controller, PAC01. Click on Paste Special and then select With Configuration. Wait for the Paste Configuration window to open. Change the Final Name of the routine from Tank1 to Tank2 and Hit Enter. Do not click OK yet. Schedule the new Tank2 program in Task_D_500ms by using the drop-down menu. PlantPAx Process Application Development Lab I 69 of 132

70 Click on the Tags folder in the Import Content area of the window. Notice that tag references in the Process Strategy for Tank1 are 100 series tags (PMP100, LT100). For Tank2, during the paste we will find and replace the 100 with 200 for all tags. Click on the Find/Replace button. Find all instances of 100 and replace with 200. Confirm that only Final Name is checked in the Find Within options. Then click the Replace All button. Now click OK. PlantPAx Process Application Development Lab I 70 of 132

71 Because the controller is running and we are making edits to the code On-line, we need choose how the edits will be imported. Check the selection for Finalize All Edits In Program during the import and click OK. Wait for the import to complete. A new program named Tank2 has been added. Add a New Tank2 to the HMI Application in FactoryTalk View Studio Maximize the FactoryTalk View Studio window. PlantPAx Process Application Development Lab I 71 of 132

72 On the P1f Home display, use the cursor to highlight the Tank1 objects and then click Arrange from the editing selections on the upper menu bar. Click Group from the drop-down menu. This groups the objects. Right-click on the grouped tank objects and select Duplicate from the dropdown menu. PlantPAx Process Application Development Lab I 72 of 132

73 Position the new tank to the right of Tank1. Right-click on the new tank group and select Tag Substitution. In the Tag Substitution window Search for 100 and Replace with 200. Click the Replace button. Click the Replace All button. PlantPAx Process Application Development Lab I 73 of 132

74 Click OK. Click on the Save button to save the updates to the P1f Home display. Minimize the FactoryTalk View Studio window. To test the code and graphic updates, Maximize the FactoryTalk View Client window. At the lower corner of the View Client screen, click the Refresh button to view the updated display. PlantPAx Process Application Development Lab I 74 of 132

75 Click on the Reset Tank Levels button on the top button bar. Wait for the level in Tank1 to fill to 60% and Tank2 to 50%. Start pump 2 (pump 1 should still be running) and verify that both tanks drain. Notice that the labels and descriptions for the pump and level objects still reflect the XT100 and MT100 descriptions, which are the default descriptions from the process strategies. In the next section of the lab, Commissioning the Device Faceplates, you will learn how to configure the tag descriptions and labels. PlantPAx Process Application Development Lab I 75 of 132

76 Commissioning the Device Faceplates In this section, you will configure the tag descriptions, labels, and interlocks for the new tanks. We will focus on tank 1. (If you have time at the end of the lab, you can correct the tank 2 information as well). This can be done from the Engineering tab of the PlantPAx device faceplates in the running Client application. For larger applications, this configuration would be completed off-line using Rockwell s Tag Data Editing Tool. From the FactoryTalk View Client window, click on the Home Screen button on the button bar to display the tank screen (if not already displayed). Notice the labels for the pumps and levels still show the default names from the Process Strategy templates. Click on the Tank 1 Level indicator to open the P_AIn faceplate. PlantPAx Process Application Development Lab I 76 of 132

77 Click on the Engineering Tab. The faceplate labels and descriptions are still at their default values from the PS_AIn Process Strategy template. We need to change this text to Tank 1 Level" and LT100 as shown below, hitting the Enter key at each field. (Note: this data is stored in the controller, you must hit Enter in order to download the new data to the controller.) Note: To make changes from the Engineering tab, the user must have the appropriate access rights. Due to time constraints, we will not be addressing security in this lab. The current login, Administrator has the highest level of security access. PlantPAx Process Application Development Lab I 77 of 132

78 Notice the description at the top of the faceplate and the label for the level indicator have been updated to reflect the changes that have just been made. The alarm thresholds for the Tank 1 level also need to be configured. Click on the Maintenance tab of the faceplate. This tab allows us to change the alarm setpoints (Thresholds). Change the PV Low-Low alarm Threshold to a value of (Click on the value to launch the numeric keypad entry popup). Note: In this lab we are configuring a single alarm limit. There is a PlantPAx Alarm Configurator tool available for configuring a large number of alarms. PlantPAx Process Application Development Lab I 78 of 132

79 Click on the alarm tab and you will see that a Low-Low alarm is now active for Tank 1 Level. Click on the Alarm Acknowledge button and the alarm indicator will stop blinking. It will remain red until the alarm condition clears. PlantPAx Process Application Development Lab I 79 of 132

80 Click on the Reset Tank Levels button and the alarm condition will clear. Close the Tank 1 Level faceplate. Click on the Tank 1 Pump to open the device faceplate. PlantPAx Process Application Development Lab I 80 of 132

81 Click the Engineering tab. Edit the description, label and tag as shown below. (Be sure to hit Enter after each text entry). Note: The motor Process Strategy that we used is preconfigured with motor run feedback, permissive, interlock, and restart inhibit objects enabled. If we did not need these for our application, we could disable the functionality for this object by removing the appropriate check boxes on this tab of the faceplate. We will keep this functionality for our application. PlantPAx Process Application Development Lab I 81 of 132

82 Configure an Interlock Since Pump 100 is still running, the tank level will decrease and a low-low level alarm will become active again. (If the pump is stopped, start it and wait for the tank level to drain). Although the tank is empty, the discharge pump continues to run. Let s configue an interlock that will stop the pump on low-low tank level. Maximize the Logix Designer window. Double-click on the Pump routine in the Tank1 program. PlantPAx Process Application Development Lab I 82 of 132

83 Select Sheet 3 from the drop down menu to view the Interlocks configuration for the pump. This Process Strategy has been configured with an interlock object, however, no interlocks have been configured for this device. Let s add an interlock on tank low-low level for this pump. To make these changes online, click the Start Pending Routine Edits button. PlantPAx Process Application Development Lab I 83 of 132

84 Add an Input Reference object and connect it to the Inp_Intlk00 input on the P_Intlk object. Double-click on the input reference and type LT100.Sts_LoLo. PlantPAx Process Application Development Lab I 84 of 132

85 Finalize all the Edits in the Program by clicking the Finalize button in the Online toolbar. Click Yes to confirm. Maximize the FactoryTalk View Client window. PlantPAx Process Application Development Lab I 85 of 132

86 Return to the Home tab of the pump faceplate.notice that the pump has been stopped and the Interlock Status button is now red. To view the Interlock faceplate, click on the red interlocks stop sign button. The interlock description has not yet been configured to match the interlock configuration that we implemented in step x above. Click on the Engineering tab. Change the label and tag text fields as shown below, hitting the Enter key after entering the text, and then click on Sheet 2. PlantPAx Process Application Development Lab I 86 of 132

87 Change the text field as shown below, hitting the Enter key after entering the text, and then click on sheet 3 of the Engineering tab. Check the box to the left of the interlock descriptor to allow navigation from the interlock faceplate to the Interlock Input Object. Change the text field as shown below, hitting the Enter key after entering the text. Return to the Home tab of the interlock faceplate. Notice a text description now appears for the interlock condition and a black navigation-box appears when you scroll your mouse over the interlock condition. This can be used to click directly to the interlock tag s faceplate. For this feature to work, a path must be configured in your global object parameters for the device. If you click on the Tank 1 Level OK interlock now, nothing will happen. Maximize the FactoryTalk View Studio window. PlantPAx Process Application Development Lab I 87 of 132

88 On the P1f Home display, select the Tank1 group and then click Arrange from the editing selections on the upper menu bar. Click Ungroup from the drop-down menu. Ungrouping will make it easier to modify the global object parameters for the pump object. Right-click on the pump and select Global Object Parameter Values. PlantPAx Process Application Development Lab I 88 of 132

89 Type /Area/Data::[PAC01] as the path for the pump object for the #103 parameter. Click OK. Click on the Save button to save the updates to the P1f Home display. Maximize the FactoryTalk View Client window. Click the Refresh button to view the updated display. PlantPAx Process Application Development Lab I 89 of 132

90 Click on PMP100 to launch the pump faceplate, and then click on the interlock button. Mouse over and click on the interlock condition. This will now launch the level faceplate, PlantPAx Process Application Development Lab I 90 of 132

91 Click the acknowledge button on the home tab of the level faceplate to acknowledge the alarm. Click Reset Tank Levels and the interlock condition will clear (Move faceplates down if they are covering the reset button). The configuration for the Tank 1 faceplates is complete. Close the open faceplates. Later, if you have extra time in the lab, feel free to configure the faceplates for Tank 2. PlantPAx Process Application Development Lab I 91 of 132

92 Configuring Alarms In this section of the lab, we will set up tag-based alarms for use with the FactoryTalk Alarm and Event software. Prior to the lab, the alarm builder tool was used to generate an alarm import file for the PAC01 controller. (Refer to publication PROCES-RM002 for more information on the alarm builder tool.) Maximize FactoryTalk View Studio. Expand the PlantPAX, Area, and Alarm folders. Right-click on PlantPAx_AE and select Import and Export Choose Import alarm configuration from XML file. Click Next. PlantPAx Process Application Development Lab I 92 of 132

93 Click the ellipsis to browse to the HMI Projects folder and select the Lab Alarms.xml file. Click Open. Click Next. PlantPAx Process Application Development Lab I 93 of 132

94 Select Update existing alarm definitions and create new alarm definitions from the import file. Click Finish. When the import completes, click OK. PlantPAx Process Application Development Lab I 94 of 132

95 Configure an Alarm Group A new feature of FactoryTalk View SE 8.1 is the ability to easily configure and filter on alarm groups. In the explorer window, expand PlantPAx_AE and double click on Alarm and Event Setup. Right click on PlantPAx_AE and select Add Group. PlantPAx Process Application Development Lab I 95 of 132

96 Type Tank1 for the group name. Right click on PlantPAx_AE and select Add Group to add a second group. Type Tank2 for the group name. Highlight the LT100 alarms (Select the first alarm and press the Shift key and select the last alarm). Drag-anddrop the LT100 alarms into the Tank1 alarm group. PlantPAx Process Application Development Lab I 96 of 132

97 Select the LT200 alarms and drag-and-drop them into the Tank 2 alarm group. Click the Save icon in the Alarm and Event Setup window. PlantPAx Process Application Development Lab I 97 of 132

98 Configure an Alarm Banner From the Explorer pane, expand the Graphics/Displays folder and double-click (FRAME)P1f Footer to open the footer display. Right click on the display and select Properties to access the Alarm and Event Banner Properties dialog box. PlantPAx Process Application Development Lab I 98 of 132

99 Click on the Columns tab. Check the Alarm Name box to display the Alarm Name in the alarm banner. Click the Event Subscriptions tab, under Scopes, click Browse. The Select Scope window appears. PlantPAx Process Application Development Lab I 99 of 132

100 Expand as shown below and select Tank1 and click OK. Click OK. Click Save to save the P1f Footer display. PlantPAx Process Application Development Lab I 100 of 132

101 View Alarm Banner and Alarm Summary Maximize the FactoryTalk View Client. At the lower corner of the View Client screen, click the Refresh button. Start both pumps if they are not already running by clicking on the pump to launch the faceplate and then clicking the start button. The low-low alarm threshold for Tank 1 was configured in the previous lab section. We will need to configure the threshold for Tank 2 in order to view the alarm in the alarm banner. Click on the Tank 2 Level indicator to open the P_AIn faceplate. PlantPAx Process Application Development Lab I 101 of 132

102 Click on the Maintenance tab of the faceplate. Change the PV Low-Low alarm Threshold to a value of (Click on the value to launch the numeric keypad entry popup). Close the open faceplates. Wait for the tanks to drain. Notice that both tank levels now indicate alarm conditions. However, only the alarm for Tank 1 appears in the alarm banner. This is because we configured the alarm banner to only show alarms in the Tank1 alarm group. PlantPAx Process Application Development Lab I 102 of 132

103 Click on the Alarm summary button in the header. Notice that the alarms for both LT100 and LT200 appear in the alarm summary. Maximize FactoryTalk View Studio. The P1f Footer display should still be open. Double-click on the display to open the Alarm and Event Banner Properties window. PlantPAx Process Application Development Lab I 103 of 132

104 From the Event Subscriptions tab, Browse and select Tank2 to add to the scope. Click OK. PlantPAx Process Application Development Lab I 104 of 132

105 Click OK. Click Save to save the P1f Footer display. Maximize the FactoryTalk View Client. At the lower corner of the View Client screen, click the Refresh button. PlantPAx Process Application Development Lab I 105 of 132

106 Notice the level alarms for both tanks now appear in the alarm banner on the home screen. Lab Summary PlantPAx is the process automation system from Rockwell Automation with all the core capabilities expected in a world-class modern distributed control system (MDCS). Configure your Integrated Architecture control system to meet the PlantPAx system guidelines and you can call it PlantPAx. The Studio 5000 applicaiton can help reduce the engineering time to assemble your integrated architecture and process application. The Rockwell Automation Library of Process Objects is a collection of Application Templates, Application Code, Graphic Objects, Faceplates and Process Control Strategies that let you quickly configure a device from I/O to operator interface in just a few mouse clicks. Engineering your modern DCS has never been easier. PlantPAx Process Application Development Lab I 106 of 132

107 Optional Lab Sections Configuring a Control Loop In this section of the lab, you will configure a control loop and a variable speed drive, which will be used for controlling pressure. Maximize the Logix Designer window. We will add the drive and the pressure control loop to task B, which is a 100 msec task. Rename the main program in Task B, from Task_B_MainProgram to Pressure_Control by double-clicking on Task_B_MainProgram to open the Program Properties window. Change the Name of the program to Pressure_Control and click OK. PlantPAx Process Application Development Lab I 107 of 132

108 In this section, we will import a pre-configured Process Strategy routine for a PID with an analog input into the program named Pressure_Control. Right-click on the program named Pressure_Control. From the menus select Add and then Import Routine. In the Process Strategies folder, select the file for a PID with analog input, (RA-LIB)PS_PID_AIn_3_5-00_ROUTINE.L5X, and click Open. PlantPAx Process Application Development Lab I 108 of 132

109 The Import Configuration window will open. Change the Final Name for the routine from XIC501 to Loop. Do not click OK. In the Import Content area of the configuration window, click on the Tags folder to view all the tags that will be imported. Click on the Find/Replace button. PlantPAx Process Application Development Lab I 109 of 132

110 X is used in the process strategy to represent a generic instrument. We will change the X to a P to represent pressure. Find all the instances of X in the tag references and replace with P. Confirm that only Final Name is checked in the Find Within options. Then click the Replace All button. We would also like to replace the default loop number from the process strategy, 501, with 400. Find all the instances of 501 in the tag references and replace with 400. Confirm that only Final Name is checked in the Find Within options. Then click the Replace All button. Now click OK. PlantPAx Process Application Development Lab I 110 of 132

111 Choose Import Logic Edits as Pending. We will make additional changes to this routine after importing the process strategy for the drive. Click OK. Next, we will import a pre-configured Process Strategy routine for a variable speed drive, into the program named Pressure_Control. Right-click on the Pressure_Control program, select Add and then Import Routine. PlantPAx Process Application Development Lab I 111 of 132

112 In the Process Strategies folder, select the file for a variable speed drive (VSD), (RA-LIB)PS_VSD_3_5-00_ROUTINE.L5X, and click Open. The Import Configuration window will open. Change the Final Name for the routine from MT300 to Drive. Do not click OK. PlantPAx Process Application Development Lab I 112 of 132

113 In the Import Content area of the configuration window, click on the Tags folder to view all the tags that will be imported. Click on the Find/Replace button. We will keep the MT designator in the tag, but change the loop number to 400. Find all the instances of 300 in the tag references and replace with 400. Confirm that only Final Name is checked in the Find Within options. Then click the Replace All button. Now click OK. Choose Import Logic Edits as Pending. We will make changes to this routine after importing. Click OK. PlantPAx Process Application Development Lab I 113 of 132

114 Double click on the Drive routine in the Pressure_Control program to open it. The output of the P_PIDE block (Out_CV) will be used as the program setpoint for the speed reference on the P_VSD block (PSet_SpeedRef ). To configure this input we need to expose the PSet_SpeedRef parameter. Click on the ellipsis on the P_VSD to view the block properties. Scroll to the PSet_SpeedRef parameter (click on Sort Parameters to view the parameters in alphabetical order) and check the Vis box to make the parameter visible. Click OK. PlantPAx Process Application Development Lab I 114 of 132

115 Add an Input Reference object and connect it to the PSet_SpeedRef input on the P_VSD object. Double-click on the input reference and type PIC400_Out_CV. Double click on the Loop routine in the Pressure_Control program to open it. PlantPAx Process Application Development Lab I 115 of 132

116 When the drive is not in program mode, we want to force the P_PIDE block to initialize its CV value and track the speed target to the drive (which may be manually controlled by the operator). We will use the P_VSD outputs Sts_Available and Val_SpeedRef as the CV Initialize request and CV Initialize values respectively. We need to make these parameters visible in the code. Click on the ellipsis on the P_PIDE to view the block properties. Check the Vis box for the Inp_CVInitVal and Inp_UseCVInitVal parameters (click on Sort Parameters to view the parameters in alphabetical order). Click OK. PlantPAx Process Application Development Lab I 116 of 132

117 Add an Input Reference object and connect it to the Inp_CVInitVal input on the P_PIDE object. Double-click on the input reference and type MT400.Val_SpeedRef. PlantPAx Process Application Development Lab I 117 of 132

118 Add another Input Reference object and configure it with the tag MT400.Sts_Available. When the Sts_Available value is False (the drive is not in program mode), the P_PIDE should initialize its CV value. We need to add a Boolean Not block to this input before connecting it to the Inp_UseCVInitVal input on the P_PIDE. Scroll through the Favorites and find the BNOT instruction. Click on the instruction to add a BNOT block to the sheet. PlantPAx Process Application Development Lab I 118 of 132

119 Connect MT400.Sts_Available to the input of the BNOT block. Connect the output of the BNOT block to the Inp_UseCVInitVal input on the P_PIDE block as shown below. Next we need to add Jump to Subroutine (JSR) instructions to execute the new routines. Double-click the MainRoutine for Pressure_Control. Click on Rung 0 to select the rung (indicated by a blue box) and then right-click and select ADD Rung. PlantPAx Process Application Development Lab I 119 of 132

120 Put the cursor on the rung and type JSR and click the Enter key. After adding the JSR to the rung, type Drive for the Routine Name. Add another rung for the JSR that will execute the Loop routine. Click on Rung 1 to select the rung (indicated by the blue box), right-click and select Copy Rung from the menu. Click on the bottom rung (End) to select the rung (indicated by a blue box) and then right-click and select Paste from the selection window. Change the Routine Name for the JSR in rung 2 to Loop. PlantPAx Process Application Development Lab I 120 of 132

121 You are now ready to finalize all of the Edits in the Pressure_Control Program. Click the Finalize button. Click Yes when prompted, to finalize all of the edit in the program. Save your Logix Designer project by clicking the Save button. Click Yes when prompted to upload the tag values prior to saving. Minimize the Logix Designer window. PlantPAx Process Application Development Lab I 121 of 132

122 Maximize the FactoryTalk View Studio window. To save time in the lab, a display named P1F Process has already been created for the drive and PID controller. We will import this display into our application and configure the button bar to launch this display. In the explorer pane, right-click on Displays and select Add Component Into Application... Browse to the C:\Lab Files\FTViewSE Components folder and select the p1f process.gfx file. Click Open., PlantPAx Process Application Development Lab I 122 of 132

123 Expand the Displays folder and Double click on P1f HButtonBar. Double click on the Screen 1 button to open the Button Properties window. Select the Action tab. Type Display P1f Process as the Release action. PlantPAx Process Application Development Lab I 123 of 132

124 Select the Up Appearance Tab. Type Process Screen as the Caption. Click OK. Click on the Save button to save the updates to the P1f HButtonBar display. Maximize the FactoryTalk View Client window. Click the Refresh button to view the updated display. PlantPAx Process Application Development Lab I 124 of 132

125 Click the Process Screen button in the navigation bar. The process screen is displayed with the VSD and PID objects, which were configured prior to the lab. On the display, click the motor to launch the P_VSD faceplate. PlantPAx Process Application Development Lab I 125 of 132

126 Select the Maintenance tab and then select Sheet 2. Enter a maximum speed reference limit of 100, by clicking on the Maximum value, typing 100 in the numeric entry keypad and then clicking OK. Select the Engineering tab and type % for the speed reference engineering unit value. Be sure to hit Enter after typing the text. PlantPAx Process Application Development Lab I 126 of 132

127 Click the PID object to launch the P_PID faceplate. Drag the P_PID faceplate to the right so that you can see both faceplates. PlantPAx Process Application Development Lab I 127 of 132

128 We will manually change the speed reference on the drive and see that the loop CV will track the reference value that we enter, since the drive is currently not in program mode. From the P_VSD faceplate, select the Home tab. Click on the Speed Reference input. Type in a new value and click OK. Notice the CV on the PID loop will track the value that you entered for the VSD speed reference. PlantPAx Process Application Development Lab I 128 of 132

129 Next we want to place the loop in auto mode and the VSD in program mode to allow the controller to control pressure. First we need to configure the gains on the PID. Select the Maintenance tab on the PID faceplate, and then sheet 3. Enter 1 for the Proportional gain and 0.5 for the Integral gain. Select the Engineering tab of the PID faceplate and then select sheet 2. Uncheck the box to force the loop to manual mode when an init request is present. This will allow us to place the loop in Auto mode, even though the VSD is not in program mode. PlantPAx Process Application Development Lab I 129 of 132

130 Return to the Home tab and place the loop in Auto mode. The PID CV output is still initializing and tracking the output of the VSD since the VSD is not in program mode. On the VSD faceplate, select the Engineering tab and then sheet 2. Click the mode configuration button. PlantPAx Process Application Development Lab I 130 of 132

131 Select Program mode as the default mode. Close the Mode Configuration window. Return to the Home tab of the VSD faceplate and request Program mode. PlantPAx Process Application Development Lab I 131 of 132

132 The PID loop will no longer be in CV initialize mode. Enter a pressure setpoint from the PID faceplate. The loop CV will increase or decrease accordingly and will update the speed reference setpoint on the drive. You have successfully configured a pressure control loop to regulate the speed of a drive. PlantPAx Process Application Development Lab I 132 of 132