SafetyNet Logic Workbench Getting Started Guide

Transcription

1 SafetyNet Logic Workbench Getting Started Guide GE Intelligent Platforms, Inc Austin Drive Charlottesville, VA

2 The information in this manual is subject to change without notice and does not represent a commitment on the part of GE Intelligent Platforms, Inc. The software described in this manual is furnished under a license or nondisclosure agreement. This software may be used or copied only in accordance with the terms of this agreement. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose other than the purchaser's personal use without the written permission of GE Intelligent Platforms, Inc. Copyright 2009 by GE Intelligent Platforms, Inc. All rights reserved. All brand names and product names are trademarks or registered trademarks of their respective companies. SA The text and screen shots in this document are compatible with Workbench Version and subsequent releases. If you are running a previous version, please contact Technical Support.

3 SafetyNet Logic Workbench Getting Started Guide 3 Contents CONTENTS... 3 SECTION 1 INTRODUCTION... 5 Scope... 7 Intended Readers... 8 Accessing Additional Help... 8 Help Files... 8 Frequently Asked Questions (FAQ)... 8 Training... 9 Website... 9 Technical Support... 9 SECTION 2 WORKBENCH SOFTWARE COMPONENTS Workbench Tag Editor IO Configurator Controller Modules Discrete Control Reports Controller Statistics Network Configuration Utility Security Features SECTION 3 INSTALLATION Pre-Installation Information Installing the PAC8000 Control Center Workbench Post-Installation Activities Repairing the Installation SECTION 4 ADDITIONAL PRODUCT CD FEATURES Additional Programs Information SECTION 5 LICENSING SECTION 6 PROJECT TUTORIAL Launching the Workbench Creating a Project... 51

4 4 SafetyNet Logic Workbench Getting Started Guide Initial Controller Setup Configuring IO Modules Creating Project Tags Mapping Tags to Channels Mapping Tags to Discrete Control Creating a Safety Shutdown Strategy Using the Static Analyzer Tools Setting the IP Address of a SafetyNet Controller Downloading the IO Configuration Downloading the Safety Shutdown Strategy Debugging the Strategy Building the Trusted Hosts Table Assigning a Keyswitch Changing Controller Modes Setting the Controller Password Safe Writes from Non-Safe Applications ADDITIONAL INFORMATION GLOSSARY... 99

5 SafetyNet Logic Workbench Getting Started Guide 5 Section 1 Introduction SafetyNet is a comprehensive solution for safety related applications, including Process Shut Down (PSD), Emergency Shut Down (ESD) Systems, and Fire and Gas (F&G) applications. SafetyNet is certified to IEC by TÜV for use in SIL2 functional safety systems. SafetyNet achieves SIL2 certification without the use of redundant IO or redundant controllers. Redundant controllers can be added to the system to provide greater system availability. SafetyNet is built on the same control platform as the PAC8000 Process Automation System, enabling you to address your process control and functional safety needs on a common control platform. A single Safety Workbench provides a fully integrated, open solution for process control, discrete automation, strategy development, and process visualization for functional safety applications. The process engineer is supplied with the tools to design, implement, document, verify, validate, and maintain a process control system using the IEC programming languages. SafetyNet consists of a number of open system components, including: Workbench - an integrated project development environment that centralizes and coordinates project engineering, including instrument index, discrete control strategies, process visualization, (operating faceplates), history (alarming and trending), and project management. HMI - components for the PAC8000 Operator Interface (HMI), plant historian, and batch recipe management. Control Platform - a rugged, field-mountable system consisting of the controller and the 8000 Process IO system. The Workbench is an integrated engineering environment, which automatically configures the operator interface and historian. Due to the open nature of the system, other components that make use of industry standards such as Modbus, OPC, Ethernet, and HART can be easily integrated.

6 6 SafetyNet Logic Workbench Getting Started Guide Note: PAC8000 Open Control components can be used with any HMI software that communicates via Modbus or OPC. The safety controller is certified by TÜV to IEC for use in SIL2 applications. It provides the same hardware functionality as standard controllers (lock step redundancy, Ethernet redundancy, Peer to Peer data communication, and communication with other Modbus devices), but limits programming functionality to a subset of the IEC languages. The supported languages include Structured Text (ST), Ladder Diagram (LD), and Function Block Diagram (FBD). In addition, the set of standard operators, functions, and function blocks are limited to a set that is easily verified to ensure correct operation.

7 SafetyNet Logic Workbench Getting Started Guide 7 Scope The intent of this Getting Started Guide is to provide assistance in building your first application using the SafetyNet Logic Workbench. The Workbench system components are described, the product installation procedure is explained, the licensing and registration process is discussed, and a full project tutorial is provided. This guide is not intended to replace any of the available training courses. However, working through these procedures leads to a greater understanding of the Workbench, thereby enhancing the lessons in the training class. It is also assumed that readers have a basic understanding of Microsoft Windows and the features of their operating system. The installation process assumes that you are installing the product for the first time. If you are upgrading an existing installation, please refer to the Upgrade Instructions that were shipped with your product CD. This is not a hardware or safety manual and no attempt is made to explain such details. For additional installation information, please refer to: 8000 Controllers Hybrid, Process, Logic, and EBIM Instruction Manual Document number: INM /x I/O modules Instruction Manual (General Purpose and 2/2 Applications) Document number: INM /x I/O modules Instruction Manual (2/1 Applications) Document number: INM /x Power Supplies Configurations and Installation Document number: INM8900 SM 8800 Safety Manual An HMI is an integral part of any control system. While some aspects of Wonderware s InTouch are described in this guide, any HMI that can communicate via OPC, Modbus RTU, or Modbus TCP can be used with the control system. For detailed HMI information, please refer to the documentation provided by your HMI vendor.

8 8 SafetyNet Logic Workbench Getting Started Guide Intended Readers This Getting Started Guide is intended for those users who are: Installing the SafetyNet Logic Workbench for the first time Upgrading an existing application of the SafetyNet Logic Workbench Learning how to use the SafetyNet Logic Workbench Currently using the SafetyNet Logic Workbench, but wish to expand their knowledge in key areas, such as the IEC programming languages. Accessing Additional Help In addition to the Project Tutorial provided in this guide, there are various documents and help files available to assist in the successful operation of the SafetyNet Logic Workbench. Some examples are identified in this section. Help Files Application Help A full set of Help files is delivered and installed with the system. From any application, (Workbench, Network Configurator, etc.) you may select Help from the pull down Help menu item, click the Help option, if one is present on the form, or press the F1 key on the keyboard to view the Help. Each Help file has a detailed index, table of contents, and search function to expedite locating additional information for a particular topic. Workbench Wizards Manual This manual lists the Wizards included with the Workbench that allow you to quickly produce graphics in Wonderware s InTouch. This manual is located at the following path: <installation_directory>\documentation\workbench Wizards.pdf Frequently Asked Questions (FAQ) In addition to the online Help, the Workbench also contains a Frequently Asked Questions section. From the Workbench, select the Help Frequently Asked Questions menu item; a list of commonly asked questions and their answers is displayed.

9 SafetyNet Logic Workbench Getting Started Guide 9 In addition to the documentation provided within the product, various services are also available to assist in accessing help. These services are described below. Training In the Americas: Website PAC8000 offers three distinct training programs with formalized, instructor-led, hands-on training to familiarize customers with the systems they have purchased. Basic Training - This four-day class is designed to give students the necessary skills to engineer, configure, and maintain a PAC8000 system. Students create several projects during the class, allowing them to work through the complete project development cycle multiple times during the class (project configuration, tag creation, IO module configuration, control strategy development, downloading, and debugging). Maintenance Training - This one-day class is designed to give students the necessary skills to maintain and troubleshoot all areas of a PAC8000 system, including hardware and control strategies. SafetyNet Workbench Training - This three-day class is designed to teach students the skills necessary to configure, program, analyze, and troubleshoot a safety system strategy. This class is not a class in functional safety, but how to use our system, which is certified for use in an SIL2 application. On-site Training - In addition to the above training courses, on-site training is also available, as needed. This allows the course to be customized for your application needs. The Website ( contains links to data sheets and other information that can help you find solutions to potential issues when building and commissioning your control system. Technical Support Europe, the Middle East, and Africa (EMEA) Online Technical Support: Phone: Technical Support support.emea@ge-ip.com

10 10 SafetyNet Logic Workbench Getting Started Guide Customer Care Primary languages of support: English, French, German, Italian, Czech Support in the Americas (Americas) Online Technical Support: Phone: Technical support Customer care Primary Languages of support: English

11 SafetyNet Logic Workbench Getting Started Guide 11 Section 2 Workbench Software Components This section provides a high-level view of the SafetyNet Logic Workbench software components. Further details for each software component can be found in the Project Tutorial section of this guide or the Workbench online Help. This section of the guide is intended for those users who are: Installing the product for the first time Interested in a broad overview of the product The Workbench software includes the following system components: Workbench The Workbench provides the foundation for defining a project and all of its components: tags, hardware configuration, tables, and control logic. The Workbench, with components indicated, appears as follows:

12 12 SafetyNet Logic Workbench Getting Started Guide The Workbench consists of two main sections the Project Explorer and the Data Entry Panel. The Project Explorer, located in the left-hand pane of the Workbench, provides assistance with adding controllers, control strategies, tags, modules, etc. You will browse the Project Explorer tree to configure projects and controllers, as necessary. Projects are defined using the menu items displayed when the Project Explorer is active. Once created and defined, projects are displayed in the Project Explorer with three nodes: Project Tag Index, Project Reports, and Launch Network Configurator. After creating a project, project tags are defined through the Project Tag Index. A project tag is a name that refers to a channel on a physical IO card. As each tag is created, it is saved in a database allowing for subsequent data retrieval through the report manager. Controllers are the next project component to be added and configured. Controllers are abstractions of the physical hardware. Once a controller is created, the following nodes appear beneath the controller node in the Project Explorer: Controller Modules, Controller Reports, Controller Statistics, Launch 8000 IO Configurator, and Launch Discrete Control Interface. Each controller contains zero or more IO modules to which physical devices, such as transmitters and valves, are connected. The physical hardware is configured using the 8000 IO Configurator. Project tags that were created earlier are then linked to channels of the IO modules. Control logic can now be written. IEC logic is written using the Discrete Control Interface, which enables you to download compiled logic to a simulator. Downloading to the simulator allows logic to be checked out before it is downloaded to the controller. (The PAC8000 Workbench allows for downloads to the controller.) The IEC logic editor supports real time viewing so that logic can be viewed with data to assist in troubleshooting. Network information and controller diagnostic information can be viewed in either the Network Configurator or Controller Statistics. The Data Entry Panel occupies the right-hand pane of the Workbench. As specific tasks are selected in the Project Explorer, the Data Entry Panel changes to facilitate data entry. Each panel is specifically designed to provide intuitive and consistent data entry fields.

13 SafetyNet Logic Workbench Getting Started Guide 13 Tag Editor Project tags are names and attributes assigned to channels on IO modules. These tags are created through the Tag Editor. In addition to collecting the basic data for the tag (via the IO Definition tab), information required to populate the HMI database, such as alarm limits, can also be specified (via the HMI tab). If a complete instrument index is needed, specific information for the instrument, such as transmitter manufacturer, can also be entered (via the Manufacturer tab). The Tag Editor has two views: single tag and multi-tag display. When multi-tag display is selected, all tags are displayed in a spreadsheet format. This mode is useful when making changes that affect multiple tags. The Tag Editor also supports searching for tags based on one or more criteria. Tags matching the search criteria are displayed in Project Explorer under the Project Tag Index node. For more information regarding tag definition, please refer to the Creating Project Tags section in the online Help. If you wish to gain experience in defining tags, see the Creating Project Tags section in the Project Tutorial of this guide or refer to the labs in the Modules section of the Workbench Core Components Training Guide.

14 14 SafetyNet Logic Workbench Getting Started Guide 8000 IO Configurator The 8000 IO Configurator is launched to configure the system hardware (controllers and IO modules) when a controller is added to the project or the Launch 8000 IO Configurator node is double-clicked (for existing controllers). When the controller node ( ) is selected, the network attributes of the controller can be specified and IO modules can be added or deleted. Once a module is added, the specific attributes for each module can then be configured. Once the required data for the controller and each IO module is entered, the configuration data is downloaded to the controller using this utility. For more information regarding the 8000 IO Configurator, please refer to the IO Configurator Training Guide, located in the documentation directory (<installation_directory>\documentation\io Configurator Training Guide.pdf) or the IO Configurator online Help (<installation_directory>\documentation\ioconfig.chm).

15 SafetyNet Logic Workbench Getting Started Guide 15 Controller Modules Project tags are associated with IO module channels in the Controller Modules form. When a Spare channel is selected, a drop down list appears and all tags of the appropriate IO type that have not been assigned to another IO module channel are displayed. Select the tag and click Apply to assign the tag to the channel. You may also choose to create new tags from this screen by selecting the New Tag option from the Tagname drop down list. This allows new tags to be created without exiting the Assign Points form. For more information regarding Controller Modules, please refer to the Assigning Modules to Controllers section in the online Help or the Creating Project Tags, or Configuring IO Modules sections in the Project Tutorial of this Getting Started Guide.

16 16 SafetyNet Logic Workbench Getting Started Guide Discrete Control The Discrete Control Interface is used for IEC Programming. Once launched, programs, functions, and function blocks are built in any of the IEC languages: Ladder Diagram, Structured Text, and/or Function Block Diagram. Any mix of languages can be used, allowing you to choose the language that is appropriate for your application. For more information regarding Discrete Control, please refer to the online Help that is accessible in the Discrete Control Interface (select the Help Contents menu item within the Discrete Control Interface), or the Creating a Safety Shutdown Strategy section in the Project Tutorial.

17 SafetyNet Logic Workbench Getting Started Guide 17 Reports All project data is saved in a SQL Server database. Since this is a standard Microsoft database used by many other products, it is simple to create queries and reports for data presentation. The Reports feature contains a number of predefined reports at the project and controller level that aid in producing project documentation. If preferred, you may also create your own custom reports. Once the form is launched, select the appropriate report from the drop down list and click Run Report. The relevant data is retrieved and presented. Once the report has been run, it can be saved, printed, or ed. The Workbench provides support for Standard and Custom reports. Standard reports are shipped with the product and pertain to either a project or a controller. Custom reports are user-created, enabling you to customize the output to fit your documentation needs. Standard reports include tags assigned to controller modules, all tags and their corresponding addresses, and tags and where they are used. Standard reports can be tailored to meet your needs and you can also write your own reports. The SafetyNet system is delivered with the Standard report LogChangeReport, which generates a list of logged changes to the Workbench projects. For more information regarding Reports, please refer to the Reports section in the online Help or the Reports section in the Workbench Core Components Training Guide.

18 18 SafetyNet Logic Workbench Getting Started Guide Controller Statistics The Controller Statistics feature displays scan time breakdown, system parameters, and event logs. To access the Controller Statistics screen, expand the controller node In the Project Explorer and double-click to display the screen below. The top portion of the Statistics tab shows the breakdown of the controller scan time so that the most time consuming portion of the execution cycle can be determined. Other diagnostic data is also displayed, including the number of controller failovers, refreshes, and warm starts. The bottom portion of the screen shows the controller event log. The event log shows the last 512 events that have occurred in the controller. Such events can be triggered by channel failures, module failures, downloads, etc. The System Parameters, Control Package Params, Comm Stats, and Module/Channel Health tabs contain parameters that relate to execution and timeouts. These parameters do not normally need to be changed. If you feel it is necessary to make changes to any of these settings, please contact Technical Support before doing so, as unexpected results may occur. For more information regarding Controller Statistics, please refer to the Controller Statistics section in the online Help.

19 SafetyNet Logic Workbench Getting Started Guide 19 Network Configuration Utility The Network Configuration Utility is a network management tool that is used to assign IP addresses to unconfigured controllers and show network information for all controllers on a process network. When the utility is launched, the network is queried for all controllers and those found are presented, as shown below. Double-click a controller name to access detailed network information and send commands to the controller. For more information regarding the Network Configurator, please refer to the Network Configuration section in the online Help, the section on Initial Controller Setup in the Project Tutorial, or Network Configuration lab in the Workbench Core Components Training Guide.

20 20 SafetyNet Logic Workbench Getting Started Guide Security Features Since SIL2 systems are used to monitor and shutdown potentially dangerous processes, it is important to prevent unauthorized changes to the data and programs running in the controller. The SafetyNet Workbench provides the following security features: Security Privileges - Each Workbench user has a user id and password with which to logon. This logon indicates the types of changes that are permitted, as well as which data can be accessed and modified. Trusted Hosts Table - The Trusted Hosts Table prevents unauthorized devices (computers, COM ports, etc.) from making changes to data in the controller. Each device that is permitted to make data changes must have its MAC address listed in the controller s Trusted Hosts Table. Keyswitch - The keyswitch is a digital input from either a standard or safe point that can be used to lock the controller. When the controller is locked no writes, configuration changes, strategy changes, etc., can be made to the controller. When unlocked, data can be changed as long as the correct privileges have been assigned in the Trusted Hosts Table. Controller Password - For additional security, the controller can be given a password, which must be entered before the Trusted Hosts Table can be downloaded or the Mode can be changed. Configuration Mode and Safe Mode - In Configuration Mode, changes can be made to the data in the controller as long you are authorized to make the change (based on the security level of the login and the access granted to the computer by the Trusted Hosts Table) and the keyswitch is unlocked. In Safe Mode, changes are only permitted to the mode, i.e. changes from safe mode back to configuration mode, and to the Trusted Hosts Table, as allowed by the keyswitch setting. Change Log - Change tracking is automatically enabled for a safety controller. You can then run a report to view the changes that have been made. Each change gives a description of the change made, the logon id of the user making the change, and the date and time the change was made. Difference Tools - When a strategy is downloaded to the controller, a backup of the project is automatically made. The Workbench provides a File Differences Utility that allows you to see the changes made between versions.

21 SafetyNet Logic Workbench Getting Started Guide 21 Section 3 Installation This section describes the process of installing the Workbench. If the Workbench is already installed on your computer and you need to upgrade your installation, please refer to the Update Instructions that were shipped with your CD. Pre-Installation Information Before installing the Workbench, please ensure the following: The drive where the Workbench will be installed has been identified. You have administrative privileges on the machine. If you do not, the installation procedure will fail. The proper operating system is installed. The Workbench can only be installed on Windows 2000 SP4 (or later) or Windows XP SP1 (or later). Earlier versions of these operating systems or operating systems not mentioned will cause the installation to end with an error. Your PC hardware meets the hardware requirements of the software. You computer must be a Pentium III 700 or greater with at least 125 MB of RAM and 680 MB of free hard drive space. If you intend to install the Workbench on a drive other than the operating system root, you must still have at least 540 MB of disk space available on the drive where the operating system is installed. In addition, you must have at least 135 MB of disk space available on the drive on which the Workbench is installed. Virus protection software has been disabled. If it has not, errors may occur during the installation or the installation may take longer than expected. As soon as the installation completes, you may re-enable the virus protection software. All processes associated with the Workbench or the Universal IO server have been stopped. If they have not, you are prompted to stop them during the installation process. Note: If Wonderware s InTouch is your HMI, it must be installed before you install the Workbench. This is necessary because the Universal IO Server, which is installed along with the Workbench, requires InTouch s common components in order to properly install SuiteLink.

22 22 SafetyNet Logic Workbench Getting Started Guide During the installation of the Workbench, other components are installed. These components include: Universal IO Server Limited Edition - In order to communicate with the controller, the Workbench requires a Modbus TCP driver. The Universal IO Server is installed for this purpose..net Framework - Some of the Workbench components are built using.net technology. In order to take advantage of these components, the.net Framework is required. MSDE - The Microsoft Desktop Engine allows the Workbench to access MS-SQL type databases. If you already have a later version of MSDE or another compatible MS-SQL database driver installed, this component will not be installed. Sequence of Events - Sequence of Events (SOE) data gives an accurate time for event occurrence, along with the event value and other useful information. This data can then be used to help determine a specific order of occurrences or "Sequence of Events." There are two different kinds of events that can be recorded: data change events from SOE modules based on channel inputs or data change events from analog or digital registers found in the controller. Data change events can be recorded no faster than the cycle time of the controller while SOE module events are recorded in accord with times in the module s data sheet (order of milliseconds).

23 SafetyNet Logic Workbench Getting Started Guide 23 Installing the PAC8000 Control Center Workbench 1. Insert the product CD into the appropriate drive. 2. The PAC8000 Product Installation window appears. Click Next Page.

24 24 SafetyNet Logic Workbench Getting Started Guide 3. The Options screen appears. Select the PAC8000 Control Center option and click Go. Note: The text and screen shots in this document are compatible with Workbench Version and subsequent releases. Version x.x.x on the screen shots refers to the current version number of the product that is being installed.

25 SafetyNet Logic Workbench Getting Started Guide If Microsoft.NET Framework Version 1.1 SP1 is not installed on your computer, the following dialog appears while this version is installed. Proceed to the next step to continue. If you already have the current version of Microsoft.NET Framework, skip to step 6 in this section. 5. You are prompted to restart your computer. Click Restart on the following screen and the installation will automatically resume upon startup. 6. The Windows Installer screen appears.

26 26 SafetyNet Logic Workbench Getting Started Guide Note: If a standalone version of Sequence of Events (SOE) is installed on this computer, the following error occurs. Remove the existing version of SOE via the Control Panel. Once SOE has been removed, begin the Workbench installation again and an upgraded version of SOE will automatically be installed. 7. The Welcome to the InstallShield Wizard for PAC8000 Control Center screen appears. This screen may be visible for several minutes while the InstallShield Wizard is being prepared. If a previous installation of the Workbench exists on this computer, you may notice a reference to the current application.

27 SafetyNet Logic Workbench Getting Started Guide If a Workbench-related service or program is currently running, the Test State of Listed Services/Programs screen appears. A checkmark indicates which services/programs are running. Click Terminate Running Services/Programs to stop the services/programs. It may be necessary to click this button more than once to stop all occurrences. Be sure to scroll down the entire list to view all programs. When all services/programs have stopped, the option to Continue is enabled. Click Continue to proceed with the installation. You may also click Cancel to prematurely exit the installation and manually stop the services/programs from running if they cannot be stopped from this screen. If Cancel is selected, an error message is displayed to report that the installation cannot continue. Manually stop the running services/programs and restart the installation process.

28 28 SafetyNet Logic Workbench Getting Started Guide 9. The Welcome screen appears. Click Next to continue. 10. The License Agreement screen appears. Review the License Agreement and select the I accept the terms in the license agreement option. Click Next to continue.

29 SafetyNet Logic Workbench Getting Started Guide If the PAC8000 Workbench has already been installed on this computer, the PAC8000 Control Center Database screen appears. (Otherwise, proceed to the next step.) This screen prompts for the PAC8000 Control Center User Name and Password, as they may have been changed from the default sa and ocpcc2003. The fields on this screen retain the default values so you only need to click Next to proceed. Note: If incorrect values are entered, a message is displayed informing you to attach the databases using the Database Maintenance Utility. You may do so once the installation is complete. (You must have administrative privileges.)

30 30 SafetyNet Logic Workbench Getting Started Guide 12. The Setup Type screen appears. Select the appropriate installation type. Complete - To install the Workbench to the C drive, select the Complete option and click Next to continue. Proceed to the next step. Custom - To install the Workbench to a location other than the C drive, select the Custom option and click Next. Proceed to step a, below.

31 SafetyNet Logic Workbench Getting Started Guide 31 a. The Custom Setup screen appears; click Change. b. Select the desired location for installation from the Change Current Destination Folder screen and click OK.

32 32 SafetyNet Logic Workbench Getting Started Guide c. The Custom Setup screen appears again. Click Next to continue with the installation. Note: This procedure only installs the PAC8000 software on the selected drive. Other files are installed to Program Files on the drive where the operating system is installed. As previously indicated, 680 MB of disk space is required for the complete installation. However, when an alternate drive is selected, 135 MB is required on the selected drive and 540 MB is required on the drive where the operating system is installed.

33 SafetyNet Logic Workbench Getting Started Guide The Ready to Install the Program screen appears. Click Install. 14. The Installation status screen appears.

34 34 SafetyNet Logic Workbench Getting Started Guide 15. The Microsoft SQL Server (OCPCC Instance) installs if it is not currently installed on your machine. Otherwise, skip to the next step. 16. The Universal IO Server (Limited Edition) installer screen appears. 17. The Preparing to Install Universal IO Server (Limited Edition) screen appears briefly. If it is necessary to upgrade your current version or if you do not already have the Universal Server installed, a limited edition of this program is automatically installed. If you already have the current version, skip to step 21 in this section.

35 SafetyNet Logic Workbench Getting Started Guide The Welcome to the InstallShield Wizard for the Universal IO Server (Limited Edition) screen appears briefly. 19. The Installing Universal IO Server (Limited Edition) screen appears. A progress bar indicates the status of the installation.

36 36 SafetyNet Logic Workbench Getting Started Guide 20. Once the Universal IO Server installation is complete, the Installing status screen reappears. A progress bar indicates the status of the installation. Please be patient, as this installation may take several minutes. 21. When the installation is complete, the PAC8000 Control Center InstallShield Wizard Completed screen appears. Click Finish.

37 SafetyNet Logic Workbench Getting Started Guide You may be prompted to restart your computer to enact configuration changes. If so, you must do so before attempting to run the Workbench. Note: If you are not prompted to restart your computer, it is considered good Windows operating system practice to do so at this point. 23. The Installation process is now complete.

38 38 SafetyNet Logic Workbench Getting Started Guide Post-Installation Activities Once the installation process has finished, complete the following: Add accounts to the Universal IO Server. The Universal IO Server is configured so that only the user who installed the software can add and communicate with devices. If other users require this ability, appropriate user accounts should be added in the Universal IO Server. For information on adding these accounts, please refer to the Security Accounts section in the Universal Server Getting Started Guide. Repairing the Installation The Workbench is shipped with a set of Dynamic Link Libraries (dll) and Executable files (exe). There may be times when installing another program changes the version of a dll or exe file. When this happens, the Workbench may no longer function correctly. To fix any problems caused by installing other programs, go to Add or Remove Programs within Control Panel, select PAC8000 Control Center, and click Change. Complete the ensuing process to repair your installation of the Workbench.

39 SafetyNet Logic Workbench Getting Started Guide 39 Section 4 Additional Product CD Features The Product Installation CD installs and accesses items that can be used to supplement the Workbench. Such items include Communication and Maintenance Tools as well as Product and Contact Information. Additional Programs The Additional Programs feature on the Product Installation CD allows you to install optional programs. These programs can be used to access Sequence of Events (SOE) data in the controller, install the full Universal IO Server, or run a support program, if instructed to do so by Technical Support. Select the Additional Programs option from the Options screen and click Go to install additional Tools and Maintenance Programs.

40 40 SafetyNet Logic Workbench Getting Started Guide Tools Additional tools may be installed to assist in communicating with other devices, such as retrieving the order in which certain IO events occurred and communicating with other devices via Modbus and/or OPC. Sequence of Events Install this application if you are using a Discrete Input Module with SOE capability or you are using the Event Recording Feature in the controller. Please refer to the Sequence of Events Getting Started Guide for installation information. IAS Object Manager Install this application if you are using Industrial Application Server from Invensys Wonderware and you would like the Workbench to automatically generate objects. Please refer to the IAS Object Manager Getting Started Guide for installation information IO Configurator (Standalone Version) The 8000 IO Configurator is installed as part of the PAC8000 Workbench. Install this standalone version if you would like to configure IO on a machine, but do not require the additional functionality of the Workbench. Please refer to the IO Configurator Getting Started Guide for installation information. AXE Comm Stats (Standalone Version) AXE Comm Stats is installed as part of the PAC8000 Workbench. Install this standalone version if you need to perform network troubleshooting on a machine where other Workbench functionality is not required. Please refer to the AXE Comm Stats Online Help for additional information. Universal IO Server (Limited Edition) A limited edition of the server is installed with the PAC8000 Workbench; this version is only authorized to communicate with PAC8000 Controllers. Install the full version if you are authorized to communicate with other device types. Please refer to the Universal Server Getting Started Guide for installation information. Engineering Library Install this application if you want to install a set of DXF files that can be used to create panel drawings or other drawings to show the layout and dimensions of the PAC8000 Hardware. Communication DTM Install this application for communication DTM for 8000 controllers.

41 SafetyNet Logic Workbench Getting Started Guide 41 Maintenance Programs Support Programs may be installed to repair components that were damaged by the installation of another application. Select this option and click Go for a list of available programs. Warning: Do not attempt to run any of the Maintenance Support Programs without instruction from technical support.

42 42 SafetyNet Logic Workbench Getting Started Guide Information Select Information from the Options screen and click Go.

43 SafetyNet Logic Workbench Getting Started Guide 43 The Information screen displays the available options for obtaining additional information concerning the PAC8000 product and GE.

44 44 SafetyNet Logic Workbench Getting Started Guide a. Select the Contact Us option and click Go to display contact information for GE. Note: It is not necessary to use this screen when contact information is needed, as company information is also available on the website ( and the Help About menu item within the Workbench.

45 SafetyNet Logic Workbench Getting Started Guide 45 b. The Documentation option invokes the Documentation screen. Select a product and click Go to view the corresponding manual.

46 46 SafetyNet Logic Workbench Getting Started Guide c. The CD Browser option allows you to view the contents of the Installation CD in an Explorer Window.

47 SafetyNet Logic Workbench Getting Started Guide 47 Section 5 Licensing The license procedure is detailed in the Proficy Common Licensing Help. This file is located in Start Programs Proficy Common License Documentation. To run the license viewer, select Start Programs Proficy Common License Viewer.

48 48 SafetyNet Logic Workbench Getting Started Guide Section 6 Project Tutorial The SafetyNet Logic Workbench is the single engineering environment used to configure and program safety controllers. The Project Tutorial walks through the steps that are necessary to program a simple control strategy for a safety controller. This project tutorial provides instruction for creating tags, configuring IO modules, assigning tags to the modules, creating a simple discrete control strategy, downloading the strategy, downloading the strategy to both the simulator and the controller, viewing the data online, and authorizing devices for access to the controller. At the end of the tutorial, you will have experience with each of the tools in the Workbench and have a rudimentary knowledge of how they are used. This tutorial assumes that you have a new safety controller or set of safety controllers and IO modules. Feel free to substitute the modules that you have for those used in the tutorial. If you do not have hardware, skip the steps that require hardware interaction. New controllers are shipped from the factory in BOOTP mode, meaning they are assigned MAC addresses, but not IP addresses. When the controller is in this configuration, the Healthy, Fault, and Failsafe LEDs flash in unison. If you are using existing controllers and intend to follow all of the steps in this tutorial, put the controllers into BOOTP mode. To do this, hold down the change state button next to the controller, power cycle the controller and continue to hold down the button until the Healthy, Fault, and Failsafe LEDs flash in unison. Setting up controller hardware requires three distinct IP addresses that are located on the same subnet. Before setting up the controller with these IP addresses, ensure that your PC has a compatible address, i.e. it is on the same subnet as the controllers. There are a number of steps to follow when developing a project that results in a defined and tested application. The following diagram provides a pictorial overview of the steps that are discussed in this project tutorial.

49 SafetyNet Logic Workbench Getting Started Guide 49

50 50 SafetyNet Logic Workbench Getting Started Guide Launching the Workbench 1. Once the software has been installed, start the PAC8000 Workbench by selecting the Workbench application from the Start menu. 2. The Connect to Database form is displayed requesting that you log on. 3. Enter Nodename\ocpcc into the Server Name field. (The Nodename is the name of the computer.) The default Username is sa and the password is ocpcc2003. Logging on as such grants you full access to all features in the PAC8000 Workbench. It is possible to create your own users with specific passwords and access levels. For more information, please refer to the Workbench Workbench Components Overview Project Explorer Menu topic in the online Help. Then select the links Administrative Tools Administer Users. Note: The Workbench defaults to the last username that was used to log on. If this is the first time connecting to the database, the default username is sa.

51 SafetyNet Logic Workbench Getting Started Guide 51 Creating a Project 1. Select the File New Project menu item to create a new project. 2. Enter SIS_Project in the Project Name field and click Apply.

52 52 SafetyNet Logic Workbench Getting Started Guide Initial Controller Setup 1. Right-click on the newly created project and select New Controller. Enter SIS_Ctrl in the Controller Name field (do not use spaces) and select Model 8851 (SafetyNet) from the Controller Type drop down list. Specify an external power of 5 amps, and click Apply. 2. The 8000 IO Configurator is launched. Specify a Node number of 50 (Modbus address) and click OK.

53 SafetyNet Logic Workbench Getting Started Guide Select the Attributes tab and enter , , and in the Master IP address, Direct A IP address, and Direct B IP Address fields, respectively, to configure the addresses in the databases.

54 54 SafetyNet Logic Workbench Getting Started Guide Configuring IO Modules 1. Right-click the controller node and select New Module to configure modules. The safety modules for the safety controller are the 8810-HI-TX and 8811-IO-DC modules. Select 8810-HI-TX from the drop down list and place the module into Slot 1. Select 8811-HI-TX from the drop down list and place the module into Slot 2.

55 SafetyNet Logic Workbench Getting Started Guide The controller remains in BOOTP mode until IP addresses have been assigned. The Network Configurator is used to assign the IP addresses to the controller. Expand the Project folder and double-click the Launch Network Configurator node. 3. The configuration database for the new controller is automatically loaded and the network is interrogated to determine which controllers are currently responding. This query takes approximately 10 seconds from the time of launch. 4. Because the new controller has not been configured, it is not seen on the network, and does not appear in the list view box. The Network Config Tool begins to listen for controllers that are broadcasting their MAC addresses. When it determines that a controller is broadcasting, the icon in the lower right corner of the form shows a disconnected network. If your new controller is installed correctly on

56 56 SafetyNet Logic Workbench Getting Started Guide the network, the following icon appears in the bottom, right corner of the utility with a yellow background and a red X: Note: If there are multiple new controllers, only one should be put on the network at a time so that it is clear which controller is being assigned IP addresses. In addition, if your controllers are a redundant pair, only one controller should be powered up at this time. Once the IP address configuration is complete, power up the second controller. The IP addresses of the second controller are automatically set by the first controller.

57 SafetyNet Logic Workbench Getting Started Guide Double-click this icon to start the configuration dialog. Alternatively, you may select the Tools Assign IP Address menu item. 6. The Assign MAC Address form is displayed, showing all of the controllers that are currently defined in the 8000 IO Configurator database. If the database has a MAC address that matches the unconfigured controller, that line is selected. Otherwise, no lines are selected. Note: The unassigned MAC address appears in the title of the form.

58 58 SafetyNet Logic Workbench Getting Started Guide 7. Select an entry and click Apply or double-click an entry to display the Assign IP Address dialog: 8. Click Cancel or Apply. If you click Apply, the network is queried to ensure that the selected IP addresses are not in use on the network. If they are in use, you are made aware of this and have the option to cancel the assignment. If the IP addresses are not in use, the IP addresses and Modbus Node Number are sent to the unconfigured controller. If the original MAC addresses were not entered, the MAC address of the unconfigured controller is written to the 8000 Configurator database.

59 SafetyNet Logic Workbench Getting Started Guide If the All Controllers option is selected on the Assign MAC Address form, you may receive a warning message upon assigning the IP addresses to the controller. This is due to the fact that the MAC address of the controller does not match the MAC address with which the IP address was previously associated. 10. Click Yes (No is the default) to assign the IP Addresses to the unconfigured controller and write the unconfigured controller s MAC address to the 8000 Configurator database. 11. Once the IP Addresses are assigned to the controller, the Network Configurator checks to see if any configuration exists in the controller. If it does, the configuration items are listed and you are asked if the items should be cleared. 12. Click Yes to clear the information, thereby making the controller configured as it was when it left the factory. Click No to leave the information intact.

60 60 SafetyNet Logic Workbench Getting Started Guide 13. Once the IP addresses are assigned, select Check Network Wait 2 Seconds from the Tools menu. This causes the network to be queried for controllers and all controllers found on the network are presented. In our example, one controller is found: Note: If controllers do not appear in the list view box, it may be necessary to select the appropriate Network Interface Card, if there is more than one in your PC. Select the Tools Check Network Select Network Card pull down menu and choose the desired card.

61 SafetyNet Logic Workbench Getting Started Guide Return to the 8000 IO Configurator. Click the green traffic light from the toolbar ( ) and select the Download button ( ) to download the configuration to the controller. Click OK on the Download Configuration Options window.

62 62 SafetyNet Logic Workbench Getting Started Guide Creating Project Tags Tags are created using the Project Tag Index in the Workbench. The only signal types necessary for interface with safety IO modules are MA, DI, and DO. If your safety system includes standard IO modules (AO, TC, RTD, etc.), you may use other signal types. To create non-io tags that can be used in the HMI, e.g. accessing a value computed in a strategy or sending a value from the HMI to the strategy, use the types ISG A, ISG D, ISG F, and/or ISG U. To write digital data from the HMI into the strategy, use the type SAFE D. 1. In the Workbench, right-click on the Project Tag Index node in the Project Explorer and click New Tag. Add the following tags with the specified parameters. Fields that are not mentioned should remain at their default values. Tag Name Description Engr Min or DI 0 State FI501 SOV501 Flow Indicator Shut-down Valve Engr Max or DI 1 State Engr Units GPM MA OFF ON NONE DO FSD501 Flow Sensor OFF ON NONE DI RST_FSD501 Shut-down Reset Signal Type OFF ON NONE SAFE D Keyswitch Keyswitch OFF ON NONE DI 2. Tags can also be imported from a CSV file using the Data Import Utility. For additional information regarding this process, refer to the Process Control Training Guide.

63 SafetyNet Logic Workbench Getting Started Guide 63 Mapping Tags to Channels 1. Expand the Controller node in the Project Explorer and double-click Controller Modules. Expand the controller in the middle pane of the resulting form. 2. Expand the 8810 module and select XM_HART (1). Click Get Assigned IO from the Assign points pane, on the right. Click Spare and select FI501, then click Apply to assign the tag to channel 1.

64 64 SafetyNet Logic Workbench Getting Started Guide 3. Select the 8811 module and click Get Assigned IO from the Assign points pane. Click Spare on the channel 1 and select SOV501, then click Apply. Click Spare on channel 2 and select FSD501, then click Apply. Finally, click Spare on channel 3 and select Keyswitch, then click Apply. 4. Once all tags have been assigned, right-click the controller in the Project Explorer and select Compile IO.

65 SafetyNet Logic Workbench Getting Started Guide 65 Mapping Tags to Discrete Control Before the IO tags can be used in the strategy, they must be mapped to the Discrete Control database. 1. Right-click the controller and select Map Data Map Discrete Control points. 2. Double-click or drag and drop the tags that you wish to use in the strategy from the Available Tags pane to the Mapped Tags pane. For our example, map the following tags, FI501_RE, FI501OK, FSD501, FSD501OK, KEYSWITCH, SOV501, SOV501OK, and RST_FSD501. (Remember <tag_name>_re holds the scaled value for analog input tags. For our example, this is the FI501_RE tag.) 3. Once all tags have been mapped, click Save. Right-click on the controller node in the Project Explorer and select Compile IO.

66 66 SafetyNet Logic Workbench Getting Started Guide Creating a Safety Shutdown Strategy The Discrete Control Interface is used for creating programs, functions, and function blocks with the Ladder Diagram (LD), Structured Text (ST), and/or Function Block Diagram (FBD) languages. 1. Double-click the Create Discrete Control Interface icon ( ) in the Project Explorer to open the Discrete Control Interface. 2. To create an ST program, right-click the Programs node and select Add Program ST: Structured Text. Enter the name FlowShutdown and add the following text to the editor: (*IF high flow or flow switch trips shutdown*) IF FI501_RE >= OR NOT FI501OK OR NOT FSD501 THEN SOV501 := FALSE; END_IF; (* On Reset, open the SOV*) If NOT SOV501 AND RST_FSD501 THEN SOV501 = TRUE; END_IF;

67 SafetyNet Logic Workbench Getting Started Guide Once the Program Organizational Unit (POU) is created, compile using File Build Program menu item in the editor.

68 68 SafetyNet Logic Workbench Getting Started Guide 4. Close the editor and return to the Discrete Control Interface. Select the Project Build Project/Library menu item to build the project so that all programs, functions, and function blocks are linked together into one downloadable image.

69 SafetyNet Logic Workbench Getting Started Guide To test the strategy, select the Debug Simulation menu item.

70 70 SafetyNet Logic Workbench Getting Started Guide 6. Live simulation data can now be viewed for the strategy. Open the Dictionary ( ) and the variables are displayed along with their real-time values. This information can be used for debugging purposes. One of the Graphical language editors (LD, FBD) can also be opened to view a live representation of the strategy executing and displaying real-time data. 7. Once you have completed the simulation and are satisfied that the strategy is executing correctly, you are ready to download the strategy to the controller using the PAC8000 Workbench. Note: Program editors can only be opened in either edit mode or simulation/debug mode. A simulation or debug session must be stopped before a strategy can be changed. For more information on building strategies in Discrete Control, refer to the Discrete Control Training Guide.

71 SafetyNet Logic Workbench Getting Started Guide 71 Using the Static Analyzer Tools Once the strategy is built and tested, it must be analyzed before it can be downloaded to the controller. There are two analysis tools, the Integrity Analyzer and the Cross Reference Analyzer, which are used as follows: The Integrity Analyzer validates that the strategy is written in one of the sanctioned languages (LD, ST, FBD) with constructs and instructions that can be easily tested. The Cross Reference Analyzer lists all changed POUs together with any dependent POUs. You must acknowledge that the list is correct before the strategy can be downloaded to the safety controller. The Cross Reference Analyzer operates on the project s browser database, which must be rebuilt after every build. Since there is no way to automatically launch the browser once a build is complete, a warning is issued when the IEC61131 Cross Reference Analyzer is launched prior to building the browser.

72 72 SafetyNet Logic Workbench Getting Started Guide 1. Before launching the analyzers, select the Project Build Project/Library menu item in the Discrete Control Interface to perform a build (if this has not already been done). 2. Once the build is complete, click the Browser button ( ) in the toolbar to launch the browser. The browser is used to create a usage map (Cross Reference table) for all variables in the strategy.

73 SafetyNet Logic Workbench Getting Started Guide The Browser dialog appears. Click the Browse button to build the usage map.

74 74 SafetyNet Logic Workbench Getting Started Guide 4. Notice that the Browse toolbar button remains depressed while the usage map is being built. 5. Once the usage map build is complete, the Browse button appears as normal and the Browser window can now be closed. 6. Now that the browser has been built, the strategy can be analyzed. The analyzer tools can be run in any order. In our example, we will run the Integrity Analyzer first. To launch this analyzer, select Integrity Analyzer from the Tools menu.

75 SafetyNet Logic Workbench Getting Started Guide The IEC61131 Integrity Analyzer is launched: The Integrity Analyzer compares the language, size, functions and function blocks, IO Types, and variables in each POU to the predefined safety rules. These rules define the safe languages, size, functions, and function blocks, as well as the allowable number of inputs to the functions and function blocks, I/O types, and variable types. The color of the POU indicates the level of non-compliance as follows: Red - Integrity analysis error. Until the non-compliance is corrected, the strategy cannot be downloaded to the safety controller. For example, if a POU is written in an unsupported language, the Language node icon on the Integrity Analyzer turns red. Yellow - Integrity analysis warning. A non-compliant structure exists, but can be authorized as safe once its use is reviewed on the Authorize dialog. The strategy cannot be downloaded to the safety controller until all warnings are authorized. For example, the ADD function is considered safe when it has between 2 and 16 input parameters; in which case, the Functions node icon turns green. However, the Functions node icon turns yellow with an ADD of 1, 17, or more input parameters, necessitating review and authorization for use. Green - No non-compliances were found when analyzing the POU section.

76 76 SafetyNet Logic Workbench Getting Started Guide 8. To authorize the strategy, select Authorize from the Analyze menu. 9. The Acknowledge Non-Compliance dialog is displayed. Verify that each noncompliant POU found by the analyzer is okay and check the corresponding boxes to acknowledge and accept them as non-hazardous. 10. Click OK to return to the IEC61131 Integrity Analyzer dialog. Click Save to commit the acknowledgement of the non-compliant POUs.

77 SafetyNet Logic Workbench Getting Started Guide Since the analysis is complete, you may close the dialog and return to the Discrete Control Interface. To complete the analysis, select Cross Reference Analyzer from the Tools menu. 12. The Cross Reference Analyzer flags, in red, any POU that has changed since the last analysis, as well as any POU that is dependent upon a changed POU. Before a download is permitted, all flagged POUs must be acknowledged, indicating that all changes are known and have been fully tested. To accept the changes made to the flagged POUs, select Authorize from the Analyze menu.

78 78 SafetyNet Logic Workbench Getting Started Guide 13. The Acknowledge Dependencies dialog appears. 14. Select the box next to each POU if the change is acceptable. Once the boxes for all POUs are checked, ensure that the Authorize download box is checked and click OK to close the dialog.

79 SafetyNet Logic Workbench Getting Started Guide Click Save in the IEC61131 Cross Reference Analyzer to commit the change acknowledgements. 16. Close the IEC61131 Cross Reference Analyzer once the changes are saved. If there is no error message displayed upon exiting the analyzer, you may proceed to the Download form in the Workbench to download the logic to the safety controller.

80 80 SafetyNet Logic Workbench Getting Started Guide If any existing non-compliances or dependencies have not been acknowledged, the IEC61131 Cross Reference Analyzer yields the following error. If this message appears, you cannot download to the safety controller until you return to the IEC61131 Integrity Analyzer and the IEC61131 Cross Reference Analyzer and acknowledge all noncompliances and dependencies. Note: Use the Tools Authorize Safety Build menu option to automate the processes of launching the Integrity Analyzer followed by the Cross Reference Analyzer.

81 SafetyNet Logic Workbench Getting Started Guide 81 Setting the IP Address of a SafetyNet Controller Before the Safety Shutdown Strategy can be downloaded to the SafetyNet Controller, the Network Configurator must be used to configure the IP addresses. Please refer to the Setting up IP Addresses lab in the Workbench Core Components Training Guide for information on setting up IP addresses. Downloading the IO Configuration The IO Configuration must now be downloaded. Please refer to the Downloading the IO Configuration lab in the Workbench Core Components Training Guide.

82 82 SafetyNet Logic Workbench Getting Started Guide Downloading the Safety Shutdown Strategy Once the download is authorized in the Discrete Control Interface, the Safety Shutdown Strategy is ready to download to the SafetyNet controller. 1. From within the PAC8000 Workbench, right-click the controller in the Project Explorer and select Download Control Strategies to access the Download form.

83 SafetyNet Logic Workbench Getting Started Guide Click Get Servers, and select the Universal IO Server in the Server drop down list.

84 84 SafetyNet Logic Workbench Getting Started Guide 3. Click Connect to establish communication with the controller.

85 SafetyNet Logic Workbench Getting Started Guide Click Download to begin the download process. Answer Yes when asked to confirm the download. Debugging the Strategy 1. Once the download is complete, return to the Discrete Control Interface. 2. Open an individual program for monitoring real-time or open the Dictionary to view all variables. 3. Select Debug from the Debug menu to open the live view. 4. To make changes to the strategy, stop the Debugger and repeat the steps outlined in the previous labs, as appropriate. Note: The Debugger can only attach to the controller in configuration mode (see Changing Controller Modes).

86 86 SafetyNet Logic Workbench Getting Started Guide Building the Trusted Hosts Table The safety controller uses the Trusted Hosts Table to configure security and prevent unauthorized devices from making changes to data. Each device that is permitted to make changes to the controller must have an entry in the table consisting of a MAC address and the changes that the device is allowed to make. 1. In the Workbench, right-click on the controller and select Security Build Trusted Hosts Table. 2. Enter the MAC Address(es) for the devices. If this is for your PC, click the Browse button and enter Me in the resulting box. The MAC address for your PC will be automatically filled in. If you wish to declare one or both of the controller COM ports to be permitted to read data from other devices, enter COM1 or COM2, as appropriate. If you wish to authorize another PC to write, enter this PC s MAC address. In most cases, you will only enter the LAN A address. However, if you have a PC with two network cards and both have permission to write data to the controller,

87 SafetyNet Logic Workbench Getting Started Guide 87 enter one in the LAN A field and the other into the LAN B field. If you wish to grant access to all devices, use a MAC address of (twelve zeros). 3. For each MAC Address entered, you must decide what types of writes are permitted: Allow Modbus Writes - The device can write Modbus data to the controller in configuration mode. Allow HART Maintenance - The device can use HART passthrough to make changes to the controller, such as use AMS software. Save Retained Variables - The controller monitor changes to data values from the selected HMI and when any changes occur, saves the values to flash memory using the internal controller algorithms. Allow Workbench Full Control - The device can use the Workbench to perform downloads and other writes that affect data in the controller. Allow Discrete Control Debugger - The device can launch the Discrete Controller Debugger to view and change data in the controller. Note: The Debugger can only attach to the controller in configuration mode.

88 88 SafetyNet Logic Workbench Getting Started Guide 4. Once the table entry is complete, click Apply to create the entry.

89 SafetyNet Logic Workbench Getting Started Guide Type COM1 into the box and then click Apply and Save to add the COM1 port to the list of authorized devices. 6. To activate the table in the controller, it must be downloaded. Click Connect to establish communication with the controller and then click Download to send the table to the controller. Note: If the controller has been password protected, the password must be entered before the download will successfully complete.

90 90 SafetyNet Logic Workbench Getting Started Guide Assigning a Keyswitch The Keyswitch is a physical digital input that can be used to lock the controller so that mode (between safe and configuration or between configuration and safe) or password changes cannot be made. 1. Right-click the controller and select Security Assign/Edit Keyswitch. 2. Double-click the point that you would like to use as the keyswitch from the list of tags displayed. For our example, use KEYSWITCH, with Key Switch health of KEYSWITCHOK. Click Apply to make the assignment.

91 SafetyNet Logic Workbench Getting Started Guide You are informed if the assignment is successful and that the configuration must be downloaded to the controller. You are also asked if you would like to launch the IO Configurator to download the configuration. Answer Yes at this prompt. 4. When the IO Configurator is launched, click the green traffic light from the toolbar ( ) to go online and then download the configuration to the controller. 5. The status of the keyswitch can now be seen on the Trusted Hosts Table. Open this form in the Workbench and click Connect. The keyswitch will be shown as locked or unlocked based on its value when Connect was clicked. If the state changes, the status will not be automatically updated. You must click Connect again to initiate the update.

92 92 SafetyNet Logic Workbench Getting Started Guide Changing Controller Modes The default state of the safety controller is configuration mode. In this mode, changes can be made to the strategy and the configuration in the controller. Once the strategy is complete and running, the controller must be placed in safe mode and the keyswitch must be locked to ensure full SIL2 compliance. No configuration or strategy changes can be made until the keyswitch is unlocked and the mode is changed to configuration. 1. To toggle the controller s mode, launch the Trusted Hosts Table and click Connect. The current mode is displayed. 2. Enter the appropriate password and click Switch Mode. If the mode change is allowed, the alternate mode will automatically be entered. If not, an error message is displayed to indicate why the mode change was not allowed. The controller cannot go from configuration mode to safe mode under the following conditions: A channel of a safety module is forced. A safety module is unhealthy. The keyswitch is unlocked. The password is entered incorrectly. The Master or Standby controller is unhealthy. The Discrete Control Debugger is active. The Trusted Hosts table is missing. Strategy files and tables were downloaded at different times.

93 SafetyNet Logic Workbench Getting Started Guide 93 Setting the Controller Password For additional security, the controller can be assigned a password so that the Trusted Hosts table and the mode cannot be changed without first entering the password. The password is added or modified through the IO Configurator. The password cannot be modified if the keyswitch is locked. 1. Launch the IO Configurator and place the controller online. Right-click the controller, and select Set Password. 2. Enter the Old Password (or leave blank if no password is currently set). 3. Enter the New Password of at least six characters and then confirm the entry by retyping the password and click OK. 4. Answer Yes when asked if you would like to proceed and the password will be set. This password must now be used when downloading the trusted hosts table or changing the controller s mode.

94 94 SafetyNet Logic Workbench Getting Started Guide Safe Writes from Non-Safe Applications There are occasions when safe data must be written from non-safe sources. A primary example of this is bypasses and resets where a bit needs to be set on the HMI screen to cause an action to be performed in the safety application. Since the HMI is not a safe device, it cannot simply set the bit in the controller. Rather, it must first write to a request tag and then confirm the write by clearing a confirm coil. This process is described in the following steps. 1. Create the digital tag using signal type SAFE D. For our example, tag RST_FSD501 has already been created with the type SAFE D.

95 SafetyNet Logic Workbench Getting Started Guide Map the tag to Discrete Control. (We have already done this in our example.) 3. Compile IO to complete the request and confirm the tags to be generated.

96 96 SafetyNet Logic Workbench Getting Started Guide 4. Double-click the Controller Reports node in the Project Explorer. Select the Registers Tag Sort report from the drop down list and click Run Report. Click OK on the Report Generation Parameter Query prompt. Select Show data in columns and scroll down the list. You will notice the entries RST_FSD501_CNF and RST_FSD501_RQT. 5. The tags are now ready for use in the HMI. Import the tags into the HMI. When a write is needed, write the appropriate value to the <tag_name>_rqt field. The <tag_name>_cnf becomes 1. To confirm the value change, set the <tag_name>_cnf to 0. If you wish to cancel the change, set the <tag_name>_rqt back to its original value or wait for the confirmation process to time out. The following are other tags of interest in the HMI when writing to digitals in safe mode: <controller_name>_axe_tht has a value of 1 if it is okay for the HMI to write to a safe digital tag. This means that the HMI PC is in the trusted host table for the controller and that the keyswitch is unlocked. If these conditions are not met, the tag has a value of 0 indicating that writes are not permitted.

97 SafetyNet Logic Workbench Getting Started Guide 97 <controller_name>_axe_ova has a value of 1 if at least one SAFE D has been written to. Otherwise, this tag has a value of The parameters Override Min and Override Max control the timing of the safe write process. These parameters can be modified on the controller s System tab in the 8000 IO Configurator. Override Min: The number of seconds before the confirm coil becomes logic 1 after a new value is given to the corresponding request coil. The default value for this parameter is 2 seconds. Override Max: The timeout period for the safe write process. When a request coil is given a new value, the confirm coil must transition from logic 1 to logic 0 in order for the write to be confirmed. The default value for this parameter is 10 seconds. Once changes are made to these parameters, the IO configuration must be downloaded to the controller for activation.