ii RSBatch Equipment Editor User s Guide

Transcription

1 Allen-Bradley PLCs

2 Contacting Rockwell Software Technical Support Telephone Technical Support Fax World Wide Web Copyright Notice 1998 Rockwell Software Inc. All rights reserved Printed in the United States of America Portions copyrighted by Allen-Bradley Company, Inc. and used with permission. This manual and any accompanying Rockwell Software products are copyrighted by Rockwell Software Inc. Any reproduction and/or distribution without prior written consent from Rockwell Software Inc. is strictly prohibited. Please refer to the license agreement for details. Trademark Notices WINtelligent Series is a registered trademark, and the Rockwell Software logo, RSAssistant, RSBatch, RSChart, RSData, RSDataPlayer, RSLogix Emulate 5, RSLogix Emulate 500, RSGuardian, RSHarmony, RSKeys, RSLinx, RSLogix 5, RSLogix 500, RSNetworx for ControlNet, RSNetworx for DeviceNet, RSPower, RSPowerCFG, RSPowerRUN, RSRules, RSServer32, RSServer, RSServer OPC Toolkit, RSSidewinderX, RSSoftLogix5, RSSql, RSToolbox, RSTrainer, RSTrend, RSTune, RSView32, RSView, RSWire, A.I. Series, Advanced Interface (A.I.) Series, AdvanceDDE, ControlGuardian, ControlView, INTERCHANGE, Packed DDE, WINtelligent, WINtelligent LINX, WINtelligent LOGIC 5, WINtelligent VIEW, WINtelligent RECIPE, WINtelligent VISION, and WINtelligent VISION2 are trademarks of Rockwell Software Inc. PLC, PLC-2, PLC-3 and PLC-5 are registered trademarks, and Data Highway Plus, DH+, DHII, DTL, Network DTL, Pyramid Integrator, PanelBuilder, PanelView, PLC-5/250, PLC-5/20E, PLC-5/40E, PLC-5/80E, SLC, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, SLC 5/05, and SLC 500 are trademarks of the Allen-Bradley Company, Inc. Microsoft, MS-DOS, Windows, and Visual Basic are registered trademarks, and Windows NT and Microsoft Access are trademarks of the Microsoft Corporation. Ethernet is a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation. ControlNet is a trademark of ControlNet International. IBM is a registered trademark of International Business Machines Corporation. AIX, PowerPC, Power Series, RISC System/6000 are trademarks of International Business Machines Corporation. UNIX is a registered trademark in the United States and other countries, licensed exclusively through X/Open Company Limited. All other trademarks are the property of their respective holders and are hereby acknowledged. Warranty This Rockwell Software product is warranted in accord with the product license. The product's performance will be affected by system configuration, the application being performed, operator control and other related factors. The product's implementation may vary among users. This manual is as up-to-date as possible at the time of printing; however, the accompanying software may have changed since that time. Rockwell Software reserves the right to change any information contained in this manual or the software at anytime without prior notice. The instructions in this manual do not claim to cover all the details or variations in the equipment, procedure, or process described, nor to provide directions for meeting every possible contingency during installation, operation, or maintenance. ii RSBatch Equipment Editor User s Guide

3 Table of contents Introducing the Equipment Editor...7 Opening the Equipment Editor...7 Equipment Editor interface...8 Components of an equipment database...10 Enumerations...10 Data servers...10 Process cells...10 Units...10 Phases...11 Equipment modules...11 Equipment module tags...11 Shared resources...11 Example P&ID...12 Creating an equipment database...12 Importing an equipment database...13 Exporting an equipment database...13 Enumerations...15 Creating enumerations and enumeration sets...15 Editing enumerations and enumeration sets...16 Deleting enumerations and enumeration sets...17 Data servers...19 Create Servers dialog box...19 Creating a data server...20 Allen-Bradley PLCs iii

4 Editing a data server...20 Deleting a data server...21 Shared resources...23 Defining shared resources...23 Process cells...25 Creating a process cell class...25 Editing a process cell class...25 Creating a process cell...26 Removing a process cell...26 Configuring a process cell...26 Verifying icon paths...27 Units...29 Creating a unit class...29 Editing a unit class...30 Creating a unit instance...30 Removing a unit instance...30 Configuring a unit...30 Linking units...31 Sharing units...32 Tags...35 Unit tags...35 Creating a unit tag...36 Editing a unit tag...36 Deleting a unit tag...37 Equipment module tags...37 Editing tags from the menu...37 iv RSBatch Equipment Editor User s Guide

5 Edit tags...37 Set tag items to default names...38 Phases and equipment modules...39 Phases...39 Creating and configuring a phase...40 Equipment modules...44 Creating and configuring an equipment module...45 Importing tag addresses...49 Sharing equipment modules...49 Equipment database file format...51 Index...53 Table of contents v Allen-Bradley PLCs

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7 Chapter 1 Introducing the Equipment Editor The Equipment Editor is a graphical interface through which a database of process equipment is created and maintained. The equipment database is available to all other RSBatch applications. During recipe configuration, the database provides a list of available units and phases. Later, during recipe verification, it ensures that the designated equipment is capable of executing the procedures. During recipe execution, resource arbitration functions use this database to allocate equipment based on recipe and operator requests. As outlined in the ISA S88.01 Batch Control Standard, the equipment database of a facility is separated into the following physical model: Process Cell Unit Equipment Module Control Module In addition to the equipment database, the Equipment Editor allows specification of communication functions, equipment phases, enumeration sets, data servers, and Archiver and Report Editor functions. Security for the Equipment Editor is implemented using the Windows NT Explorer s Security option. (Refer to the RSBatch Administrator s Guide for instructions on implementing security). Opening the Equipment Editor Click the Start button, point to Programs, then to RSBatch, and select Equipment Editor. Allen-Bradley PLCs 7

8 Equipment Editor interface The RSBatch Equipment Editor is used to configure the facility s equipment database. The components defined in the Equipment Editor will be used to interface with the process-connected devices in the facility. The Equipment Editor window contains the following components: Class View area Displays the existing cell classes, unit classes, or phases in the active equipment database. The column heading will reflect the active level. Double-clicking (or right-clicking) the icon will open the edit dialog box for the item. Design View area This area is used to construct the equipment database and displays the layout of the active level. In the select mode, double-clicking an item will display the layout of the next lower level. Right-click the item to open the edit dialog box. Equipment Editor menu bar The following describes the menu bar commands: The File menu lists options for opening an existing equipment database, creating a new equipment database, closing the equipment database, saving an equipment database, and importing and exporting files. The Edit menu allows you to edit the various equipment database components, as well as perform a tag import. The Class menu allows you to create a new class of items for the current level. The View menu allows you to specify the Equipment Editor components to be displayed, and to indicate the zoom percentage. The Options menu allows you to specify the directories for the equipment database icons, and to configure the RSBatch Server options. Refer to the RSBatch Administrator s Guide for information on configuring server options. The Help menu provides you with on-line help and information regarding the software and the system. Equipment Editor toolbar 8 RSBatch Equipment Editor User s Guide

9 The Equipment Editor Toolbar contains a group of buttons used to perform commands in the Equipment Editor. The buttons, from left to right, are: New: Creates a new equipment database. Open: Opens an existing equipment database. Save: Saves the active equipment database. Cut: Deletes the highlighted item. Copy: Copies the highlighted item. Paste: Pastes the cut or copied item. Share: Shares the selected unit or phase. Go Down: Moves down through the levels, displaying the next lower level. Go Up: Moves up through the levels, displaying the next higher level. Zoom: Allows you to specify a magnification (between 50% and 200%) of the current SFC display. Add New Object: Opens the appropriate Create dialog box for the active level. Edit Area: Allows you to edit the area information. Edit Enumerations: Opens the Create Enumeration Sets and Enumerations dialog box. Edit Servers: Opens the Create Servers dialog box. Edit Shared Resources: Opens the Edit Resources dialog box. Edit Properties: Opens the appropriate Edit dialog box for the selected item. Edit Tags: Opens the Edit Tags dialog box. Select Instance: Changes the cursor to the selection tool. Link Units: Changes the cursor to the linking tool. Unlink Units: Changes the cursor to the unlinking tool. Invoke Recipe Editor: Opens the Recipe Editor. Status bar The name of the selected process cell appears in the lower right corner on the status bar, with the name of the selected unit to the left of the process cell name. Introducing the Equipment Editor 9 Allen-Bradley PLCs

10 Components of an equipment database An equipment database contains information on all of the components configured for one area of a specific physical plant. The area corresponds to a single RSBatch Server. The equipment database is saved as a configuration file for use by the RSBatch Recipe Editor and View. It is recommended that the equipment database be created in the order that is shown below. In some cases, upper level equipment will need to be re-configured after the lower level equipment has been defined. A brief description of the equipment database components follows: Enumerations Enumerations are strings with assigned ordinal values. RSBatch uses the string value and the process-connected device uses the corresponding ordinal value. Enumerations are used to allow RSBatch the ability to display meaningful text to an operator, instead of a number. Data servers Data servers are used to pass data between the RSBatch Server and the processconnected device. Data servers are configured for each physical data server which will communicate with an RSBatch server. This allows RSBatch to access current tag data which is necessary to successfully run recipes, arbitrate equipment and control single phases. Process cells A process cell is a logical grouping of equipment required for the production of one or more batches. A process cell must include all of the components required to run a specific recipe, since recipes cannot cross process cell boundaries. Units A unit is a collection of associated control modules and/or equipment modules that carry out one or more major processing activities. Units are presumed to operate on only one batch at a time. Units operate relatively independently of one another. 10 RSBatch Equipment Editor User s Guide

11 Often in process plants there exists similar sets of equipment and it is useful to describe these sets as classes. When a recipe is written using a unit class, the operator can be allowed to determine the most appropriate unit at the time the batch is created, or while the batch is running. Phases A phase is a general representation of a group of equipment which performs a subfunction for a unit. An instance of a phase is referred to as an equipment module. Each phase contains attributes common to all equipment modules of that specific phase type. Phases used to create recipes in the RSBatch Recipe Editor. Equipment modules An equipment module is an instance of a specific phase. When a phase is added to a unit it becomes an equipment module. An equipment module maps to the equipment phase in the engineered logic via tag addresses. Only one instance of a specific phase may be added to each unit. When an equipment module is required in multiple units, it may be shared between the units. Equipment module tags Equipment module tags represent data that are associated with a specific equipment module during the execution of a recipe. The number of tags associated with an equipment module is dependent upon the actual phase configuration. Each equipment module has a minimum of ten tags with which it is associated. Additional tags may be configured. There are three types of configurable tags: Parameter, Report, and Request. If the Phase is configured as requiring any of these tags, there will be a corresponding tag created in the equipment module. Shared resources Shared resources represent the lowest level of the equipment database, the control module. Examples of control modules are pumps, motors, and valves. It is important to understand the difference between Shared Resources and the process of Sharing Resources. Sharing resources involves placing the same equipment in different units or process cells and designating that equipment as Shared. Shared resources are control modules that may be utilized by multiple units and/or phases. Review the plant s phase logic to identify the shared resources that are referenced within the phase logic. Introducing the Equipment Editor 11 Allen-Bradley PLCs

12 Example P&ID The following P&ID is the basis for the sample Equipment Database (Batchsim.cfg) supplied with RSBatch. Creating an equipment database 1. From the Edit menu, select Area. 2. In the Edit Area dialog box, enter the area name in the Name box. Use a distinct name for each area. 3. Enter a new version number in the Version box. Select OK to return to the Design View area. The area name is displayed in the title bar of the Design View area. 4. From the File menu, select Save or Save As. 5. In the Save As... dialog box, enter the appropriate file name and click OK to save the equipment database. The equipment database is saved to the configuration file and can be opened at any time for modification. 12 RSBatch Equipment Editor User s Guide

13 Note It will be necessary to re-verify any recipes which are to run against this equipment database, and restart the batch server, in order to use the new equipment database. Importing an equipment database RSBatch will allow you to import an equipment database text file. The file must contain the required information and it must be in the proper file format. Refer to Appendix A for the file format information. 1. From the File menu, select Import. 2. In the File Import dialog box, locate and select the file to be imported. 3. Click Open to initiate the import process. A message box appears with the name of each component being imported. You can click the Cancel button to cancel the import process. 4. When the import process is complete the following message will be displayed: All sections have been imported! Click OK to complete the import process and return to the Equipment Editor. Exporting an equipment database RSBatch will also allow you to export an equipment database to a text file. Refer to Appendix A for an example output text file. 1. Ensure that the equipment database to be exported is open. 2. From the File menu, select Export. The File Export As dialog box will be opened. 3. Locate and select the file into which you want to export the equipment database. Or, enter a new file name in the File Name box. 4. Click Save to initiate the export process. If the file already exists, you will be prompted to confirm that you want to replace the file. 5. The following message will be displayed when the export process is complete: Area configuration data has been exported to the file: [path&filename]. 6. Click OK to complete the export process and return to the Equipment Editor. Introducing the Equipment Editor 13 Allen-Bradley PLCs

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15 Chapter 2 Enumerations Enumerations are sets of strings with assigned ordinal values. RSBatch uses the string value and the PCD uses the corresponding ordinal value. Enumerations are used to allow RSBatch to display text to the operator, instead of a number. Enumeration sets are used to group related enumerations. Example: The agitator in Premixer B (Unit #2) might use the following enumeration set: Enumeration Set Name MOTORS Enumeration Name Ordinal String Enumeration_1 0 OFF Enumeration_2 1 ON Creating enumerations and enumeration sets 1. From the Edit menu, select Enumeration Sets. Allen-Bradley PLCs 15

16 2. For enumeration sets: In the Create Enumeration Sets and Enumerations dialog box, click the New button in the Sets box. In the Create Enumeration Set dialog box, enter the new enumeration set name. Click OK to return to the Create Enumeration Sets and Enumerations dialog box. The new enumeration set name is displayed in the Enumeration Sets column. 3. For enumerations: In the Create Enumeration Sets and Enumerations dialog box, select the enumeration set you wish to add to, and click the New button in the Enumerations box. Enter the enumeration name and the ordinal, or accept the ordinal default. Click OK to return to the Create Enumeration Sets and Enumerations dialog box. The new enumeration name is displayed in the Enumerations column. Editing enumerations and enumeration sets 1. Open the Create Enumeration Sets and Enumerations dialog box. 2. Click the enumeration set or enumeration to be edited. 3. Click the appropriate Edit button. 4. For enumerations: Enter the new enumeration name and/or a new ordinal. 16 RSBatch Equipment Editor User s Guide

17 5. For enumeration sets: If the enumeration set has not yet been assigned to any tag, parameter, or report items, then the Edit Enumeration Set Name dialog box opens. Enter the new enumeration set name. If the enumeration set has been assigned to any items, then a warning appears with a list of the items to which the enumeration set has been assigned. 6. In the warning dialog box, click Yes to edit the enumeration set name. The items listed in this dialog box will be modified to include the new enumeration set name. Click No to cancel the modification. 7. Click OK to return to the Create Enumeration Sets and Enumerations dialog box. Deleting enumerations and enumeration sets 1. Open the Create Enumeration Sets and Enumerations dialog box. 2. Click the enumeration set or enumeration to be deleted. 3. Click the Delete button. 4. For enumerations: If the enumeration is not used as a default for a phase parameter, then a warning appears verifying deletion of the enumeration. Click Yes to delete the enumeration. Click No to cancel the deletion, close the warning dialog box, and return to the Create Enumeration Sets and Enumerations dialog box. Otherwise, a message appears stating that the enumeration cannot be deleted and gives the phase parameter name which has this enumeration as the default value. The phase parameter must first be modified to remove the enumeration as the default value before the enumeration may be deleted. 5. For enumeration sets: If the enumeration set has not yet been assigned to any tag, parameter, or report items, then a warning appears verifying deletion of the enumeration set. If the enumeration set has been assigned to any items, then a warning appears with a list of the items to which the enumeration set has been assigned. 6. In the warning dialog box, click Yes to delete the enumeration set. Click No to cancel the deletion, close the warning dialog box, and return to the Create Enumeration Sets and Enumerations dialog box. Enumerations 17 Allen-Bradley PLCs

18 Note Items that were using the deleted enumeration set will be defaulted to: Type= Integer Eng.Units= Eng.Units. 18 RSBatch Equipment Editor User s Guide

19 Chapter 3 Data servers Data servers are configured for each physical data server which will communicate with an RSBatch Server. This allows RSBatch to access current tag data which is necessary to successfully run recipes, arbitrate equipment and control single phases. Data servers must be configured before tags are created. Create Servers dialog box The first server in the Server column is used as the default data server. The list is sorted alphabetically. Application: The application name from which to retrieve tag information. The specific name is defined by the data server application (typically user-defined when configuring the application). Topic: The subdivision identifier within the application from which to retrieve tag information. The specific name is defined by the data server application. Watchdog: The name of a time-out field within the data server. RSBatch sets the value of this field to 1, then expects the PCD to clear this field within a specified time-out period. If the PCD does not, RSBatch assumes communication is lost. Bad Value String: The string which is sent to RSBatch to represent bad values which have been sent from the application. Locale: A drop-down list box of possible language formats. The RSBatch Server uses the selection made to determine which language format to use when communicating with the data server. Allen-Bradley PLCs 19

20 Character Mapping: Options which define the text that the data server will be using when communicating with the RSBatch Server. ASCII uses one byte characters, and UNICODE uses two byte characters. Request State: Options which define the request state for the data server. Substitute Advises for Requests: A check box that should be selected for data servers which do not support requests. Request Initial Data: A check box that should be selected for data servers that fail to provide an initial data value on an advise. Creating a data server 1. From the Edit menu, select Server. 2. In the Create Servers dialog box, click the New Server button. 3. In the Edit Server Name dialog box, enter the server name. Click OK to return to the Create Servers dialog box. The new server name is displayed in the Servers column, and the default values for the Application, Topic, Watchdog and Bad Value String are displayed. 4. Enter the appropriate values for the Application, Topic, Watchdog, and Bad Value String. 5. Select the appropriate Locale from the drop-down list box. 6. Select the appropriate Character Mapping option. 7. Select the appropriate Request State check box. Editing a data server 1. Open the Create Servers dialog box. 2. Select the data server to be edited, then click the Edit Server button. 3. In the Edit Server Name dialog box, enter the new server name. Click OK to return to the Create Servers dialog box. The new server name is displayed in the Servers column. All equipment module tags which are assigned to the modified data server will be updated to reflect the changes made. 20 RSBatch Equipment Editor User s Guide

21 Deleting a data server 1. Open the Create Servers dialog box. 2. Select the server to be deleted, then click the Delete Server button. 3. If the server is not currently used by any tags, then a dialog box is displayed asking you to verify deletion of the server. Click Yes to delete the server. Click No to cancel the deletion, close the warning dialog box, and return to the Create Servers dialog box. 4. If the server is currently used by any tags, then a warning appears displaying the associated phases, phase tags, and unit tags that will be removed and asking to verify deletion of the server. Click Yes to delete the server and remove all associated phases and tags. Click No to cancel the deletion, close the warning dialog box and return to the Create Servers dialog box. Data servers 21 Allen-Bradley PLCs

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23 Chapter 4 Shared resources Shared resources represent the lowest level of the equipment database, the control module. Examples of control modules are pumps, motors, and valves. It is important to understand the difference between Shared Resources and the process of Sharing Resources. Sharing resources involves placing the same equipment in different process cells or units and designating that equipment as Shared. Shared resources are control modules that may be utilized by multiple units and/or phases as Needed Equipment. Review the facility s phase logic to identify the shared resources that are referenced within the phase logic. Note When a resource is deleted, it is removed from all Needed Equipment lists in which it previously existed. Defining shared resources 1. From the Edit menu, select Resources. 2. In the Edit Resources dialog box, click the Add Class button. 3. In the Edit Resource Class dialog box, enter the new resource class Name (for example, Pump, Motor, Valve, etc.). 4. Select OK to return to the Edit Resources dialog box. The new resource class is displayed in the Resource Classes column of the Edit Resources dialog box. Allen-Bradley PLCs 23

24 5. Select the desired resource class, and click the Add button. 6. In the Edit Resource dialog box, enter the resource Name in the Edit Resource dialog box. (For example, Pump101, PV203, etc.) 7. Enter the appropriate Equipment ID or accept the default ID. 8. Assign a number to Max Owners. This number represents how many process cells, units, and/or equipment modules can maintain ownership of this resource at one time. 9. Click the Add button to open the Select Equipment dialog box. A plus sign (+) to the left of the equipment type indicates that equipment of that type have been defined. Clicking the plus sign expands the list to display the defined equipment. After a list is expanded, the plus sign changes to a minus sign (-) to indicate that the list can be collapsed. The lack of a plus sign or minus sign to the left of an equipment type indicates that no equipment of that type have been defined or that the equipment type cannot be used as a needed equipment item at the current level. 10. Select the equipment needed by the resource and click OK. The Select Equipment dialog box closes and the selected equipment will be displayed in the Equipment Needed box. 11. Click OK to return to the Edit Resources dialog box. 24 RSBatch Equipment Editor User s Guide

25 Chapter 5 Process cells A process cell is a logical grouping of equipment required for the production of one or more batches. Process cells are grouped into classes. For each different type of process cell in a selected area, a process cell class must first be created. Once the Process Cell Class has been created, an instance of that class may be created. Creating a process cell class 1. Verify that the column heading in the Class View areas is Cell Classes. 2. From the Class menu, select New. 3. In the Create Process Cell Class dialog box, enter the appropriate process cell class name. 4. Select an icon from the Icon column. Click OK to return to the Class View area. The Create Process Cell Class dialog box closes and the selected icon and cell class name are displayed in the Class View area. Note If the icon column is empty, refer to the Verifying Icon Paths section on page 27. Editing a process cell class 1. Click the process cell class to be edited. 2. From the Edit menu, select Properties. 3. In the Edit Process Cell Class dialog box, enter a new process cell class name, and/or select a new process cell class icon. Click OK to return to the Class View area. Allen-Bradley PLCs 25

26 Creating a process cell 1. Click the desired process cell class. The cursor changes to a. 2. Place the cursor in the desired location in the Design View area and click. The process cell icon is placed in the Design View area with a default name of PROCESS_CELL# (where # is an integer which is assigned sequentially beginning with 1). Removing a process cell 1. Select the process cell to be removed and press DELETE. 2. The Remove Process Cell warning appears listing the associated units and phases which will be removed when the process cell is deleted. Click Yes to delete the process cell, or click No to cancel the deletion and return to the Equipment Editor. Configuring a process cell The following is a list of fields in the Edit Process Cell dialog box: Process Cell Name: The name of the process cell. (The default name is PROCESS_CELL#, where # is a consecutive number starting with 1, assigned to each process cell as it is added to an area.) Process Cell Icon: The icon selected for the process cell class. (view-only) Process Cell Class: The name of the process cell class. (view-only) Equipment ID: The equipment identification number that identifies this process cell. (A default ID is automatically assigned to the process cell, based on the next available sequential number. The first item added to an area is assigned ID#1.) The equipment ID must be the same as the equipment ID which is used by the phase logic to request this process cell. Maximum Owners: The maximum number of owners which may simultaneously own this process cell. (The default is 1.) 26 RSBatch Equipment Editor User s Guide

27 Equipment Needed: A list of the equipment for which exclusive ownership is required by this process cell in order to begin execution. (The default is blank.) In general, the Equipment Needed should be assigned at the lowest possible level, allowing for maximum efficiency when running multiple processes. Do not make any of the equipment in the Equipment Needed list dependent upon the piece of equipment which requires it as Needed Equipment. 1. Click a process cell icon in the Design View area. 2. Select Properties from the Edit menu. 3. In the Edit Process Cell dialog box, enter the process cell name in the Name box. 4. Enter the equipment ID in the Equipment ID box. 5. Enter the maximum number of owners in the Max Owners box. 6. Click the Add button to open the Select Equipment dialog box. A plus sign (+) to the left of the equipment type indicates that equipment of that type have been defined. Clicking the plus sign expands the list to display the defined equipment. After a list is expanded, the plus sign changes to a minus sign (-) to indicate that the list can be collapsed. The lack of a plus sign or minus sign to the left of an equipment type, indicates that no equipment of that type have been defined or that the equipment type cannot be used as a needed equipment item at this level. 7. Select the equipment needed by the process cell and click OK. The Select Equipment dialog box closes and the equipment selected will be displayed in the Equipment Needed box. 8. Click OK to return to the Design View area. Verifying icon paths The directory paths for each type of icon are set by the install procedure and will only need to be modified if the bitmaps have been moved to another directory. 1. From the Options menu, select Directories. 2. In the Select Directories dialog box, verify the directory paths for each type of icon. 3. Click OK to return to the Design Area. Process cells 27 Allen-Bradley PLCs

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29 Chapter 6 Units A unit is a collection of associated control modules and/or equipment modules that carry out one or more major processing activities. Units process only one batch at a time. Units operate relatively independently of one another. Often in process facilities there exist similar sets of equipment, and it is useful to describe these sets as classes. When a recipe uses a unit class, the operator will be required to bind the recipe to a specific unit at the time the batch is created. This allows the operator the freedom to choose the most appropriate unit at runtime. Creating a unit class 1. Double-click the process cell to which you wish to add a unit class. Verify that the column heading in the Class View area is Unit Classes. The current unit classes for the selected process cell will be displayed in the Class View area. 2. From the Class menu, select New. 3. In the Create Unit Class dialog box, enter the appropriate unit class name. 4. Select an icon in the Icon column. Click OK to return to the Class View area. Note Note To navigate to the UNIT level, double-click a Process Cell icon, or select a Process Cell icon and click the Go Down toolbar button. If the icon column is empty, refer to the Verifying Icon Paths section on page Allen-Bradley PLCs

30 Editing a unit class 1. Select the unit class to be edited. 2. From the Edit menu, select Properties. 3. Enter a new unit class name, and/or select a new unit class icon. Click OK to return to the Class View area. Creating a unit instance 1. Select the Unit Class that is to be placed in the Design View area. 2. Place the cursor in the Design View area where the unit is to be located and click. Removing a unit instance Configuring a unit 1. Select the unit to be removed and press DELETE. 2. A warning appears listing the associated phases which will be removed when the unit is deleted. Click Yes to delete the unit, or click No to cancel the deletion and return to the Equipment Editor. The following is a list of fields in the Edit Unit dialog box: Unit Name: A unique name which is assigned to this unit. Unit names are displayed to the operator during batch execution. Unit Class Icon: The unit class icon. (view-only) Unit Class: The name of the class of the unit. (view-only) 30 RSBatch Equipment Editor User s Guide

31 Unit Tags: Unit tags represent data associated with the unit that will be used with recipes. They are organized by classes. Unit tags are created at the time the unit is configured. Equipment ID: The unique number that identifies this unit. This must be the same equipment ID which is used in the phase logic to request this unit. Maximum Owners: A unit can be used by only one batch at a time. Therefore, the maximum owners at any particular time would be 1. (view-only) Equipment Needed: A list of the equipment for which exclusive ownership is required by this unit in order to begin execution. 1. Select the desired unit icon in the Design View area. 2. From the Edit menu, select Properties. 3. In the Edit Unit dialog box, enter the unit name in the Name box. 4. Enter the equipment ID in the Equipment ID box. 5. Click the Add button in the Arbitration section to open the Select Equipment dialog box. A plus sign (+) to the left of the equipment type indicates that equipment of that type has been defined. Clicking the plus sign expands the list to display the defined equipment. After a list is expanded, the plus sign changes to a minus sign (-) to indicate that the list can be collapsed. The lack of a plus sign or minus sign to the left of an equipment type indicates that no equipment of that type has been defined or that the equipment type cannot be used as a needed equipment item at this level. 6. In the Unit Tags group, click the Add button and create the required unit tags. Refer to page 35 for detailed information on Unit Tags. Linking units Links are used to define the upstream/downstream relationships between units within a process cell. The links are used by RSBatch to determine which units will be available to select from when defining equipment requirements for procedures. 1. From the Edit menu, select Mode then Link. The cursor changes to +. Units 31 Allen-Bradley PLCs

32 2. Click and hold the mouse button on the source unit icon. Drag the cursor to the destination unit icon, and release the mouse button. 3. Repeat Step 2 until all units are linked as needed. Sharing units When a single unit is required by more than one process cell, it should be shared. This allows any of the process cells which are sharing the unit to gain ownership of the unit during batch execution. It is not necessary to create multiple units in different process cells. 1. Create the unit which is to be shared. Ensure that this unit is physically able to be shared. 2. Move to the process cell which does not contain this unit. 32 RSBatch Equipment Editor User s Guide

33 3. Click the Share toolbar button to open the Share Unit Between Process Cells dialog box with a list of existing process cells. A plus sign (+) to the left of the process cell indicates that units have been defined within that process cell. Clicking the plus sign expands the list to display the defined units. After a list is expanded, the plus sign changes to a minus sign (-) to indicate that the list can be collapsed. The lack of a plus sign or minus sign to the left of a process cell, indicates that no units have been defined within that process cell. 4. Display the units in each process cell by clicking the plus (+) sign for the appropriate process cell folder. 5. Select the unit which is to be shared, and click OK. The Share Unit Between Process Cells dialog box closes. The selected unit s icon, with a small hand at the bottom left corner, is displayed in both process cells. Note Deleting an instance of a shared unit only deletes the link to that unit. The unit will not be deleted until the last instance of the unit is deleted. Units 33 Allen-Bradley PLCs

34 34 RSBatch Equipment Editor User s Guide

35 Chapter 7 Tags A tag is used to represent one piece of information in the PCD. Tags can be associated with a Unit or an Equipment Module. Unit tags represent data associated with a unit class and are used for class-based recipes. Equipment Module tags represent data that are associated with a specific equipment module during the execution of a recipe. Unit tags Unit tags are organized by classes and are created at the time the unit is configured. Each unit tag may only be assigned once within an equipment database. And, each unit may only have one instance of a specific unit tag class. These tags must be configured to point to the appropriate item address. The following is a list of fields in the Create Unit Tag dialog box. Unit Tag Name: The name of the unit tag. This name should follow the facility s naming conventions. Tag Class Name: A drop-down list box from which to choose the appropriate tag class name for the unit tag. If the appropriate class is not in the list, a new tag class name may be added by typing the class name in this box. Tag Type: A drop-down list box from which to select the appropriate data type for the unit tag. Valid types include: Real, Integer, String, and Enumeration. Enumeration: A drop-down list box from which to select the appropriate enumeration. This list only appears if the tag type is Enumeration. Item: The address in the data server which the tag will use to read and write its value. 35 Allen-Bradley PLCs

36 Server Name: A drop-down list box from which to select the data server from which the tag is acquiring data. This list will include all configured data servers for the active area. Server Application: The name of the application within the data server from which the tag is acquiring data, as defined in the data server. (view-only) Server Topic: The name of the topic within the data server from which the tag is acquiring data, as defined in the data server. (view-only) Server Timeout: The name of the time-out field within the data server, as defined in the data server. (view-only) Note Compile a list of data servers and tag addresses to which RSBatch will connect prior to creating the unit tags. Creating a unit tag 1. Right-click the appropriate unit. The Edit Unit dialog box opens. 2. From the Unit Tags section, click the Add button. The Create Unit Tag dialog box opens. 3. From the Edit Unit dialog box, click the Unit Tags Add button. 4. In the Create Unit Tag dialog box, enter the unit tag name in the Name box. 5. Select the appropriate tag class from the Tag Class drop-down list box, or enter a new tag class. 6. Select the appropriate tag type from the Type drop-down list. 7. If the type is Enumeration, select the appropriate enumeration name from the Enum drop-down list box. 8. Enter the appropriate addressable location in the Item box. 9. Select the appropriate server from the Server Name drop-down list box. 10. Click OK to return to the Edit Unit Tags dialog box. Editing a unit tag 1. Right-click the appropriate unit. The Edit Unit dialog box opens. 2. From the Unit Tags section, click the Edit button. 36 RSBatch Equipment Editor User s Guide

37 3. In the Edit Unit Tag dialog box, make the required modifications and click OK to return to the Edit Unit dialog box. Deleting a unit tag 1. Right-click the appropriate unit. The Edit Unit dialog box opens. 2. From the Unit Tags section, click the Unit Tags Remove button. The unit tag will be removed without a warning. Equipment module tags The number of tags associated with an equipment module depends upon the phase configuration. Each equipment module is associated with a minimum of ten tags. Additional tags may be configured. There are three types of configurable tags: Parameter, Report, and Request. If the phase is configured as requiring any of these tags, there will be a corresponding tag created in the equipment module for each one. (Refer to page 46 for information on configuring Equipment Module tags.) Editing tags from the menu Unit tags and equipment module tags may be viewed and/or edited from within one dialog box. The Edit Tags dialog box lists all of the tag classes which are configured for the selected equipment database, along with the tags which are associated with each tag class. Edit tags 1. From the Edit menu, select Tags. 2. In the Edit Tags dialog box, select the appropriate tag class in the Tag Classes section. Select the tag to be edited in the Tags section, and click the Edit Tag button. 3. In the Edit <Tag Type > Tag dialog box will be opened, where <Tag Type> represents the type of tag being edited, make the required modifications to the tag. 4. Click OK to return to the Edit Tags dialog box. Tags 37 Allen-Bradley PLCs

38 Set tag items to default names 1. From the Edit menu, select Set Default Tag Items. 2. A warning appears to verify that you want to set all of the tags to their default names. Click OK to continue, or Cancel to cancel the process. 3. A message dialog box appears when the process is complete. Click OK to return to the Design View area. Note Refer to page 48 for instructions on setting a single equipment module s tag items to their default names. 38 RSBatch Equipment Editor User s Guide

39 Chapter 8 Phases and equipment modules A phase is a reusable process-oriented function. Examples of phases are Heat, Mix, Add, etc. A phase describes what is to occur, not how to do it. An instance of a phase is referred to as an equipment module. Each phase contains attributes common to all equipment modules of that specific phase type. Phases and equipment modules are used to link the engineered logic to the RSBatch recipe. A phase defines the RSBatch recipe phase, and an equipment module maps to the equipment operation or equipment phase in the engineered logic. Phases Every phase is automatically assigned ten default tags which are required by RSBatch. The default tags do not need to be included in the count for the Number of Request Tags, but they will need to be defined along with any additional request tags. Set the number of request tags equal to or greater than the number of request tags in the phase logic. The following is a list of fields in the Create Phase dialog box: Phase Name: The name of the phase. Select Icon Column: Displays all of the icons available for selection. Scroll through the icons using the up and down arrows in the vertical scroll bar. 39 Allen-Bradley PLCs

40 Phase Type: A field used to categorize phases for reporting purposes. Phase Parameters: A list of phase parameters. Phase Reports: A list of phase report items. Phase Messages: A list of phase messages. Number of Parameter Tags: The number of memory registers within the phase to which RSBatch can write parameter information. This is generally equivalent to the number of parameters defined for the phase. Number of Report Tags: The number of memory registers within the phase to which RSBatch can write report tag information. This is generally equivalent to the number of reports defined for the phase. Number of Request Tags: The number of memory registers within the phase to which RSBatch can write request tag information. Numbers of Message Partners: The number of additional phases with which the phase must communicate in order to operate properly. Creating and configuring a phase 1. Select a unit icon and click the Go Down toolbar button. The Design View area displays the Unit s vessel icon and Phases is displayed as the column header in the Class View area. 2. From the Class menu, select New. Note Use names that can be easily understood. Phase names are displayed to the operator during batch execution. 3. In the Create Phase dialog box, enter an appropriate phase name and phase type. 4. Select the appropriate icon in the Icon column. If the Icon column is empty, refer to the Verifying Icon Paths section on page Enter any required Parameters and Reports. 6. Enter any required Messages. 7. In the Number of Tags group, enter the appropriate number of tags for the parameters, reports, and requests. 8. Enter the appropriate number of message partners in the Number field. 40 RSBatch Equipment Editor User s Guide

41 9. Click OK to return to the Class View area. The selected icon is displayed in the Class View area. Creating a phase parameter item Phase parameters are values that are passed from RSBatch to the phase logic during the execution of a recipe. Phase parameters must correspond to the actual, configured phase logic parameters. A phase parameter is defined for the phase and the corresponding parameter tags are defined for the actual equipment module. The parameter definition will not be carried over to the parameter tag definition. The number of parameter tags generally is equivalent to the number of parameters defined for the phase. Review the phase logic to ensure that the number of parameter tags associated with the phase corresponds to number of the parameter tags configured for the process-connected device(s). Once the parameters are defined and the number of parameter tags have been specified, the individual tags must be defined. The following is a list of fields in the Edit Phase Parameter dialog box: Name: The name of the phase parameter. ID: The identification number of the phase parameter. Type: The phase parameter data type: Real, Integer, String, and Enumeration. Eng. Units: The engineering units for the phase parameter. Enum: The name of the enumeration set, if the Type is "Enumeration". High: The high limit for the phase parameter. Low: The low limit for the phase parameter. Default: The default value for the phase parameter. Scale: A check box to indicate if the phase parameter is scaled with a recipe. Phases and equipment modules 41 Allen-Bradley PLCs

42 Note Note Parameters configured in the Equipment Editor for a PCD should be compatible with the Recipe Formula Parameter data type if the data is to be downloaded. Real, Integer and Enumeration Recipe Formula Parameters may be stored to Real PCD registers. Integer and Enumeration Recipe Formula Parameters may be stored to Integer PCD registers. Strings must be stored to string PCD registers. If the number of parameter tags does not equal the number of parameters for the specified phase, the phase logic must use request data parameters to specify how the parameters are uploaded by RSBatch. 1. Select the appropriate phase in the Class View area. 2. From the Edit menu, select Properties. 3. In the Edit Phase dialog box, click the Add button in the Parameters section. 4. In the Edit Phase Parameter dialog box, enter the parameter name in the Name box, and parameter ID in the ID box. 5. Select the appropriate parameter type from the Type drop-down list box. 6. If the type is Real or Integer, enter the following: Engineering Units, High value, Low value, and Default value. 7. If the type is Enumeration, select the appropriate enumeration set from the Enumeration drop-down list box and select the appropriate default enumeration from the Default drop-down list box. 8. If the Type is String, enter the Engineering Units, and the Default string. 9. Select the Scale check box if this parameter is scaleable with the batch. 10. Click OK to return to the Edit Phase dialog box. Creating a phase report item Phase Reports are used to pass values from the PCD to RSBatch. These report values define how the phase functioned and can be used to create batch reports. A phase report must be created for all the report items that RSBatch is to include in the event journal. A phase report is defined for the phase and the corresponding report tags are defined for the actual equipment module. The number of report tags generally is equivalent to the number of reports defined for the phase. The report definition will not be carried over to the report tag definition. 42 RSBatch Equipment Editor User s Guide

43 The number of report tags generally is equivalent to the number of reports defined for the phase. Review the phase logic for the selected plant to ensure that the number of report tags corresponds to the actual number of report tags configured for the process-connected device. Once the reports are defined and the number of report tags have been specified, the individual tags must be defined. Note Null phases should not include phase parameter items. The following list describes the fields in the Edit Phase Report dialog box: Name: The name of the phase report. ID: The identification number of the phase report. Type: The phase report data type: Real, Integer, String, and Enumeration. Eng. Units: The engineering units for the phase report. Enum: The name of the enumeration set, if the Type is "Enumeration". 1. Select the appropriate Phase icon in the Class View area. 2. From the Edit menu, select Properties. 3. In the Edit Phase dialog box, click the Reports Add button. 4. In the Edit Phase Report dialog box, enter the report name in the Name box, and report ID in the ID box. 5. Select the appropriate data type from the Type drop-down list box. 6. If the Type is Real, Integer, or String, enter the Engineering Units. 7. If the Type is Enumeration, select the appropriate enumeration from the Enumeration drop-down list box. 8. Click OK to return to the Edit Phase dialog box. Phases and equipment modules 43 Allen-Bradley PLCs

44 Creating a phase message item Phase messages are typically used for journal entry purposes. In some instances the message may be displayed to the operator. A phase message has two pieces of data associated with it, the name and the message ID. A phase message must be created for each message sent to RSBatch from the phase. 1. With the appropriate Phase icon selected in the Class View area, select Properties from the Edit menu. 2. In the Edit Phase dialog box, click the Messages Add button. 3. In the Edit Phase Message dialog box, enter the appropriate message in Name box and message ID in the ID box. 4. Click OK to return to the Edit Phase dialog box. Equipment modules An Equipment Module is an instance of a specific phase. When a phase is added to a unit it becomes an Equipment Module. Only one instance of a specific phase may be added to each unit. When an Equipment Module is required in multiple units, it may be shared between the units. An Equipment Module must be configured after it is added to a unit. As a minimum, each tag in the Equipment Module must be modified to indicate the tag s addressable location. (This can also be accomplished by importing the tag addresses, as described on page 49.) The fields in the Edit Equipment Module dialog box are as follows: Name: The name of the equipment module. Phase Name: The name of the phase from which this equipment module was created. (view-only) Phase Icon: The icon associated with the phase. (viewonly) 44 RSBatch Equipment Editor User s Guide

45 Equipment Module Tags: A list of all tags that need to be defined for the equipment module. Server button: Sets the server for the selected tag, or all tags associated with this equipment module. Import button: Allows the import of a tag address from an Allen-Bradley 6200 programming software text file. Defaults button: Returns all tag items to their default tag names. Tag Name: The name of the highlighted tag. (view-only) Tag Type: The type of the highlighted tag. (view-only) Tag Comments: Comments associated with the default tags. (view-only) Equipment ID: A unique number which identifies this equipment module. It must be the same ID which is used in the phase logic to request this equipment module. Max Owners: Only one owner is allowed for equipment modules. (view-only) Equipment Needed: A list of the equipment for which exclusive ownership is required by this equipment module in order to begin execution. Creating and configuring an equipment module 1. Select the apppropriate Phase icon on the Class View area. 2. Place the cursor in the Design View area where the equipment module is to be located, and click. 3. Select the newly created equipment module icon. 4. From the Edit menu, select Properties. 5. In the Edit Equipment Module dialog box, enter the equipment module name in the Name box. 6. Enter the equipment ID in the Equipment ID box. Phases and equipment modules 45 Allen-Bradley PLCs

46 7. Click the Add button in the Equipment Needed section to open the Select Equipment dialog box is displayed. A plus sign (+) to the left of the equipment type indicates that equipment of that type have been defined. Clicking the plus sign expands the list to display the defined equipment. After a list is expanded, the plus sign changes to a minus sign (-) to indicate that the list can be collapsed. The lack of a plus sign or minus sign to the left of an equipment type, indicates that no equipment of that type have been defined or that the equipment type cannot be used as a needed equipment item at this level. 8. Select the equipment needed by the equipment module and click OK. The Select Equipment dialog box closes and the equipment selected will be displayed in the Equipment Needed box. Configuring an equipment module tag All equipment module tags must be configured to include the tag Item. An Item references the name of the addressable location to which the tag data is stored. In some cases the server will require a change. The first data server that appears in the Servers list in the Create Servers dialog box will be used as the default for equipment module tags. Equipment module tags are automatically named, and the names can not be modified. If the equipment module name changes, the tag name changes. The tags are created based on the number of tags specified in the phase. The following is an outline of the naming conventions used for equipment module tags. The examples are based on a phase called CHARGE1. The ## is a sequentially assigned number, beginning with 01. In this example you would replace the ## in the Class names with RSBatch Equipment Editor User s Guide

47 Equipment module tag naming conventions Class Name Tag Name Example Parameter Tags PARMTR## [Equipment_Module_Name]P## CHARGE1P01 Report Tags REPORT## [Equipment_Module_Name]R## CHARGE1R01 Request Tags REQUST## [Equipment_Module_Name]Q## CHARGE1Q01 Default Tags COMMAND [Equipment_Module_Name]_OC CHARGE1_OC FAILURE [Equipment_Module_Name]_F CHARGE1_F OWNER [Equipment_Module_Name]_W CHARGE1_W PAUSE [Equipment_Module_Name]_P CHARGE1_P PAUSED [Equipment_Module_Name]_PD CHARGE1_PD REQUEST [Equipment_Module_Name]_RQ CHARGE1_RQ SINGLE_STEP [Equipment_Module_Name]_SS CHARGE1_SS STATUS [Equipment_Module_Name]_ST CHARGE1_ST STEP_INDEX [Equipment_Module_Name]_SI CHARGE1_SI UNIT [Equipment_Module_Name]_UN CHARGE1_UN 1. Select the appropriate Equipment Module icon in the Design View area. 2. From the Edit menu, select Properties. 3. In the Edit Equipment Module dialog box, double-click the desired Equipment Module tag listed in the Equipment Module Tags box. 4. In the Edit Equipment Module Tag dialog box, select the appropriate Type from the drop-down list for all non-default tags. The type selected should match the type defined for the phase. 5. Enter the addressable location for the selected tag in the Item box. 6. Select the appropriate data server from the Server drop-down list box, if the default is not correct. 7. Click OK to return to the Edit Equipment Module dialog box. Phases and equipment modules 47 Allen-Bradley PLCs

48 Assigning a data server to an equipment module tag The Server button allows you to change the server for a specific tag, or all tags within the selected equipment module. When assigning a data server with the Server button, only the selected tag will be changed, unless the Change All Tags check box is selected in the Set Tag Server dialog box. 1. Select the appropriate Equipment Module icon in the Design View area. 2. From the Edit menu, select Properties. 3. In the Edit Equipment Module dialog box, click the Server button to open the Set Tag Server dialog box. 4. In the Set Tag Server dialog box, select the appropriate server from the Server drop-down list box. 5. Select the Change All Tags check box to change the server for all the tags associated with the selected equipment module. Or, clear the check box to change the server only for the selected tag. 6. Click OK to accept changes and return to the Edit Equipment Module dialog box. Setting an equipment module s tag items to the default tag names You may reestablish the default addresses for an equipment module s tag items by using the Defaults button. Any addresses that have been defined for tags in the selected equipment module will be replaced with the name of the equipment module tag. Note This is an irreversible action! Once the Defaults button is clicked, all tag items are automatically changed. 1. Select the appropriate Equipment Module icon in the Design View area. 2. From the Edit menu, select Properties. 3. In the Edit Equipment Module dialog box, click the Defaults button. 4. A message appears stating that all tag items have been set to their default names. (Refer to page 48 for instructions on setting all tag items to their default names.) 48 RSBatch Equipment Editor User s Guide