Accord Builder. User Guide

Transcription

1 User Guide Document: V 3.6 User Guide R01 V3.6 User Guide R01 Page 1 of 110

2 Table of Contents 1 Introduction General Summary and Definitions Accord Platform and Plant PLC Control Terms Equipment Terms Program Terms Installation Requirements Recommended Installation Controller Runtime System Routines PLC Operating System Functionality Equipment Objects Program Objects System Configuration Builder Layout Model Summary Name of Plant Configuration of Equipment Units Unit Common Functionality Insertion of Units Add Items to Units Copy and Paste Units Cross Reference screen Renaming of Unit Group Completion of Unit Insertion and Configuration V3.6 User Guide R01 Page 2 of 110

3 6.6.1 Linking of Units Configuration of Equipment Devices Configuration of Digital Inputs Setup Tab PLC I/O Description Card Setup Description Configuration of Digital Device Objects Setup Tab Setup Fields I/O Address Setup Enablers Interlocks Tab PLC I/O Description Card Setup Device Description Fields Deletion of Digital Devices Deletion of Valves in two Units Configuration of Digital Outputs Setup Tab Interlocks Tab PLC I/O Description Card Setup Digital Output Description Tab Configuration of Analog Input Objects Analog Input Setup Tab Analog Input PLC I/O Description Card Setup Analog Input Description Configuration of Analog Device Objects Analog Device Setup Tab V3.6 User Guide R01 Page 3 of 110

4 7.5.2 Analog Device PLC I/O Description Card Setup Analog Device Description PID Loop Controller PID Loop Note Configuration of PID Loop Controller PID Loop Description Steps in setting up a PID controller Configuration of Programs Program General Insertion of a Program Program Properties Equipment Units in Program Configuration of Conditions Source and Setpoint declaration Configuration of Combined Conditions Boolean Gate Descriptions Boolean Gate Operations Configuration of Alarms Configuration of Operations Enabling an Operation Configuration of Steps Properties Enabling Conditions and Combined Conditions Enabling of Operations Enabling Alarms Enabling Device Activations Configuring Step On-Transitions V3.6 User Guide R01 Page 4 of 110

5 8.10 Step Transitions Program Recipe Setpoints Step Order Decisions General Model Items Program Order Variables Documents Generation Generating the Documents Customising the Documents Properties Setting up the Equipment Site Test Document Setting up the FDS/SDS or SAT document Audit Trail Project and Edit Menus Model Menu Creating an project - New Loading an existing Model - Load Merging Models Copying Model Save As Deleting Model - Delete Backup Model to file - Backup Restoring from File - Restore Exit Edit Menu Equipment Default Values I/O Address Table V3.6 User Guide R01 Page 5 of 110

6 Cut - Copy - Paste Find Item in Equipment and Find Item in Program Advanced Item Search Search Tool Tools Menu Consistency Check System Options Help menu System Information Licensing V3.6 User Guide R01 Page 6 of 110

7 1 Introduction is a graphical modelling application used to develop control system designs for systems implemented using the Accord platform. It provides a modelling environment for Equipment and Programs. Using, engineering personnel can design process systems quickly and consistently. Builder includes full functionality for system modification; for item addition, deletion and modification. After design using Builder, systems are imported to Server and the model is implemented automatically using supplied PLC Library and HMI may be implemented using Accord HMI. also provides the functionality to print matching validation design and test documents. Accord Platform Modules It is important to note that the above illustration is a recommended setup and not a requirement. A single PC of suitable specification can be used to host all elements of the Accord platform if required. V3.6 User Guide R01 Page 7 of 110

8 2 General Summary and Definitions 2.1 Accord Platform and Plant Accord PLC Accord Server Accord Reports Accord HMI Plant Database PLC Graphical User Interface for configuring the process Model. PLC Runtime Library routines to control the process. This application manages the PLC communications. It provides download to PLC, and functions for Data Logging, Redundancy, Security and Recipes. It also provides information for Accord HMI, and other modules. This application allows query of the Accord Server Database using the objects and structure in the project. It allows for time or event based reports with export to various formats. An application hosting Accord.Net controls. This provides an integrated Scada for the project. The process plant or machine to be modelled and controlled. The information for configuration and documentation of the control system project is contained in a SQL Server database. The configured project will be implemented on a PLC hosting Accord PLC Library. This downloaded to the PLC using the standard PLC editor. V3.6 User Guide R01 Page 8 of 110

9 2.2 PLC Control Terms These explanations are meant to reflect common industry understanding. These signals may be either electrical or on a bus system. Digital Output Digital Input Analog Device Analog Input A Signal, having two states (On/Off, 1/0, True/False) sent from PLC to control a device. A Signal, having two states (On/Off, 1/0, True/False) received by PLC giving status information about process item or device. A variable setpoint from PLC to a controllable item. This may be either electrical or over a bus system. A variable feedback indication signal from an instrument. This may be either electrical or from a bus system. V3.6 User Guide R01 Page 9 of 110

10 2.3 Equipment Terms Valve Motor Digital Output Analog Device - Control Valve Analog Device - Variable Speed Drive Digital Input Switch Analog Input Transmitter PID Controller Unit An item whose activation allows material to flow from one part of plant to another, material being solid, liquid or gas. Always has a PLC Digital Output and may have one or more Feedbacks. An item whose activation causes material to be transported. Always has a PLC Digital Output and may have one or more Feedbacks. An Output from the PLC without Feedback. A Valve whose modifiable opening is dependent on an analog signal. This is a PLC Analog Output. A Motor whose variable rotation speed is dependent on the strength of an analog signal. This is a PLC Analog Output. This is an indication that a physical state has been achieved. This is an indication of the value of a physical state. This is a PLC Analog Input. PID (Proportional, Integral, Derivative) This is a controller for an analog device, which uses common PID characteristics and terminology. Example - Flow Control loop using Variable Speed pump This is a group of devices and instruments which form a logical section of plant. Examples; Water Supply vessel, Reactor, Conveyor, CIP Supply Line V3.6 User Guide R01 Page 10 of 110

11 2.4 Program Terms Program This is a set of items forming a distinct part of the process. It is also known as a program or sequence, as it may consist of a sequence of steps. Example - A Sequential Program to clean a part of plant Step This is an individual program stage performing a specific section of the program. This consists of step components. Example - An Initial Rinse step at start of Cleaning Program Condition This is a test for status of a single item at a particular point. Example Water Supply Tank below Empty Level. Combined Condition This allows combined Boolean logic to be applied to items. Example - High Pressure Level Switch AND Pressure High High Alarm Recipe Step List : Default sequence of steps for the Program. Setpoints : List of setpoints for the program. Decisions: List of On/Off Selections for the program. Setpoint This is a value written in Recipe or HMI or which is examined to determine if a condition is met. It is part of the default Recipe for the Program. Example Rinse Temperature Setpoint Operation This is a function for changing a value or a program status or step. Example Supply Control Valve to Feed Setpoint. Alarm This is a fault in a program due to an operational failure. It may be configured to cause the program to go into Alarm and Hold. Example Water Supply at Low Level. Activation This is a signal activate a digital device or digital output. Variable This value is written by the PLC, usually as mathematical Operation result. Example Water Volume used in Rinse. Constant This value is written only at configuration in for common time and setpoint values. V3.6 User Guide R01 Page 11 of 110

12 3 Installation 3.1 Requirements Recommended Processor Memory Disk Space 1.6 GHz Quad Core Processor (or better) 4GB (or higher) A large disk is recommended for data acquisition, depending on the requirements of the project(s) Accord Server will host. DBMS Microsoft SQL 2014 Screen Resolution 1024x768 (or higher) Operating System Windows 7 [Service Pack 1], Windows 8 Network Interface 1 GBps, Wired (Static IPv4) V3.6 User Guide R01 Page 12 of 110

13 3.2 Installation is installed as part of Accord Project installation. Accord Server and HMI Design are also installed. Before installing Accord Project, it is recommended to verify the PC meets the recommended requirements above. To install Accord Server, simply do the following: 1. Install Accord Setup to install SQL instance and create database structures. 2. Double click on the Accord Project Installer.exe file. 3. Click Next. Accord Project Installer.exe Accord Project 4. Read the Accord Server License Agreement. Installation Wizard 5. Select Next if you wish to continue installing, otherwise click Cancel. V3.6 User Guide R01 Page 13 of 110

14 Accord Project License Agreement 6. Optionally provide the User Name and Organisation Name, click Next. Note: User or Customer Information This information is entirely for use by the local computer. V3.6 User Guide R01 Page 14 of 110

15 7. There is a default install location for Accord Project, click Install to begin the installation process. 8. Review the installation summary and click Install to confirm otherwise, click Back if you wish to modify any of the preceding options. 9. Upon completion of the installation process, click Finish to exit the installer., Server and HMI Design are now installed. V3.6 User Guide R01 Page 15 of 110

16 4 Controller Runtime System Routines 4.1 PLC Operating System Functionality This is a Library required to provide system functionality and should not be modified. The Accord PLC Library may be downloaded to PLC or placed on PLC storage (micro memory card) using standard PLC editor. Main Call-Up Routine This calls up all other routines, being background routine, equipment routines and program routines. This is called once per scan of the PLC. Background Routine This routine generates general flags and predefined time pulses and cycle intervals for use by routines. Equipment Routines These routines process all configured equipment objects; Valves, Motors, Analog Inputs, Analog Devices, Digital Inputs, Digital Outputs. Program Routines The Program Routines process all configured programs, as step objects and component objects. V3.6 User Guide R01 Page 16 of 110

17 4.2 Equipment Objects Equipment is comprised of the following types. All items of a similar type will be controlled by a common routine which processes each item in turn. 1. Digital Inputs 2. Digital Devices (Valves and Motors) 3. Digital Outputs 4. Analog Inputs 5. Analog Devices 6. PID controllers 4.3 Program Objects Programs are processed only when they are Active. Programs o Processing of items in the Program Conditions Combined Conditions Steps o Steps Processing of items configured for the Step Conditional Activations Unconditional Activations Pulsed Activations Operations Alarms Each Program contains a default Recipe Setpoints Step Order Decision Selections Variables and Constants are general for the configured system o Variables o Constants V3.6 User Guide R01 Page 17 of 110

18 5 System Configuration 5.1 Builder Layout Each new Model for new system is started using this New screen. The initial window is comprised of the following: Equipment toolbox on left side Program toolbox on right side Equipment configuration section in left side panel Program configuration section in right side panel Details section under the Plant icon A search window accessed by the search icon in lower right side There is also the following information along the bottom border of Builder Name of user and PC which is read from Windows Name of project database, from database creation V3.6 User Guide R01 Page 18 of 110

19 5.2 Model Summary This is accessed from the Model Menu The Details section allows the user to input and store the following information: Model Name Project Purchase Order Company Name Area or section of the company or plant PLC Type A General Overview V3.6 User Guide R01 Page 19 of 110

20 5.2.1 Name of Plant Builder Initial Screen The plant may be given a name designation by right clicking on the plant icon in the equipment configuration section and accessing Project Model Summary. This is also available in the Edit menu. The project being built may be given a name as required. In this case the name being given to the project is AT CIP Set 1 Tank 1 Line C1. Descriptions and configuration can be updated or edited at any time. V3.6 User Guide R01 Page 20 of 110

21 6 Configuration of Equipment Units Equipment is contained in Units, to reflect process drawing, which are comprised of: Analog Devices (with PID Loops) Analog Inputs Digital Outputs Digital Devices Digital Inputs Items associated with a vessel or section of line are placed in a Unit. There are two types of units: Vessel Units and Line Units. In configuring a process plant a Vessel Unit contains equipment which is connected to the Vessel and a Line Unit is a usually section of line between block valves or a block valve and an end-of-line drain valve. A Line Unit is a usually a section of plant which is used for transfer. In units are grouped for presentation purposes and are both Vessel and Line Units may contain equipment Devices and Instruments. Examine the plant drawing and process description to decide on the use of Units. A continuous operation system, in which there is one main program, may be configured using 1 Unit. A sequential system, in which there is more than one program, and the different programs will use different parts of the equipment would be configured using Units. 6.1 Unit Common Functionality A Unit is a logical section of plant, and use of equipment units allows safe operation: 1. If a device (analog or digital) in a unit is in Maintenance then devices in that unit may not be activated 2. If a device (analog or digital) in a unit is in Error and the device is enabled to cause a Program Alarm then the program which is using or attempting to use the unit is placed in Alarm. 3. If a Unit is in use by a program then another program which attempts to select the Unit may be placed in Alarm. When a unit is configured it may be placed in a program in the Unit Routes component holder in the program. The program will then be able to use, or access, devices and instruments in the unit. V3.6 User Guide R01 Page 21 of 110

22 6.2 Insertion of Units Units are inserted into the Model by 1. Dragging from the toolbox into desired group 2. Right click on location and adding the device type. 2. Insertion of a Unit There is a prompt for the object name to be entered. This may be based on the vessel identification in plant drawings (P&ID s). In this example the name CIP Tank is given to the vessel. Insertion of a Unit A description of the unit should now be entered in the vessel properties description tab. Entered information will also be presented in documents. V3.6 User Guide R01 Page 22 of 110

23 6.3 Add Items to Units Equipment may be added into the unit corresponding to process drawings. Devices that are required to be linked by maintenance or error status should be added to the same unit. Equipment items may be added by 1. Dragging in the appropriate icon from the equipment toolbox 2. Right clicking on the vessel to select appropriate item type Vessel Unit containing Valve, Analog Input and Digital Inputs. V3.6 User Guide R01 Page 23 of 110

24 6.3.1 Copy and Paste Units In addition to insertion of devices, right clicking on the vessel gives the options to Rename, Delete, or Copy the Unit. A vessel or line unit may be copied and pasted within the object unit vessel group or line group. Copying a vessel creates an exact copy of all the information for the vessel, including all components. The copied unit and all the components must be renamed, and re-configured with correct settings. Copy function in Right-Click for Unit A copied unit may be pasted within the group, as an exact copy with new components with temporary names. (The names of the copied items are automatically assigned as copies (1)). After the paste function the component devices may be renamed and their short descriptions may be changed. The appropriate I/O addresses must be changed. Other aspects of the copied items may be changed as required. V3.6 User Guide R01 Page 24 of 110

25 6.4 Cross Reference screen Cross References may be accessed by right-click or by a button in the configuration panel. This shows the cross references for valve V01 Water Supply. Cross reference screen The unit shows the unit that the item belongs to. The tabs show all the areas where the items could be cross referenced. The number in brackets in the tabs refers the number of occurrences in areas where this item is used. The Go To button will access the item referenced. The user should click on a line and press "Go To" to access the item. i.e. clicking on the second line in the grid above will bring up the details for Step Cold Rinse. A popup with details and cross reference properties may also be accessed. V3.6 User Guide R01 Page 25 of 110

26 6.5 Renaming of Unit Group The vessel or line group may be renamed by right clicking on the object and using the rename function. V3.6 User Guide R01 Page 26 of 110

27 6.6 Completion of Unit Insertion and Configuration The equipment units are inserted and configured until all devices and instruments are inserted in correct vessel unit and line units. Line units are inserted, named and configured in the same manner as vessel units. Line units may also be copied and pasted. V3.6 User Guide R01 Page 27 of 110

28 6.6.1 Linking of Units Vessel or line units are linked when a digital device is part of both units. This is achieved by selecting the valve in one unit and right clicking to copy the valve and then selecting the required second unit and right clicking to use the function Paste to Second Parent. This function is only valid for Digital Valves. Selection of Valve in Vessel and Insertion by Paste to second parent in Line Unit It is possible to link any two units in this manner. Such linking needs to be carried out carefully to reflect the actual plant or process. A valve that is a component of two units is accessed and treated in the same manner as a valve that is a component of only one unit. It is important to link units using this function in order to ensure that attributes of both units that are dependent on devices are treated exactly the same. Such attributes are: 1. Unit, and any Program using the Unit, may be put in Alarm if the valve is in error. 2. Unit is placed in maintenance if the valve is in maintenance. V3.6 User Guide R01 Page 28 of 110

29 7 Configuration of Equipment Devices 7.1 Configuration of Digital Inputs Digital Inputs are items such as Level Switches, Proximity Switches, signals from other PLC s, buttons and other inputs that do not have a corresponding digital output. Following insertion in a unit, a digital input is configured with settings that will determine its operation and its description in documentation. During insertion, the input is given a name and short description. The name may be changed at any time. There are three tabs in the digital input properties configuration section. The name and units of the digital input are given in the Current Item section. Cross reference, Save and Close buttons are also provided. General Equipment Item Setup tab V3.6 User Guide R01 Page 29 of 110

30 7.1.1 Setup Tab The following aspects of the device must be filled as required: Values Address Delay On SP Delay Off SP Normally Open / Normally Closed This is the PLC input address for the device. This must correspond to the electrical point address of the item according to PLC format. This is the de-bounce time, in seconds, for which the digital input must be electrically present before it is recorded as being ON. This is the time, in seconds, for which the digital input must be not electrically present before it is recorded as being OFF. A digital input is normally recognized as being ON when the electrical signal to the PLC input point is present. By selecting the Normally Closed Input, the user can declare that the input will be ON when the electrical signal is not present. A common example of this is a Vessel Low Level Signal where (for failsafe reasons) the true low level (tank empty) is recognized when the signal is present. State Text This text is used to describe the On and Off states of the item in the HMI controls. This is a free text field. Device Control Indicate Only Digital Inputs by usually referenced in Programs. This option is used if the item is only required to be monitored. Device Alarm Generate Alarm Place Unit in Alarm This is used to put cause an On state to cause a HMI Alarm. The Short Description will appear in the Alarm Control. This is used to put cause an On state to cause a Program Alarm. V3.6 User Guide R01 Page 30 of 110

31 7.1.2 PLC I/O Description Card Setup A PLC is composed of a CPU and I/O cards on racks, and in some cases communications processors, special function modules and bus based I/O. Card Setup Information tab The PLC I/O Description for the item is described in the Card Setup Information tab. The fields for Panel, Central Rack, Slot and Channel are all text input fields. Once a text is entered for a device or instrument, it then becomes available for other objects in the project. There is no validation on this information; the same combination of information could be entered for more than one device. This would be erroneous as each device must be unique, so care must be exercised in inputting the information. The type of electrical signal associated with the Digital Input is also described in this tab. In this case a 24v DC signal is identified. The information stored in this area is used for documentation and does not comprise object data for PLC control. V3.6 User Guide R01 Page 31 of 110

32 7.1.3 Description The description tab contains the following data input fields. All these fields are free text fields and may be filled according to user preference. Symbol Part Number Type Description Long Description Supplied By Notes This may be an asset number or any unique identifier which describes the object within the entire company. This could contain references to the plant, the area within the plant, the unit and the digital input name itself. This is the supplier reference for the item. This is a general description of the type of item. If a type is entered, then it becomes available to all other objects of the same type. This describes the object in more detail, if required. Name of the supplier. General Notes on the object. This may contain reference to maintenance manuals, maintenance history or location and type of spare parts. V3.6 User Guide R01 Page 32 of 110

33 7.2 Configuration of Digital Device Objects Following insertion in a unit each digital device must be configured with settings that will determine its operation and its description in documentation. During insertion the device is given a name. The name may be changed at any time. There are four tabs in the valve or motor properties configuration section. The name and parent units of the valve or motor are given in the Current Item section. Each Digital Device is assigned 1 Output and a number of Feedbacks may be configured. The type required is selectable in the setup area Setup Tab Setup showing types of Valve Feedbacks V3.6 User Guide R01 Page 33 of 110

34 There are following types of Digital Valve Feedbacks: No Feedback 1 Feedback (Feedback True when Activated) 1 Feedback (Feedback True when Deactivated) 2 Feedbacks (Feedback True when Activated & Feedback True when Deactivated) Feedback True when Activated may be thought of as a Normally Open feedback Feedback True when Deactivated may be thought of as a Normally Closed feedback Setup showing assigned Valve I/O There are following types of Digital Motor Feedbacks: No Feedback Run Feedback (Normally Open) Run Feedback (Normally Open) with Isolator (Normally Closed) Run Feedback (Normally Open) with Trip (Normally Closed) Run Feedback (Normally Open) with Isolator (Normal Closed) and Trip (Normally Closed) A Run feedback indicates that the motor contactor is engaged. V3.6 User Guide R01 Page 34 of 110

35 7.2.2 Setup Fields The following aspects of the device must be filled as required: Settings Fail to Open/Run Fail to Close/Stop Delay On SP Delay Off SP Pulse Cycle Time Pulse Time SP This is the time, in seconds, that the valve or motor is allowed to travel without correct feedback status. If this time elapses then the valve or motor is placed in error. This is the time, in seconds, that the valve or motor is allowed to have an Activated feedback while deactivated and at rest. This indicates a feedback signal when not expected e.g. a valve lifting against pressure. This is the time, in seconds, that the valve or motor activation will be delayed by the device routine. This is used to avoid pressure issues. This is the time, in seconds, that the valve or motor deactivation will be delayed by the device routine. This is used to allow closing of the valve or motor in a controlled manner to avoid line hammer and other pressure issues. This is the overall time of the valve or motor pulsing cycle in seconds. This is the time, in seconds, that the valve or motor will be pulsed for during the pulse cycle. Example Cycle time = 60, Pulse Time SP = 15 Valve will be activated for 15 seconds, deactivated for 45 seconds, activated for 15 seconds in a cycle while requested by program step. State Text This text is used to describe the On and Off states of the item in documents and controls. This is a free text field. V3.6 User Guide R01 Page 35 of 110

36 7.2.3 I/O Address Setup The I/O for the item must be filled in. It will be checked for duplication in consistency check. Addresses Type Output Feedbacks This sets the type and number of feedbacks for the device. This is the PLC Digital Output address for the device. This may be Electrical or Bus address. PLC Input address for Feedbacks. Valve- Deactivated Valve- Activated Motor-Isolator Motor-Run Motor Trip Feedbacks Types for Valves 1. 1 Feedback when Deactivated (Normally Closed) - Valve with feedback signal that is On (True) when the valve is deactivated 2. 1 Feedback when Activated (Normally Open) - Valve with feedback signal that is On (True) when the valve is activated 3. 2 Feedbacks - Valve with Activated and Deactivated feedback signals 4. No Feedback - Valve with only an Output and no associated Inputs. Note: Valves are understood to be Air/Motor to open & Spring to close. In the case of a valve which is Air/Motor to open & Air/Motor to close, this may be catered for as two valves. V3.6 User Guide R01 Page 36 of 110

37 Feedbacks Types for Motors 1. Run Feedback (Normally Open) - Motor with a Running feedback signal that is On (True) when the motor is activated. 2. Run (Normally Open) and Isolator (Normally Closed) - Motor with a Running feedback signal that is On (True) when the motor is Activated and an Isolator signal that is true at all times to indicate that the motor is not electrically isolated 3. Run (Normally Open) and Trip (Normally Closed) - Motor with a Running feedback signal that is On (True) when the motor is Activated and a Trip signal that is true at all times to indicate that the motor is not tripped. 4. Run (Normally Open) and Isolator (Normally Closed) and Trip (Normally Closed) - Motor with a Running feedback signal that is On (True) when the motor is Activated and an Isolator signal that is true at all times to indicate that the motor is not electrically isolated and a Trip signal that is true at all times to indicate that the motor is not tripped. 5. No Feedbacks - Refers to a motor which only has an activation Note; For Output and Feedback addresses; PLC addresses are represented per PLC editor. Example used Siemens notation and numbers 4 & 7 correspond to Q 4.7 in Siemens PLC notation which is Output byte 4, bit 7. Note: Accord configured I/O is usually processed cyclically in the PLC. V3.6 User Guide R01 Page 37 of 110

38 7.2.4 Enablers Enablers Remain during Hold Active Program This enabled the item to stay On or Activated if the Program ( sequence) that has activated the item goes into Hold or Error state Conditionally Activate with Pulse Enable Reserved for Automatic This enables the item to be pulsed according to a condition in the Program. This is to have the item reserved for automatic only. when this is selected then Manual mode can only be selected with a specific additional override. Place Unit/Program Error in This is to enable the item to cause a Program to go into Alarm. Some valves or motors are not required to cause programs to go into Error, but in general this box will be ticked. Device Control Manual Only This option is used if the Device will not be controlled automatically, only controlled from HMI. Short Description; A short one-line description for the Device. V3.6 User Guide R01 Page 38 of 110

39 7.2.5 Interlocks Tab Interlocks are conditions of devices and instruments that prevent a device from activating. This is to prevent damage to equipment or to material. For example, a pump may not run if a low level in a pipe exists to prevent the pump running dry, or two particular valves may not open together to prevent product mixing. Interlocks are applicable to HMI manual activation as well as automatic activations. Clicking on the Edit Interlocks button brings up the Interlocks Tab. There are two types of interlocks allowed. In the first section the device will be Interlocked unless One item is True, and in the second section the device will be Interlocked if Any item is True. Both sections are considered always, - the Device will be interlocked on either section. Interlocks Tab. In the example the Motor P01 CIP Supply Pump is interlocked if: 1. If V04 is Deactivated and V05 is Deactivated. OR 2. If V02 is deactivated All of the appropriate items are made available by means of drop down menus. V3.6 User Guide R01 Page 39 of 110

40 There is a system Option in the Tools menu to make Interlocks Unit based or Plant-wide based. In the case of Interlocks Unit based then the items which are available are those that are in the same unit(s) as the device Types of Interlocking Items: A Valve is activated open A Valve is deactivated closed A Valve is in Alarm -error A Motor is activated running A Motor is deactivated stopped A Motor is in Alarm -error A Digital Output is activated A Digital Output is deactivated The result of a digital input is High (true) The result of a digital input is Low (false) An analog input has a High-High Alarm An analog input has a High Alarm An analog input has a Low Alarm An analog input has a Low-Low Alarm An analog input does not have a High-High Alarm An analog input does not have a High Alarm An analog input does not have a Low Alarm An analog input does not have a Low-Low Alarm Once the type of condition is chosen the relevant items which are already configured in the same unit(s) become available for the choice of interlocking item in the drop-down menu. The particular interlocking item is chosen from the drop down menu and the Interlock added by clicking Add Interlock. Interlocks may be removed at any time by clicking Remove Interlock. To save the interlocks click the Save button V3.6 User Guide R01 Page 40 of 110

41 7.2.6 PLC I/O Description Card Setup A PLC is composed of a CPU and I/O cards on racks, and in some cases communications processors, special function modules and bus based I/O. Card Setup The PLC I/O description for the digital device is described in the card setup tab. The fields for Panel, Central Rack, Slot and Channel are all text input fields. Once a text is entered for a device or instrument it then becomes available for other objects in the project. No validation is performed on this data. The same combination of information could be entered for more than one device. This could give rise to erroneous documentation as each device must be unique, so care must be exercised in entering this information. The type of electrical signal associated with the digital device is also described in this tab. In this case a 24v DC signal is identified. The information stored in this area is used for documentation and does not comprise object data for PLC control. The fields are free text fields and data may be used more than once (i.e. the Slot Nr.) It is the overall combination of data input that should be unique. V3.6 User Guide R01 Page 41 of 110

42 7.2.7 Device Description Fields The description tab contains the following data input fields. All these fields are free text fields and may be filled according to user preference. Symbol Part Number Type Description Short Description Long Description Supplied By Notes This may be an asset number or any unique identifier which describes the object within the entire company. This could contain references to the plant, the area within the plant, the unit and the digital device name itself. This is the supplier reference for the item. This is a general description of the type of item. If a type is entered, then it becomes available to all other objects of the same type. This describes the objects function in a short phrase. This describes the object in more detail, if required. Name of the supplier. General Notes on the object. This may contain reference to maintenance manuals, maintenance history or location and type of spare parts. V3.6 User Guide R01 Page 42 of 110

43 7.2.8 Deletion of Digital Devices To delete a digital device, right click the desired device and select the delete option. A delete can only take place if the digital device is not referenced by a program or interlock. If the digital device is in use by a program, a message will be displayed. In this case the device activations must be removed from steps before the delete can be completed. This can be accomplished from the activations tab by right-click and Delete All Activations. Similarly the device must be removed from any interlocks in other items. V3.6 User Guide R01 Page 43 of 110

44 7.2.9 Deletion of Valves in two Units On attempting to delete a digital device (valve) which is used in two units, a prompt will be displayed. This prompt will request the user to choose between Delete Link Deletes only the link between this valve and the parent unit. Delete Valve Deletes the valve and links to any other parent units. Cancel Delete - cancels the delete V3.6 User Guide R01 Page 44 of 110

45 7.3 Configuration of Digital Outputs Following insertion in a unit object each digital output must be configured with settings that will determine its operation and its description in documentation. During insertion the digital output is given a name and short description. Digital outputs are items such as signals to other PLC s, lamps, solenoid, and other outputs that do not have a corresponding feedback. If a digital device (valve or motor) is to be installed without a feedback then it could be installed as a digital output. There are four tabs in the digital output properties configuration section. The name and units of the digital output are given in the Current Item heading Setup Tab V3.6 User Guide R01 Page 45 of 110

46 Setpoints Delay On SP Delay Off SP Pulse Cycle Time Pulse Time SP This is the time, in seconds, that the digital output activation will be delayed by the device routine. This feature is used to avoid pressure issues. This is the time, in seconds, that the digital output deactivation will be delayed by the device routine. This feature is used to allow closing of valve or motor in controlled manner to avoid line hammer and other pressure issues. This is the overall time of digital output pulsing cycle, in seconds. This is the time, in seconds, that the digital output will be pulsed for during the cycle. Example - Cycle time = 60, Pulse Time SP = 15, digital output will be activated for 15 seconds, deactivated for 45 seconds, activated for 15 seconds in a cycle while requested by program step. Addresses Type Output There is no feedback for this object. This is the PLC output address for the device. This must correspond to the address on the electrical drawings for the control system. Enabling Flags Remain active during Program Fault Conditionally Activate with Pulse Enable Reserved for Automatic This setting allows a valve or digital output activated if a program is in fault, to avoid process issues due to fault, to allow a natural flow to continue, or to allow a fan to remain on. This enables the item to be pulsed according to a condition in the Program This is to enable the item to be a part of the automatic control. Device Control Manual Only Digital Outputs by default are controlled automatically by the system. If manual control only is required tick the check box. V3.6 User Guide R01 Page 46 of 110

47 7.3.2 Interlocks Tab Interlocks are conditions of devices and instruments that prevent a device from activating. This is to prevent damage to equipment or to material. Interlocks are applicable to manual HMI and automatic activations by a program. Digital Outputs have same interlocks facility as Digital Devices Clicking on the Edit Interlocks button brings up the following panel which allows the interlocks to be allocated as desired PLC I/O Description Card Setup A PLC is composed of a CPU and I/O cards on racks, and in some cases communications processors, special function modules and bus based I/O. Digital Outputs have PLC I/O description facility as Digital Devices The PLC I/O description for the digital output is described in the card setup tab. The fields for Panel, Central Rack, Slot and Channel are all text input fields. Once a text is entered for a device or instrument it then becomes available for other objects in the project. No validation is performed on this data. The same combination of information could be entered for more than one device. This could give rise to erroneous documentation as each device must be unique, so care must be exercised in entering this information. The type of electrical signal associated with the digital output is also described in this tab. In this case a 24v DC signal is identified. The information stored in this area is used for documentation and does not comprise object data for PLC control. The information stored in this area is used for documentation and does not comprise object data for PLC control. V3.6 User Guide R01 Page 47 of 110

48 7.3.4 Digital Output Description Tab The description tab contains the following data input fields. All these fields are free text fields and may be filled according to user preference. Symbol Part Number Type Description Short Description Long Description Supplied By Notes This may be an asset number or any unique identifier which describes the object within the entire company. This could contain references to the plant, the area within the plant, the unit and the digital output name itself. This is the supplier reference for the item. This is a general description of the type of item. If a type is entered, then it becomes available to all other objects of the same type. This describes the objects function in a short phrase. This describes the object in more detail, if required. Name of the supplier. General Notes on the object. This may contain reference to maintenance manuals, maintenance history or location and type of spare parts. Digital Outputs have PLC I/O description facility as Digital Devices. V3.6 User Guide R01 Page 48 of 110

49 7.4 Configuration of Analog Input Objects Following insertion in a unit each analog input must be configured with settings that will determine its operation and its description in documentation. During insertion the analog input is given a name and short description. These name may be changed at any time. There are three tabs in the analog input properties configuration section. The name and units of the analog input are given in the Current Item heading Analog Input Setup Tab V3.6 User Guide R01 Page 49 of 110

50 The following aspects of the instrument must be configured: Values I/O Address Input Type Min Range Max Range Scaling Factor Alarm Value HH Alarm Value H Alarm Value L Alarm Value LL Alarm Delay Time Hysteresis This is the channel of the instrument, represented in word format. Example - 128, corresponds to I/O channel 128. This refers to the type of connection to the PLC, which will affect the scaling routine. The following types are configurable: 1. Electrical Input e.g. 0-5 V, or 4-20 ma 2. Bus Real - The signal is read from Bus channel with applied Scaling Factor. 3. Bus Word (Integer) - The signal is read from Bus channel with applied Scaling Factor. This is the lower value of the range in engineering units that the Electrical Input is to be scaled between. This is the upper value of the range in engineering units that the Electrical Input is to be scaled between. The Factor applied to Bus Based Inputs to obtain Engineering Units. This is the setpoint at which the High High Alarm occurs. Available for use in interlocks or program items. This is the setpoint at which the High Alarm occurs. Available for use in interlocks or program items. This is the setpoint at which the Low Alarm occurs. Available for use in interlocks or program items. This is the setpoint at which the Low Low Alarm occurs. Available for use in interlocks or program items. This is the time in seconds that must elapse before an Alarm is triggered. The scaled value in engineering units must be greater than or less than the respective setpoint for this time. This is the value that the scaled value must recover by in order to release the alarm point. Example - If the high alarm is set to 90 and the alarm timer is 5 seconds and the hysteresis is set for 2 then the high alarm will be set if the analog input scaled value exceeds 90 for 5 seconds continuously. The high alarm will only be released as soon as the value falls below 88. V3.6 User Guide R01 Page 50 of 110

51 IQ Information Tolerance No. of Points This is the error allowed for a particular reading. It is in terms of the scaled engineering units value. This is the number of readings that are to be tested during the IQ. Engineering Units This is the name of the process units that is to be used in documentation and HMI Controls. The IQ information fields are used to supply information for the IQ document. In the IQ document a table is produced. Each row in the table is a test for the analog instrument. The number of rows is given by the No. of points above in the IQ set-up area. The Max and Min are always included and the other points are evenly spaced in the range e.g. an instrument of range 0 to 100 with 5 test points will be tested at 0, 25, 50, 75, and 100. For each test point a tolerance is applied. This tolerance is the error that can be tolerated in order for the instrument to pass the test at that point. The standard Siemens scale is 0 to The raw value being read by the PLC from the instrument item may be monitored in the register status area of Accord Server. The tolerance value input at is used to derive the equivalent value in terms of the raw value. This max raw value error is then shown in the table. The recorded value observed from the PLC must be within the raw value error in order for the instrument to pass the test. E.g. An instrument of range 0 to the mid-range point of 50 would correspond to divided by 2 or If a tolerance of 1 is applied the possible error is limited to 276. The raw value being read from the instrument must be between and ( ) and ( ). WireBreak Alarms Place Unit/Program in Error Enables the item to be tested for WireBreak at PLC level This is to enable the items to cause a Program to go into Alarm. Some Instruments are not required to cause programs to go into Error, but in General this box will be ticked. Device Control Indication Only Analog Inputs are usually referenced in PID Loops or Programs. This option allows for an Analog Input to be only Indication only and not required to be referenced. V3.6 User Guide R01 Page 51 of 110

52 7.4.2 Analog Input PLC I/O Description Card Setup A PLC is composed of a CPU and I/O cards on racks, and in some cases communications processors, special function modules and bus based I/O. The PLC I/O description for the analog input is described in the card setup tab. The fields for panel, central rack, slot and channel are all text input fields. Once a text is entered for a device or instrument it then becomes available for other objects in the project. There is no validation on this information, the same combination of information could be entered for more than one device. This would be erroneous as each device must be unique, so care must be exercised in entering the information. The type of electrical signal associated with the analog input is also described in this tab. In this case a 4-20 ma - 2 wire signal is identified, which corresponds to a setting of C in the PLC measuring module. The information stored in this area is used for documentation and does not comprise object data for PLC control. V3.6 User Guide R01 Page 52 of 110

53 7.4.3 Analog Input Description The description tab contains the following data input fields. All these fields are free text fields and may be filled according to user preference. Symbol Part Number Type Description Short Description Long Description Supplied By Notes This may be an asset number or any unique identifier which describes the object within the entire company. This could contain references to the plant, the area within the plant, the unit and the analog input name itself. This is the supplier reference for the item. This is a general description of the type of item. If a type is entered, then it becomes available to all other objects of the same type. This describes the objects function in a short phrase. This describes the object in more detail, if required. Name of the supplier. This may contain reference to maintenance manuals, maintenance history or location and type of spare parts. V3.6 User Guide R01 Page 53 of 110

54 7.5 Configuration of Analog Device Objects Following insertion in a unit object each analog device, (or analog output) must be configured with settings that will determine its operation and its description in documentation. During insertion the analog device is given a name and short description. These may be changed at any time. There are three tabs in the analog device properties configuration section. The name and units of the analog device are given in the Current Item heading Analog Device Setup Tab V3.6 User Guide R01 Page 54 of 110

55 The following aspects of the device must be filled as required: Values I/O Address This is the channel of the instrument, represented in word format. Example - 128, corresponds to I/O channel 128 Output Type This refers to the type of connection to the PLC, which will affect the scaling routine. The following types are configurable: 1. Electrical Output e.g. 0-5 V, or 4-20 ma, scaled from Engineering Units. 2. Bus Real - The Engineering Units value is sent to address with applied Scaling Factor. 3. Bus Integer - The Engineering Units value sent to Bus address with applied Scaling Factor. Min Range Max Range This is the lower value of the range in engineering units that the Electrical Output is to be scaled for. This is the upper value of the range in engineering units that the Electrical Output is to be scaled for. IQ Information Tolerance No. of Points This is the error allowed for a particular reading. It is in terms of the scaled engineering units value. This is the number of readings that are to be tested during the IQ. Engineering Units This is the name of the process units to be used in documentation and HMI controls. Device Control Manual Only Analog Devices by default are controlled automatically by the system. If manual control only is required tick the check box. V3.6 User Guide R01 Page 55 of 110

56 7.5.2 Analog Device PLC I/O Description Card Setup A PLC is composed of a CPU and I/O cards on racks, and in some cases communications processors, special function modules and bus based I/O. The PLC I/O description for the analog device is described in the card setup tab. The fields for panel, central rack, slot and channel are all text input fields. Once a text is entered for a device or instrument it then becomes available for other objects in the project. There is no validation on this information, the same combination of information could be entered for more than one device. This would be erroneous as each device must be unique, so care must be exercised when entering the information. The type of electrical signal associated with the analog device is also described in this tab. In this case a 4-20 ma device is identified. The information stored in this area is used for documentation and does not comprise object data for PLC control. V3.6 User Guide R01 Page 56 of 110

57 7.5.3 Analog Device Description The description tab contains the following data input fields. All these fields are free text fields and may be filled according to user preference. Symbol Part Number Type Description Long Description Supplied By Notes This may be an asset number or any unique identifier which describes the object within the entire company. This could contain references to the plant, the area within the plant, the unit and the analog device name itself. This is the supplier reference for the item. This is a general description of the type of item. If a type is entered, then it becomes available to all other objects of the same type. This describes the object in more detail, if required. Name of the supplier. General Notes on the object. This may contain reference to maintenance manuals, maintenance history or location and type of spare parts. V3.6 User Guide R01 Page 57 of 110

58 7.6 PID Loop Controller PID Loop Note A PID Loop Controller is used to control an Analog Device, based on a desired setpoint and feedback (in a loop fashion) from an Analog Instrument, also called the process variable. An example is where Heat is transferred by allowing a quantity of steam to pass through a control valve. Initially the Temperature in the system (process variable) read by the Analog Input Temperature Transmitter will be low. As the system heats up the Control Valve will begin to close. The ideal is to maintain the Control Valve Analog Device at an output which maintains the temperature Process Variable at the desired Setpoint. The difference between the Setpoint and the Process Variable is called the Error. The Loop controller allows the system to provide a low steady-state Error for different Setpoints. PID stands for Proportional, Integral and Derivative control. The three terms refer to portions of the controller loop which provide the output value from the controller which is sent to the Analog device being controlled. Proportional Control, also called gain, is a straight multiplier factor on the Error Integral Control, is based on the average Error over recent time period. Derivative Control is based on the rate of change of the Output and (Error) A controller only using Proportional control (P) would always generate an output which would cause the Process Variable to oscillate. Use of the I and D terms allows the user to generate controller action which will provide the required system response in terms of the output not oscillating at steady state. The process of modifying P, I and D terms to achieve smooth nonoscillating response is known as tuning the loop. Many systems just use P and I control and leave the derivative D term at 0. V3.6 User Guide R01 Page 58 of 110

59 7.6.2 Configuration of PID Loop Controller Following insertion in a unit object each PID Loop must be configured with settings that will determine its operation and its description in documentation. During insertion the PID Loop is given a name and short description. These may be changed at any time. There are two tabs in the PID Loop properties configuration section. The name and analog device of the PID Loop are given in the Current Item heading. The PID loop is always associated with the analog output. PID Controller Setup V3.6 User Guide R01 Page 59 of 110

60 The following aspects of a PID Loop may be configured: Settings Explanations AI Source This is the Analog Input or Variable that is used as the Process Variable. It must be already configured. P Proportional, or Gain, Factor. I Integral Factor. D Derivative Factor. Response Time Lag A factor for how quickly the loop is to react. It is used to set the rate of decay of Derivative term effect. The larger the value the slower the loop will act. Upper Limit Output Maximum Range value for the Loop. Lower Limit Output Minimum Range value for the Loop. Often same as the Analog Device. Integral Reset Value Integral component value used when loop is starting up. This is not be used if there is a stored Integral Value from Store Integral when in Steady State. Sample time This is the interval between successive processing of the PID loop. This is set up in the PLC hardware to be 100 milliseconds. All PID loops are processed from OB35 in Simatic S7 PLC. The Hardware configuration will have OB35 interrupt time set to 100 milliseconds. Steady State Deadband Deadband around the Setpoint within which the Loop is deemed to be in steady state. If the loop achieves this state for 100 seconds (given sampling time of 100ms) then the Integral component is stored when the Store Integral when in Steady State is enabled. Example- If the Steady State Hysteresis is 2.0 for a Loop with setpoint of 80.0 and then the Steady State is achieved when the Process Variable is between 78.0 and 82.0 for 100 seconds. Derivative Deadband The Derivative Deadband is the minimum amount of an error change that will cause a change to the derivative component of the PID calculation. It is a Deadband on the error with respect to the Derivative Component of the PID loop. Store Integral when in This allows the integral component to be stored, which will give a Steady State faster response in case of a PID restart. These settings are also available in Accord HMI PID Controls for tuning. V3.6 User Guide R01 Page 60 of 110

61 7.6.3 PID Loop Description The description tab contains the following data input fields. Description This is a general free text description of the object, supplied for documentation purposes Steps in setting up a PID controller These steps are generally carried out at HMI or Scada commissioning. 1. The PID Loop sample time will be 100 Ms- this means that the PID Loop and error is evaluated and output is manipulated every 100 milliseconds. 2. The response lag time depending on how quickly the physical loop is to react; Initial guides for this are; Flow controller - in the range 2-5 seconds Temperature controller in the range seconds Test the accuracy of these times by manually activating (opening) the PID Loop output item (analog device - control valve) and measure the time before a response is noted, being a change in the process variable (e.g. Temperature Transmitter). V3.6 User Guide R01 Page 61 of 110

62 3. To Tune the PID Loop Initially set Integral and derivative (I & D) terms to 0 (zero) Give an expected setpoint (or 50-70% of the maximum expected output). Adjust the P term until the PID Loop oscillates around the setpoint without closing or reaching upper or lower limits. Measure the time between peaks (i.e. the time for 1 complete cycle between maximum output and minimum output) Apply P, I and D terms as follows Proportional and integral control - Using PI control - Use the formula (flow control) P=Initial gain/2.2 I=Periodic time/1.2 Proportional and integral and derivative control - Using PID Loop control - Use the formula (Temperature Control) P=Initial gain/1.7 I=Periodic time/2 D=I/4 4. PID Loop Restart If the PID Loop is required to Start from value other than Min Range then for check (tick) the box for Store Integral When in SS. This will cause the integral component of the PID Loop output to be stored when the PID Loop is in steady state, and Loop will load this value on new starts. Note: Ensure disturbance variable is not set too high as this disables a derivative change effect if the error change between PLC cycles is too small. i.e. If the PID Loop reacts very slowly ensure the derivative term is not redundant. V3.6 User Guide R01 Page 62 of 110

63 8 Configuration of Programs 8.1 Program General Programs are comprised of steps and a recipe and other components of the steps. A Program may be considered as a Sequence of Steps for Automatic Operation. These components may be generated and linked in order to provide all the functionality required for the program. The full list of components required is, (as well as reference to equipment devices) Common Items Program Program Order Variable Constant Collection of program items and a sequence of Steps. Order in which programs are to be processed. Register whose Floating Pt value is written by the PLC. Register which has a constant Floating Pt value in the PLC. Program Items Route Units Condition Combined Condition Operation Alarm Step Activation Collection of the units associated with the Program. Test of a state or signal or value. Combinational Boolean logic function. Function to perform a mathematical or control function. Fault in process operation; Critical or Event. Stage of the program. Command to activate a Digital Device. Program Recipe Items Step List Setpoints Decisions Default sequence of steps. Setpoints, changeable at HMI or Scada Selections, changeable at HMI or Scada V3.6 User Guide R01 Page 63 of 110

64 A Program is configured or built by configuring program and by listing them (for enabling) in Steps. Items are configured by dragging the appropriate icon from the Program toolbox or by right-click in the component holder and adding component such as Add Operation. Equipment Units must be dragged to Equipment container in order to Activate devices or use items in Conditions etc. V3.6 User Guide R01 Page 64 of 110

65 8.2 Insertion of a Program A program is inserted into the configuration by dragging a program icon from the toolbox to the Program Configuration area, or by right clicking and Add Program. The inserted program must be named. In example the program is named CIP Program. The program sub component holders are automatically generated. Initial Program insertion Initial Program Containers V3.6 User Guide R01 Page 65 of 110

66 8.3 Program Properties Following Insertion the program initial properties may be configured. Program Properties tab Program Properties: Single Step this is for a Background Program which is to run continuously. These programs run Common or Safety functions. Step On in Hold - The default setting is that a program will not step on automatically if it is in hold or Alarm. This means the Operator must acknowledge the Alarm or restart the program manually. The Enable setting will allow the program to step on Automatically if a Critical Alarm has occurred or if the program is put in Hold by operator. Power Recovery - If the PLC fails all the information for the system is retained until the PLC is powered up again. The program may be configured to restart in any case or be configured to go into Hold, and then will require Operator to restart the program. Unit Selection - Normally a program will Reserve or Select units when it is Active. This means that another program attempting to start using those units will go into Alarm, assuming the Unit Selected Alarms are still in the First Step. However some programs for background or common functions may not be required to Reserve or select units. PreStart Operator Actions notes this information will be used in project documentation. V3.6 User Guide R01 Page 66 of 110

67 8.4 Equipment Units in Program Programs work on Equipment, and Equipment is arranged in Equipment Units. If an Equipment Item is in Alarm, and a program is Active in a Step which activates devices in the Unit, then program will go into Alarm. This is achieved simply by placing the required Equipment into the program Equipment holder. The vessel and line equipment units for the program are dragged from the vessel and line groups into the Equipment holder. Only devices in Units in the program Equipment holder are available for use in the program. Program Unit Details A Unit should only be in use by one program at a time in the running plant. When each unit is placed in a program, two alarms are automatically associated with it - Unit Selected Check and Unit Maintenance Check. These alarms are automatically inserted into Step 0. They may be removed if not required. These error checks are important for program interlock, product security and personnel safety. The user may also insert a Unit in Manual Alarm here to cause an Alarm if the program is Active while a device in one of the program equipment units is in Manual. V3.6 User Guide R01 Page 67 of 110

68 8.5 Configuration of Conditions A condition is added to the program by dragging the condition icon from the toolbox to the program condition component holder, or by right clicking on the holder and Add Condition Add Condition The inserted condition must be given a unique name. V3.6 User Guide R01 Page 68 of 110

69 Condition Entries The following are filled in for the condition 1. The Condition Type must be selected. 2. The Value types for comparison of 2 values. Value Equal to Setpoint (for a Delay Time) Value Greater than or equal to Setpoint (for a Delay Time) Value less than or equal to Setpoint (for a Delay Time) Value not equal to Setpoint (for a Delay Time) V3.6 User Guide R01 Page 69 of 110

70 3. A Delay type which times a period within the step or an Event Simple Delay, used to indicate interval within Step. This timer is not paused if the step is in hold or Stopped. An Event Delay, for a state for defined time. This may be continuous or may pause and resume as the state changes. 4. The Program type which is used to monitor the condition of another program. Test if a Program is in a Step Test if a Program is in a particular status (Running, Hold, Alarm, TimeHold) Test if a Program is Active (Program is Active, in any status) 5. A Scada/HMI command. This is an Operator HMI command which is reset immediately by the PLC after usage. Note: There is also a Scada/HMI Decision in the Program Recipe. This is an Operator HMI toggle type selection which is not reset by PLC, used for items such as Pump Duty / Standby selections or Local / Remote control or other operator selectable aspects which require a Yes / No decision. These items are in the Recipe, as their initial state may vary for different recipes. Appropriate item types and items are available in drop-down lists for each condition type. V3.6 User Guide R01 Page 70 of 110

71 8.5.1 Source and Setpoint declaration The following are possible types for Condition Source and Setpoints Value type conditions: Source Types: o Analog Inputs o Analog Devices o Setpoints o Variables Setpoint Types: o Setpoints o Variables V3.6 User Guide R01 Page 71 of 110

72 In the above example an evaluation of the CIP Return Temperature is to be performed. The Source Type is an Analog Input and the particular item is the Temperature Transmitter TT 03. The Setpoint Type is a Setpoint (Recipe Setpoint). The condition is configured with delay timer for 5 seconds. This condition will be True when the value of TT03 Return Temperature is less than Setpoint Low Return Temperature Alarm SP for 5 seconds continuously. Note: Setpoints and Variables may be generated by clicking on the NEW button. For Setpoints a default value is used in Builder but may be changed in runtime at SHMI/Scada or Recipe Manager. The maximum and minimum values will be bounds that apply in HMI/Scada and Recipe Manager. There is an Option to allow Setpoint to be changed or not allow it to be changed, when program is Active. V3.6 User Guide R01 Page 72 of 110

73 8.6 Configuration of Combined Conditions A combined condition is added to the program by dragging the combined condition icon from the toolbox to the Combined Condition holder or by right clicking on the holder and Add Condition This Combined Condition tests that the Detergent Temperature and Strength have been reached in Hot Detergent Wash and after a Step Delay. V3.6 User Guide R01 Page 73 of 110

74 8.6.1 Boolean Gate Descriptions The combined condition is made up of a series of Gates. Each gate can be used to evaluate a Boolean logic condition. A spreadsheet utility is provided in the help area to allow users to test the logic prior to confirming and downloading. GATE BOTH EITHER NOT BOTH NEITHER ONLY 1 SAME A NOT B Description True if both inputs to gate are true. True if either input to gate is true. True if both inputs to gate are false. True if either input to gate is false True if both inputs to gate have different states. True if both inputs to the gate have the same state. True if input to first gate is true and the input to second gate is false. V3.6 User Guide R01 Page 74 of 110

75 8.6.2 Boolean Gate Operations BOTH Gate - Both inputs to gate are true. If state=1 of input X AND state=1 of input Y then Result=1. Input X Input Y Result EITHER Gate - Either input to gate is true. If state=1 of input X OR state=1 of input Y then Result=1. Input X Input Y Result NOT BOTH Gate - Both inputs to gate are false. If NOT state=1 of input X AND NOT state=1 of input Y then Result=1. Input X Input Y Result NEITHER Gate - Either input to gate is false If NOT state=1 of input X OR NOT state=1 of Input Y then Result=1. Input X Input Y Result V3.6 User Guide R01 Page 75 of 110

76 ONLY 1 Gate - Both inputs to gate have different states If state=1 of input X AND NOT state=1 of input Y OR if NOT state=1 of input X AND state=1 of input Y then Result=1. Input X Input Y Result SAME Gate - Both inputs to the gate have the same state If NOT state=1 of input X AND NOT state=1 of input Y OR if state=1 of input X AND state=1 of input Y then result is 1. Input X Input Y Result A NOT B Gate - Input to first gate is true and the input to second gate is false If state=1 of input X AND NOT state=1 of input Y then Result=1. Input X Input Y Result V3.6 User Guide R01 Page 76 of 110

77 8.7 Configuration of Alarms Alarms are used to give warnings or to stop the program from performing unsafe or undesired operations. A alarm is assigned to a program by dragging the alarm icon to the component holder and configuring the error as required. Critical Alarm Configuration V3.6 User Guide R01 Page 77 of 110

78 Alarm Container Alarm Enabler item types are Conditions Combined Conditions Digital Inputs Analog High High Alarms Analog High Alarms Analog Low Alarms Analog Low Low Alarms Step Time; Check performed on Step Time elapsing. Also known as Watchdog Time Valve Error Motor Error Unit in Maintenance Unit in Manual Unit Selected Alarm may be configured on items being true or false where appropriate. Items of type chosen are available in the enabler list. An Alarm may be one of the following; V3.6 User Guide R01 Page 78 of 110

79 Critical alarm. Non Critical alarm. Event. A Critical Alarm will cause the Program to go into Alarm and Hold. This must be Reset before the Program can Restart. A Non Critical Alarm is a Warning, it will not cause the Program to go into Hold. It will be registered at HMI/Scada and must be acknowledged there. An Event may be logged, and will not appear in HMI/Scada The Description tab is used to enter a long description of the alarm for documentation purposes. An Alarm may be Added to or Removed from Steps in the Usage in Steps tab Alarm Usage in Steps tab V3.6 User Guide R01 Page 79 of 110

80 8.8 Configuration of Operations Operations are used to perform mathematical or sequence functions in the program. An Operation is added to the program by dragging the Operation icon from the toolbox to the program and configuring the Operation or by right-click and Add on the Operation holder. The value in the Setpoint Supply Temperature Target SP, is transferred to the PID Loop Temperature Control. The Operation is implemented while the Valve SV 01 is Activated. V3.6 User Guide R01 Page 80 of 110

81 The following types of operations may be implemented Operations: Operation Addition Subtraction Multiplication Division Assignment Absolute Value(modulus) Square Square Root Exponential Logarithmic Trigonometric Sine Cosine Tan Arc Sine Arc Cosine Arc Tan Description Using Values of two operands of types Variables, Setpoints, or Scaled values of Analog Inputs or Analog Devices. Using Value of one operands of type Variables, Setpoints, or Scaled values of Analog Inputs or Analog Devices. Using Value of one operands of type Variables, Setpoints, or Scaled values of Analog Inputs or Analog Devices. AVG Periodic Value Change Program Start (Restart) Program Stop (End) Program Step On Program Hold Program Time Hold Program Time Hold Release Set Item Reset Item Generation of Average of a number of samples of an Analog Input or Variable Periodic increment or decrement of Variable or Analog Output by defined value in defined time period. Starts a target Program, or Restarts from Hold State Ends a target Program Puts a target Program into a selected Step Puts a target program into Hold state. Puts a target program into Time Hold state. Puts a target program into Timing state. Set a Condition Result or an Auto Activation or Alarm Reset a Condition or an Auto Activation or Alarm Care must be taken to ensure correct operation when writing to other programs. V3.6 User Guide R01 Page 81 of 110

82 8.8.1 Enabling an Operation An Operation may also be configured to occur at the start of a step, at the end of a step, to be always occurring during a step, or to be conditionally enabled. The item type to enable the Operation is chosen and the objects of that type are then made available in the enabler item area. The conditional enabling may occur for 4 cases; Active while condition TRUE - While the enabling object is true Active while condition FALSE - While the enabling object is false Active on condition TRUE - When the enabling object becomes true Active on condition FALSE - When the enabling object becomes false The enabler Item types for above conditions may be one of the following Condition Combined Condition Digital input Analog High High Alarm Analog High Alarm Analog Low Alarm Analog Low Low Alarm Step time; where the configured step time has elapsed. Valves Activated / Deactivated Motors Activated / Deactivated Digital Outputs Valve Alarm Motor Alarm Unit Selected Unit in Maintenance Unit in Manual Analog WireBreak The above items can be used in a true or false state where appropriate. The Description tab is used to enter a long description of the alarm for documentation purposes. The Operation is enabled in a step by using the Usage in steps Tab. Here steps are Added/Removed to the Steps Using this Operation window. V3.6 User Guide R01 Page 82 of 110

83 8.9 Configuration of Steps Alarms and Operations are enabled in required steps. Step Transitions are configured also Properties Properties include a default Step time and Descriptions fields Step Properties The above Properties Tab contains the following: Field Short Description Long Description Operator Selection Notes Step Time Setpoint Description This is a basic description which will appear in the documentation. A fuller description can be entered here, which will be included in the FDS document appendix. Notes which will be included in the FDS Document. The notes entered here would guide the operator in preparation for the step or in the event of errors or unusual events. Each step has an allocated time. Generally this time is used as a step duration, in which case the program will move to the next step (see step order) when the duration time has elapsed. Step Time may be used as a watch-dog timer in an Alarm. Step time counts down when Program is not in Hold or TimeHold. V3.6 User Guide R01 Page 83 of 110

84 8.9.2 Enabling Conditions and Combined Conditions These items are automatically enabled in all steps while the Program is Active Enabling of Operations Configured Operations may be enabled for required Steps. The Operation will be enabled for implementation while the program is in the Step. Available Operations are already configured in the program. The Operation is enabled for the step by adding it to the Operations enabled for this step area. A Operation may be enabled for multiple steps in a program. If an Operation is not enabled for a step then is will not be executed while that step is active. A Operation may be removed from a step also by selecting the Operation in the right hand box Operations enabled for this step box and clicking on the remove button. V3.6 User Guide R01 Page 84 of 110

85 8.9.4 Enabling Alarms This tab allows Alarms to be enabled in a step. An Alarm may be configured at any time and subsequently added to steps. The addition of an alarm to a step means that the alarm will be monitored while the program is processing the step. An Alarm is enabled in a step by selecting it and adding it to the Alarms enabled for this Step. These Alarms will be monitored while the step is active. An Alarm may be added for monitoring to multiple steps in a program. If an alarm is not added to a step then is will not be monitored while that step is active. An Alarm may be removed from a step also by selecting the alarm in the right hand box Alarms Enabled for this step box and clicking on the remove button. The system automatically assigns unit based alarms (Unit Selected and Unit Maintenance) to each program for each unit that is added to the Equipment Unit component holder. These alarms are automatically assigned to Step 0 - Pre Start Checking. These alarms may be added to other steps also and may be removed from any step. V3.6 User Guide R01 Page 85 of 110

86 8.9.5 Enabling Device Activations Required Digital Devices (valves, motors, digital outputs) may be activated in a step. Only Devices in Units that have been added to the Program Equipment are available for Automatic Activation. The PLC program will automatically monitor for all device errors in Equipment Units of devices being activated. The devices may be activated in one of three ways: 1. Always during the step 2. Pulsed during the step, according to the pulse setpoint and cycle times. 3. Activated conditionally on one of the following; Condition Combined condition Alarm Digital input Analog High High Alarm Analog High Alarm Analog Low Alarm Analog Low Low Alarm Step time Valves Activated / Deactivated Motors Activated / Deactivated Digital Output Activated / Deactivated Valve Alarm Motor Alarm Analog Input WireBreak The above items can be used for a true or false state where appropriate. The activations tab shows step activations, which may be accessed using the Edit Activations button. List of Activations for a device are also available in the panel for Valve Motor or Digital Output. V3.6 User Guide R01 Page 86 of 110

87 8.9.6 Configuring Step On-Transitions Step-On transitions The following types of Step-On transitions may be configured: 1. Normal Step On Transition Causes the program to Step-on to next step in the Step Order. 2. Alternate Step On transition Causes the program to go to another step other than the next in Step Order. This may be useful for situations such as a recirculation requirement on a pasteurizer. 3. External Step On This means the program will not step on automatically, it must be stepped on by an operation or by Operator at HMI. When a program leaves a step - Activations, Operations and Alarm monitoring on items configured for the step are finished. The program may return to the step again per Recipe or an Operation or Alternate Step On. Normal and Alternate Step On transitions may be enabled by the following: V3.6 User Guide R01 Page 87 of 110

88 Conditions Combined Conditions Step Time Digital inputs Analog High High Alarms Analog High Alarms Analog Low Alarms Analog Low Low Alarms Valve Activated / Deactivated Motor Activated / Deactivated Valve Error Motor Error Digital Output Activated / Deactivated Analog Input WireBreak These items may be used in a True or False state as appropriate. Steps in Step holder are listed in default Step Order 8.10 Step Transitions This tab allows the Normal, Alternative and External Step Transitions to be configured. V3.6 User Guide R01 Page 88 of 110

89 9 Program Recipe 9.1 Setpoints Setpoints are used in Conditions and Operations. They may also be viewed, added or modified in the Program Recipe. The minimum, maximum and default values for each recipe setpoint may be modified in this screen. These values will be applied as limits for operator setpoint entry in HMI controls. Setpoints may be deleted by selecting and right-click and Delete. If a Setpoint is in use it cannot be deleted. Setpoints may be renamed by selecting and right-click and Rename. In some cases it is useful that Setpoints may only be changed prior to the start of a Program; that they cannot be changed while the program is running. The option at the right hand side for Change while program active V3.6 User Guide R01 Page 89 of 110

90 9.2 Step Order Recipe Step Order The step order determines the order of processing of steps to carry out the default sequence using Normal Step on transitions. A step may be inserted in more than one location in the step sequence. Each step must be used at least once in the program. The step order can be modified by selecting the step to be moved in the sequence and clicking on Move Up or Move Down. Clicking on a Step will cause the Cross references for the Step to update at the bottom of the screen. The Tab field will show the relevant Cross reference / Usage information for the Step here. 9.3 Decisions These are digital selections in HMI. They may be True or False. The initial state of the Decisions may be changed in a Recipe in Recipe Manager. V3.6 User Guide R01 Page 90 of 110

91 10 General Model Items The following are accessed by clicking on Programs or from the Edit menu Program Order The configured programs are placed in order for processing by the PLC. All configured programs must appear in the list. V3.6 User Guide R01 Page 91 of 110

92 10.2 Variables Variables are common across all programs and may be read or written by all programs. Variables may be modified by clicking on or right clicking on the variable row. Variables List systems may be configured to interact with other PLC code using Variables. This may apply to Inter PLC communications. PLC Addresses for Variables are obtained from Accord Server following Full Download to a PLC. The user may write to, or read from, an Address by writing PLC code. operating system will not interfere with any other PLC code. The user should only interface using the Variables. V3.6 User Guide R01 Page 92 of 110

93 11 Documents Generation provides the printing of documentation which matches the Model. This documentation is printed to MS Word and is valid for use in Design and Testing stages of projects. The Documents Menu presents all the auto-generated Documents. It also provides viewing the Audit Trail for loaded Model. Builder provides automatic generation of the following Documents per menu list 1. Process Description 2. Functional Design Specification 3. Program Software Design Specification 4. I/O Address List 5. Equipment Software Design Specification 6. Equipment Cross Reference Document 7. Equipment Site Test / Install Qualification 8. Factory Acceptance Test 9. Site Acceptance Test 10. Activations Chart 11. Pin Chart 12. Development Audit Trail Documents menu Documents are generated by Builder to MS Word.doc format. This means they can be further edited for Header and Footer and other style elements before usage or generation as.pdf. V3.6 User Guide R01 Page 93 of 110

94 11.1 Generating the Documents To generate a document click the Documents menu in the top menu bar and select the required document. The document will begin to generate to MS Word. Note use of copy-paste in other applications while document is generating may affect the document. Each generation of a Document will be identified by a Revision number for the document. Document generation is logged for Audit Trail Customising the Documents Properties To access Document Set-Up click Documents Menu and Setup Documents. This data will be printed in introduction sections of Process Functional Design Specification, Program Software Design Specifications, Equipment Site Test, Factory Acceptance and Site Acceptance Documents. V3.6 User Guide R01 Page 94 of 110

95 Setting up the Equipment Site Test Document To setup the test procedures for the Equipment Site Tests, click Documents Menu and select Setup Equipment Site Test Document. Specific tests for each type of Equipment Test may be edited here. Default tests are included. The configured tests are applied to all devices of type in turn in the printout. Types are Analog Inputs, Digital Inputs, Motors, Valves, Digital Outputs and PID Loops. V3.6 User Guide R01 Page 95 of 110

96 Setting up the FDS/SDS or SAT document To setup these up, click Documents Menu and select Setup required This screen allows selection of programs and steps to be included in documents. V3.6 User Guide R01 Page 96 of 110

97 11.3 Audit Trail All changes to the Model are recorded and may be viewed. To access the audit trail for the Model, click on Documents menu and select Audit Trail. The Audit Trail can be filtered by date, event, username. When the required data is displayed on screen, pressing the Save Document button will generate a word document with the displayed data. V3.6 User Guide R01 Page 97 of 110

98 12 Project and Edit Menus 12.1 Model Menu The Model menu presents options to create New, Load, Save As, and Delete Models, and to backup the Model to a single file (*.bak) and restore from a.bak. Accord Models are stored as SQL tables. Accord Setup application installs and configures SQL automatically as required for all Accord modules Creating an project - New To create a new Model go to Model menu and New Model and enter the name for the Model. Builder will then create the initial Database for the Model Loading an existing Model - Load To load an existing Model - click Model Menu and Load Model. Builder will search for SQL instances on PC and on connected networks. V3.6 User Guide R01 Page 98 of 110

99 To load an project from a different machine, click on the SQL Servers drop down box. This will present a list of all PC s that have Accord installed. Once the PC is selected, the list of Accord Models Builder on the PC will be presented in the Select Database drop down box. The required project may be accessed by selecting it. It continues to reside on the original PC. A New Model may be created on the networked PC by using Create Model Merging Models The tick box Merge selected model with the current model allows the user to Merge two Models. This means that all items (Equipment and Programs) of the selected model will be copied into the Model which is currently loaded. The current model will be expanded. It is advisable to make a copy of the current model project prior to this. The expanded model will contain all the programs of the two models and new Programs must be placed in the Program Order list Copying Model Save As To copy a Model - click on the Model menu and click Save As and enter the new name. There is an option to copy the Audit Trail information also. The original Audit trail data will remain in the original project. V3.6 User Guide R01 Page 99 of 110

100 Deleting Model - Delete To delete a Model - click on the Model menu and click on Delete. The Model to be deleted may be selected from List. This screen will present a list of all Models on the PC except the currently loaded Model Note: It is not possible to delete a Model that has been loaded in the current session of using. To delete a Model that has been loaded or created in this session, it is necessary to stop and restart and then delete the Model Backup Model to file - Backup To Backup a Model - click on the Model menu and select Backup This provides function to select Folder and enter the name for the Backup. V3.6 User Guide R01 Page 100 of 110

101 Restoring from File - Restore To restore a backup - click on the Model menu and click on Restore Model. Builder will provide selection of folder and file. Accord Projects must have unique names Exit This allows end of session. V3.6 User Guide R01 Page 101 of 110

102 12.2 Edit Menu The Edit menu presents access Equipment Default Values and I/O Address Table. It also presents options to Cut, Copy and Paste items in the Model. It also presents options for editing the Model Summary, accessing Variable and Program Order lists. It also presents Find search options for location of items in Equipment and Programs. Builder Edit menu V3.6 User Guide R01 Page 102 of 110

103 Equipment Default Values This provides default values for new equipment items. All aspects of all equipment items are included. Changes to values will only be applied to items added to the Model subsequently. V3.6 User Guide R01 Page 103 of 110

104 I/O Address Table Equipment I/O Addresses may be modified here. An I/O address or short description may be modified by selecting the cell and entering new value. The tables are sortable by Name and Address. All data can be copied to MS Office applications for editing Cut - Copy - Paste The clipboard in is only for text entries, not for configuration objects. Accord Builder supports Ctrl-C and Ctrl-V also. V3.6 User Guide R01 Page 104 of 110

105 Find Item in Equipment and Find Item in Program The Find Item requires the full Item name to be entered into the Search box, but it does not have to be in the correct case. Builder will open the configuration of the item Advanced Item Search The Advanced Item Search provides finding any item by item type. The Advanced Item search screen presents all items in the system. In the above example, CV01 or VSD 01 may be selected in the Analog Devices drop down menu. The selected item will be found and opened on pressing Find button. V3.6 User Guide R01 Page 105 of 110

106 12.3 Search Tool The search tool is at the bottom of the screen, and this shows all the items created in the project in alphabetical order Tools Menu Tools Menu Consistency Check The consistency check examines the project to confirm that devices are used and that addresses are unique and conform to PLC rules. The check must be performed before a download to a PLC. Consistency check for documents is optional. Items listed in the Consistency Check may be accessed by clicking the row in the Check. V3.6 User Guide R01 Page 106 of 110

107 System Options To alter options within the system, click the Tools option in the Main menu bar and select the Options entry. This will present the following screen: Interlock Settings This controls Interlock Drop Down list for quicker item selection in Only items in the same Unit are available OR All Equipment items are available in list Condition Visibility This controls Condition availability for selections in items configurations Conditions are only available in parent program OR are available in all programs. Program must be Active status for condition to be evaluated. Alarm Visibility This controls Alarm availability for selections in items configurations Alarms are only available in parent program or available in all programs. Program must be Active status for Alarm to be processed. V3.6 User Guide R01 Page 107 of 110

108 Device Alarm Visibility This controls individual Device Alarm availability for selections in items configurations A Device Alarm may only be used in Programs that contain the Unit, OR all devices are available in all Programs. These options are defaulted to represent the local state which is usually good enough in a system that does not have complicated requirements. V3.6 User Guide R01 Page 108 of 110

109 12.5 Help menu System Information To access information about this installation, click the Help menu and select About. This will present information about Accord and to the operating system. V3.6 User Guide R01 Page 109 of 110

110 Licensing To access licensing, click the Help menu and select Licencing. The current Licence code may be viewed here. To update the license, enter new voucher number and press the Activate button. Accord Builder will then connect to licensing server and verify the installation and display new licence code. To enable Builder for a Timed Demo period, tick the Evaluation button. V3.6 User Guide R01 Page 110 of 110