Home

Display - Service, Support

1. Press att_ _c_ to select a new chart quickly N to see the values of the data e Use the Monitor Option press art points in the chart e Document your chart entries by using comments often where appropriate e Use the Animate Option press art _ to see a detailed view of the currently active APT object SFC CFB device I O point declaration etc e Use the keys for Monitor and Animate to toggle back and forth between a chart and the APT object on which the cursor is placed This is faster than exiting from either the chart or the object by pressing Esc Press _F7_ the function key for split screen to look inside a CFC or SFC for more information about how the CFC or SFC was programmed SIMATIC APT Applications Manual 3 6 Miscellaneous Hints Guidelines for More Efficient Use of APT SIMATIC APT Applications Manual Follow these guidelines to help you use APT most efficiently Use the online Help for quick access to information Validate individual objects frequently as you build your program Use the Multi File option to validate several objects at a time Because program or unit level validations can be lengthy processes it is preferable to validate individual SFCs CFCs and tables This is particularly true when you have made only a few changes within one or two objects You do not gain by validati
2. 0c cece ete eens Build Operator Station Database 0c ccc ccc nee e eee e eens Verify Operator Station Graphics 2 000 cece eet enna Finish Levelt TASKS ses a sacs e e Ren aod A ot en A aden hao lee aa as Create the Code Templates for Procedural Control 0 00eeeeeeeees Subordinate Sir OSes geen mir a ee eat foe eer ee ee E ec idos Main SFC Contents 1 9 1 13 1 14 1 15 Create the Code Recipes and Recipe Templates Build the Template 0 0 cece eee e RITE ARIES Build the Recipe o oooococcoccconrcn een eens Create Data Dictionary 000s ccc cn Create the Code Procedural Control Logic 000cee cece eee eee eee Create the Code Structural Control Logic 00ce eee cece eee Create the Code Objective Control Logic 0 cee e eee eee eee Build the Sequence Recipe Template 000 c cee cece eect eee eens Define the Sequence Recipe Value Names 0 0 0 cece nett e eee n eee Build the Sequence Recipe 0 0 c cece tenet eens Create the Permanent Main SFC oocooccccccooc n ee nee nee nee nnes Create the Sequence Array 0 00 cee eens Create the Procedure Manager SFC 1 ttn tne eens Finish Level 2 Tasks ori ir ale acd ate xh ae Sane aad PA Grew ee ae See wa Create the Code Level 3 Control 2 0 cece eee eee eee eee eens Addi Normal SFCS siccceccsav h
3. 0 0eceeeeeeeeeees 16 8 Transfer Data for Activating Standby TRAFDAT 0 cc cece ec eee eee eeeees 16 8 6 5 Configuring Expansion Units from COM 155H 00cceeceee eee e cnet eee eeees 6 10 Configuring Expansion Units I O 314 0 cece nett 6 10 6 6 Configuring I O from COM 155H ce cece eee e eee e eee eee teen eeeeenaes 6 11 IOGOMNF asociada Pits Gd O Pa eases ede hada dae dod we 6 11 Chapter 7 APT and the OSx Operator Interface oooooooooomoo 7 1 7 1 Using APT to Configure an OSx Database 00 cece eects 7 2 7 2 Marking Tags for Translation 0e cece eee eee eee eeeeeee Recommendations for Marking Objects 000 c cece eee tenet eee 7 3 Compiling the Program oococcccccnccccr eee eee Recommendations for Compiling a Program Report by Exception sees iissa cece ne tne teen ete eee eens Reserving Memory for RBE Series 505 00000 cece eet eee eee 7 4 TranSiatingTagS 0er A One Appendix A Defining a Variable s Address 00oooooooomommmmmo A 1 Appendix B Extensions Fixed by the Compile Appendix C OSx PCS and TISTAR Tag Translation C 1 Determining a Variable s Address Reading Translated Tag Reports Using DeDUg aptos is Reading Symbol Address Reports Using the APT DC Utility 00 tenet eens Reading the INSTALL TAG File for TISTAR Release 1 x and 2 x Series 505 Reading the INSTALL TAG Fil
4. 0 0 cece Configuring the PEERLINK Module for Series 505 Controllers o oooo o Configuring the HSPI and HSC Modules for Series 505 Controllers Configuring ET200 miccional Contents v 3 9 3 10 3 11 OSX HINTS cocer rediere Bare a a di Selecting APT Object Names 0 cece eee eee enna Selecting Array Names steri ss iian deed vere rede eda a a ea de Selecting Recipe Names 000 cece eee nett e eee ae Selecting Unit Names occococcccccccccc nents Animating Non Standard Symbols Validation FAUTE cios et a eed a eee ee nee eed Ae eee Pe nee Rae pe ees Relating APT and the Non OSx Operator Interface Database 4 Recommendations to the CVU1000 10000 User 0 ccc cece eee 3 31 Chapter 4 APT and Controller Memory oooococooccccccnr o 4 1 4 2 OVEIVIEW viuiainoracadd noia o aa Source Code 1 nent nee eee e teen nee a nnes Downloaded Program Memory and I O Usage 02 0c cece eters OVEIVIOW tios kine ah dcr ane dae Se A he ed Se Me a a Reserving Memory 0400 eis fas BINS gone aN ee wed dowd eae eee de ee Guidelines for Series 505 Controllers 000 c cece eect nett eee eee Changing Values in Memory 000 neunana neeaae Reserving I O Locations in Series 505 Controllers 00 cc cee cence eee eee Determining Memory and I O Usage 2 cece cece tenet eens Loops
5. 0 0 000 cece eee eee 5 8 5 5 Example TUTSIM Algorithm for Mass Balance 0000 e cece eee eens 5 9 5 6 Example TUTSIM Algorithm fora PID Loop 00 0 cece eee eee tenes 5 9 6 1 Creating an Address Report 000 cece cece eee nett e eens 6 4 6 2 Analysis of DBs DXs for COM 155H 2 06 eee eens 6 5 6 3 Initialize Operating System Screen oocccoccccccccccnc eee eee 6 4 Values Required by APT o o oocooccocccoo een eee eens 6 7 6 5 Analysis of DBs DXs for COM 155H 2 2 ee tenets 7 1 Portion of an Example INSTALL TAG File for PCS 3 X 1 0 0 00 cece ce eee 7 3 A 1 Format for an N Line in the INSTALL TAG File for TISTAR 1 x and 2 x 004 A 9 A 2 INSTALL TAG File Example for PCS 3 x and OSX 4 X 0 0 cee A 11 A 3 INSTALL TAG File Spreadsheet Example for PCS 3 x and OSx 4 x 0 0 eee eee A 12 C 1 APT Tag Correlation with OSx MTR1 Status Word 00 0 cece eee eee eee es C 8 C 2 APT Tag Correlation with OSx RMTR Status Word 00 ecc cece eet e cece teen ee nes C 3 APT Tag Correlation with OSx MTR2 Status Word 0 0 ccc ccc cette eens C 12 C 4 APT Tag Correlation with OSX VLV1 2 tenets C 15 C 5 APT Tag Correlation with OSx VLV2 0ooccoccccccocccncc eens C 17 xX Contents List of Tables 1 1 1 2 2 1 2 2 2 3 6 1 7 1 7 2 7 3 A 1 A 2 A 3 A 4 A 5 A 6 C 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C 11 C 12 C 13 C 14 C 1
6. Start_Fill False Start_Agit False Start_Drain False Figure 1 9 Example SFC Templates The final transition of each subordinate SFC in the example waits for the start command to clear and ensures that the temporary Main SFC determines when the functions run If the Main SFC waits until the done flag for an SFC is true and then clears the Start command then each subordinate SFC executes only once and resets for another Start command 1 30 Approach to APT Program Design SIMATIC APT Applications Manual Main SFC Use declaration flags for start flags Start_Fill Start_Agit Start_Drain and for done flags Fill Done Agit Done Drain_Done As you finish creating each SFC template exit and validate the SFC Then continue creating templates until all the initial operational procedures are defined When the individual SFC templates are identified define an SFC to act asa procedure activator This is the Main SFC and its primary function is to activate the individual SFCs The operation is comparable to a subroutine call in a BASIC program or a procedure in a C program The subordinate SFCs once activated begin to monitor their respective Start commands and are executed as needed The subordinate SFCs remain active active idle active working or active done and waiting Design this Main SFC with the knowledge that it may be the Main SFC only temporarily As you refi
7. Comm path integer number less than 32768 that identifies the communication path Must be same value entered for the USR block parameter 2 Comm name method for communicating with the controller DIRECT direct cable connection HOST UNILINK Host Adapter CVU CVU TIWAY Adapter or the 386 ATM Coprocessor Comm port communication port number For Comm name DIRECT or HOST enter 1 for COM1 2 for COM2 etc For Comm name CVU enter any integer e Secondary Secondary address For Comm name DIRECT or HOST enter any integer For Comm name CVU enter the TIWAY address 5 6 Dynamic Program Simulation SIMATIC APT Applications Manual PROGRAM and UNIT commands The PROGRAM and UNIT commands identify the APT compiled program and unit These commands direct the BLOCK command where to search to resolve the symbol Consider these commands as toggles to be placed as needed before block commands The UNIT command without a name searches Program Content level symbols BLOCK command The BLOCK command defines the controller address for any USR block You can define up 100 USR blocks Any BLOCK defined in the file without a corresponding USR block is ignored during run time The parameters for BLOCK are defined below Block number TUTSIM block number e Address Controller address If not defined the utility aptusr exe can determine the address aptusr exe can also replace the address with a revised a
8. Y Create Status Pages Create Data Dictionary Y Program Procedural Control Fill Out Templates for Procedural Control SFCs Program Structural Control Create Procedure Activator SFC Y Program Objective Control Create Sequence Recipe Create Main SFC Create Sequence Array Create Procedure Manager SFC Y Level 3 Tasks Continuous Improvements Figure 1 5 Steps of Designing Process Control continued SIMATIC APT Applications Manual Approach to APT Program Design 1 19 1 5 Create the Code First Steps Plan Memory Allocation Select Naming Convention Plan Testing and Simulation Partition the Process into Units In Section 1 4 you can find the list the tasks that comprise the bottom up implementation Figure 1 5 shows you the order for completing the tasks and also illustrates how the process design engineer can coordinate efforts with the operator interface design engineer This section describes in detail what you need to do when you execute each task of the process control design If you do not intend to monitor your process with an OSx operator interface you must decide early in your process control design which controller memory locations are to be reserved for your operator interface APT can be programmed to avoid these locations when y
9. 000 cece ete teen eee 1 18 1 6 Example of CFC GroupingS 0 0 cece eee eee e eee ene 1 23 1 7 Example Interlock Blocks 0 cece cece tee eee eens 1 25 1 8 Example Interlock GroupingS 0 00 cece cece eens 1 26 1 9 Example SFC Templates 0000 cece cece nett e nett eens 1 30 1 10 Example Procedure Activator SFC 0 0 c cece eet eee eens 1 31 1 11 Example Recipe Template 00 cece cette 1 32 1 12 Example Recipe ceca iat ene nate eee cba 1 33 1 13 Example Data Dictionary Template 0 cece tenes 1 34 1 14 Example Data Dictionary Recipe 0 cette etnies 1 35 1 15 Example Procedure SFC 0 eee nee nents 1 37 1 16 Example Procedure Activator SFC 0 0 ccc cece nee 1 38 1 17 Relationship of the Procedure Activator to Procedural SFCs 00 00 cece eens 1 39 1 18 Example Sequence Recipe Template ooocococcccccccnccnc e 1 40 1 19 Example Sequence Recipe 2 ccc cece eee nee e eee eee 1 41 1 20 Example Main SFC 00 ccc nee eee ee eee ene 1 43 1 21 Example Procedure Manager SFC oooccccccccccco aaneen 1 45 1 22 Sequential Control Hierarchical Relationship 00060 e cece eee eee 1 46 1 23 APT Hierarchical Relationship 0 cette ens 1 47 1 24 Project Development Time Relationship 0 0 cece ees 1 48 2 1 Washer Example PAID 00 cece ete eens 2 5 2 2 Cooker
10. Fill level 3 High Medium Low Fill_lev3 Fill level 3 Gallons Figure 1 11 Example Recipe Template 1 32 Approach to APT Program Design SIMATIC APT Applications Manual Build the Recipe Create a recipe within the main unit of the process the unit that handles the primary task s of the process This will be the working recipe the recipe that contains the current recipe element values when the process is active When you download a recipe during runtime you will be copying one of your library recipes into this working recipe Assign the working recipe a short name e g WR for Working Recipe so that the element names can be as long as possible Then enter the value for each element Figure 1 12 shows the setpoint values for the laundry example The values Hot Warm Medium etc are integer constants that you need to define in the Declaration Table This can be done either before or after you enter them as values in the recipe value fields Define each one at either the global or the unit level and assign it a unique numerical value NOTE APT only accepts text in recipe value fields if the text is the name of either an integer or a real that is declared as a constant Recipe Values Value Units Element Name Description Hot Celsius Tmp_sp1 Temp SP 1 Warm Celsius Tmp_sp2 Temp SP 2 Cold Celsius Tmp_sp3 Temp SP 3 High Gallons Fill_lev1 Fill level 1 Medium Gallons Fill_lev2 Fill level 2 Low Gallon
11. Shapes Y Select the Controller Create Forms Determine l O Y Module Layout Y Place Graphics on Y Configure I O Screen i Y Define Discrete Devices Associate Tag Names with Dynamic Symbols Do These Tasks in Parallel Y i Design Continuous Control Create the Simulation Program Loops amp Analog Alarms Algorithms Optional Program Other Continuous Functions Program Automatic Start Program Other Alarms Program Safety and Shutdown Interlocks t y Identify Addresses for Operator Interface Database Continued on Next Page Figure 1 5 Steps of Designing Process Control 1 18 Approach to APT Program Design SIMATIC APT Applications Manual Bottom Up Implementation Continued from Previous Page Y Build Operator Interface Database Y Verify Operator Station Graphics Y Level 2 Tasks Y Control Software Design Do These Tasks in Parallel Operator Interface Design y Create Templates for Procedural Control SFCs Create Recipes Y Refine Graphics Y Animate Words Symbols Create Templates Recipes for Setpoints Alarm Values Loops etc Y Create Help Screens
12. Downloading Program to Controller in the Compiling an APT Program chapter of the SIMATIC APT User Manual To access the object reports in the APT hierarchy you must have a successfully compiled program Generate a simple one if necessary Then go to the Program Content Directory and place your cursor on the following item OBJECT Successfully compiled program Follow these steps 1 Press _r_ or use the OPTs icon to select Report The dialog window appears as shown in Figure 6 1 2 Place an X between the brackets following the P C address to APT symbol name option to either save or print the report 3 After selecting your report move the cursor to OKAY and then press Enter 4 Return to the APT hierarchy and read or print the report in Saved Reports REPORTS Save Print APT symbol name to P C address P C address to APT symbol name X SFC CFC math to P C address SFC cross reference Translated tags Cross Reference 1 SFC steps and transitions STEP 5 symbol files Figure 6 1 Creating an Address Report 6 4 Redundant Configuration for 5 SIMATIC APT Applications Manual Figure 6 2 shows a sample address report Both data words and I O are shown in the address report 20 Apr 1995 07 01 14 PAGE 1 PLC ADDRESS TO APT SYMBOL NAME PROGRAM NAME BLD1A Symbol Name Type A_STRT1 BOOLEAN B STRT1 BOOLEAN TOTAL_A NTEGER A_BIAS REA
13. RT1 NUM_RUN and RT1 FILL SP are integers Each tag has an initial value of zero They are both a part of the recipe RT1 The Series 505 address of RT1 NUM_RUN is V5 and RT1 FILL SP is V6 as listed under the VALUE and STATUS attributes The tag called RT1 TEMP is a real number It has an initial value of zero and its Series 505 address is assigned to the VALUE attribute as V 7 which is to say that RT1 TEMP actually takes up the addresses V7 and V8 It is also used in the recipe RT1 Five boolean variables GLYCOL TEG OIL AIR and WATER are used in the recipe RT1 Their Series 505 addresses are assigned to COMMAND and STATUS as C17 C18 C19 C20 and C21 respectively The VALUE attribute is passed for the reals and integers and the COMMAND attribute is passed for the booleans The components in the recipe are listed in the component section under recipe RT1 You can see the APT name under the component name and the PCS OSx name under the tag name The name of the loop is TLOOP and it is a LOOP tag type TLOOP is a temperature control loop assigned to process group 1 Clean Tank The number immediately following the word LMode in the MODE attribute identifies the address of the loop in the controller that is Loop1 Many loop attributes are passed to PCS OSx The process group numbers are in hexadecimal form There are 32 process groups Process group number 0 x 1 refers to only using process group 1 Process group number 0 x ffff
14. used by the controller and creates the install tag file that contains object data When you compile the program controller addresses are fixed for each object that you marked in Step 1 3 Translate the tags Section 7 4 Translation places the tag data which was created by the compile step into a formatted OSx database You must follow each step for any operator interface For OSx all three steps can be done by selecting the appropriate option while you are executing APT For any other operator interface you can do Step 1 and Step 2 while executing APT The third step is a manual procedure in which you must prepare the database to be used by the operator interface Refer to Appendix A for recommendations about how to proceed 7 4 APT and the OSx Operator Interface SIMATIC APT Applications Manual 7 2 Marking Tags for Translation Use the Mark Tags option to select those objects that are used by the operator interface and that must have fixed controller addresses If your application requires it you can also unmark an object after you you have marked it for translation The SIMATIC APT User Manual describes the steps involved in marking and unmarking objects for translation You can use the APT Mark Tags option for any type of operator interface Tag translation creates the OSx tags from APT objects Table 7 1 shows the OSx tag types and their corresponding APT objects Several APT objects are used specifically as configuration tools f
15. 7 7 Index 4 PCS continued RBE 1 12 translating tags C 23 C 24 C 25 advanced blocks dynamic blocks C 2 limiter blocks C 26 math blocks other blocks overview C 2 C 29 C 30 selector blocks C 31 standard blocks C 31 valve control blocks unit tag translation using objects to configure 7 6 PCS tag types 7 5 Perspective on process defined steps 1 4 Power failure devices 3 22 recovery logic S5 controllers 3 22 Series 505 controllers Power supply UPS option Procedural control defined 1 12 subordinate SFC code subordinate SFC templates temporary main SFC templates Procedure activator SFC Procedure manager SFC Process analysis defined steps 1 6 Process code implementation defined steps automatic start 1 24 controller addresses 1 28 controller selection 1 21 data dictionary discrete devices 1 21 T O configuration T O modules loops analog alarms on off control memory 1 20 names Process code implementation continued steps continued operator interface i raphics other alarms other continuous functions partition permanent main SFC code procedure manager SFC code recipe 1 33 recipe template safety interlocks sequence array sequence recipe sequence recipe template simulation math subordinate SFC code subordinate SFC templates temporary main SFC code 1 38 temporary main
16. Data for Activating Standby TRAFDAT 20 cc cece eee e eee eee Configuring Expansion Units from COM 155H coococcccocnn Configuring Expansion Units I O 314 2 0 eens Configuring I O from COM 155H 21 cece eee IOGONE senusien nine aaa e pide aes aidualeeniqd aaa ie SIMATIC APT Applications Manual Redundant Configuration for 5 6 1 6 1 Configuring an S5 155H Redundant System for APT Overview The S5 redundant controller system 155H is composed of two separate controller racks each one containing one 948R CPU The code for controlling the process can be programmed in APT However in order to run an APT program on an S5 redundant system you must first configure the Operating System parameters using the COM 155H software package which is purchased separately APT does not configure the Operating System parameters for you This chapter explains how to recover the data you need from APT and what parameters to enter in COM 155H This document is not a tutorial you must already be familiar with the information about COM 155H that is provided in the S5 155H Programmable Controller CPU948R Manual Options for Setting When you are initially configuring your redundant system there are two Up Your Redundant sequences you can follow based on whether you wish to set up a new Configuration process or modify an existing process When you set up a new process you can reduce development time by writing an
17. Do This Not This If B Then If B Then If C Then If C Then Else Else Endif Endif Figure 3 7 Indent Math Code 3 4 Programming Hints SIMATIC APT Applications Manual Use Event Math The 545 545L 555 565 565T 565P and 575 controllers allow no more than CFBs 32 cyclic SF programs to be queued at a given time If you need additional timed cyclic events incorporate event math blocks in your program and use an RLL or STL timer to time the cycles Refer to Figure 3 8 Declarations Timer slow or fast BLK01_TMR Boolean entity BLKO1_OVRN Blocks Event Math CFB BLKO1 BLKO1_TMR ENABL TRUE BLKO1_TMR RESET NOT BLKO1_TMR TOUT BLKO1_OVRN BLKO1_TMR TOUT AND BLKO1_TMR ENABL BLKO1_OVRN AND NOT BLK01_TMR TOUT BLKO1 ENABL BLKO1_TMR TOUT OR BLKO1 ENABL AND NOT BLK01 ENABLD Figure 3 8 Use Event Math Blocks to Create Cyclic Events You can check the boolean entity an optional part to the code BLK01_OVRN to see if the event is overrunning Use Active Versus When you want boolean math to be executed continually use the Active Continuous Option option as opposed to the Continuous option with enabling This requires less code and ensures that the math processing is not turned off SIMATIC APT Applications Manual Programming Hints 3 5 Math Hints continued RLL Math Is Processed Faster than SF Math for Series 505 Controllers 3 6 Programming Hints The Series 505 contro
18. Exchanger Example for Series 505 Controllers Process Description for the Heat Exchanger 00 cee eee eee eee eee ee Process Functions of the Heat Exchanger cece cece eee tenet eee P amp ID for the Heat Exchanger cece eee cette nett eee Process I O for the Heat Exchanger cece e eee eee eet eens Contents Chapter 3 Programming Hints 0 002 e eee eee eee eee eee 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 Organization of APT Logic 0 0 ccc eee eet Understand the Logic Structure 0 0 c cee eet eee es MATIAIDES daa ina Avoid Making Same Comparison Twice 00 cece on Use Boolean Logic when Possible oooococcocoocooocor teen eens Write Clear and Readable Code 0 ccc cence ene nen een enes Use Event Math CFBS 0 cc ccc etn e teen eens Use Active Versus Continuous Option 000 ccc eee eens RLL Math Is Processed Faster than SF Math for Series 505 Controllers Consolidate CFB Math for Series 505 Controllers 20 0 0c ccc cee eee eee eee SF Program Loop Analog Alarm Hints for Series 505 Controllers How Priority for SF Tasks Is Determined for Series 505 Controllers Detecting Task OverrunS 0 0 c cette eee eee eee Handling Task OVeMmunS 2 02 scene peed ered eee seenad ad peewee Correlating Loop and Real Math Processing
19. MDS MDN and MUD for OSx PCS MTR1 motor types Figure C 1 shows the MTR1 status word OSx Status Set in OSx Running Interlocked Setpoint a AN Not Stopped stopped In use Travel Manual set Not Alrm UnAck running Mode Ovrd Fdbk Active Attribute Bit Positions APT Extensions FTR LOCKD TRVL STPPD FTS DSBLD OVRD RUNNG NRDY MSTRT Not implemented in OSx Figure C 1 APT Tag Correlation with OSx MTR1 Status Word C 8 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Table C 8 shows the APT extension correlation with OSx MRT1 attributes Table C 8 APT Tag Correlation with OSx MTR1 Attributes OSx Status Bit Data Read fom Controller Controller 1 OSx Command Form Data OSx Attribute Written to Controller Override P C Memory Location 32768 Disable C of Length 1 Mode_Cmd P C Memory Location Disable C of Length 2 Lock Unlock Setpoint PC Memory Location C of Length 1 Timeout_1 P C Memory Location x 0 1 sec a amine a TCP x status wor Timeout_2 ae Location Integer x 0 1 sec OSx status word Not implemented in Refer to Figure C 1 2 Mxx represents MSN MSS MDS MDN or MUD APT Extension 2 Mxx DSBLD 1 Mxx LOCKD 1 Mxx LOCKD 0 Mxx MSTRT 1 Mxx RTCP Mxx STCP 3 For OSx the Timeout_1 and Timeout_2 attributes are reflected in the status word via the combination of the running
20. Marking the second array element for translation will cause an overwrite of the boolean location immediately following the array which could cause unpredictable operations that could result in death or serious injury and or damage to equipment You must either fully understand the consequences of marking the second array element or declare a three element boolean array instead C 20 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Both APT declaration timers Fast Timer and Slow Timer have preset and current values that correspond to the OSx timer types The Enable and Reset control bits are translated like a boolean or DO variable Table C 16 lists the extensions that are translated for both timers Table C 16 Declaration Timers ao RSET Timer Reset SS Declaration counters have preset and current values that correspond to the OSx counter type The Input and Enable control bits are translated like a boolean or DO variable Table C 17 lists the extensions that are translated for counters Table C 17 Declaration Counters ctr counter name Counter Value no extension SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 21 Translating APT Objects to OSx PCS and TISTAR continued Recipes The OSx tag type and the corresponding recipe types are listed in Table C 18 When you translate a recipe APT translates the elements to OSx as normal integers boolean entities etc The defaul
21. Math Blocks Group 1 Math Blocks Group 2 Anti Reset Windup Constraint Type 2 0c naeun nn Anti Reset Windup Select Type 0c ec cece eee tenet ene Scale Correlated Lookup Table 000 cece cece eee eed eee eens Average Selector High and Low Selector Blocks ooooooccoccocccnc on Inswitch Selector Median Selector Outswitch Selector Threshold Selector Analog Alarm Split Range Valve Sequencer Proportional Time Control 00 00 cece nanenane Motor Position Control Contents Preface Purpose of This The SIMATIC APT Applications Manual is intended to help you design and Manual write an application program for controlling a factory process using APT You will find programming hints specific examples some philosophy about designing the controls for a factory process and several executable demonstration APT programs New Features of The capabilities of APT have been enhanced in Software Release 1 9A The APT documented differences between APT Release 1 9 and Release 1 9A are indicated by change bars in the manual page margins Controller Families APT continues to support two controller families the Series 505 and the SIMATIC 5 Most programming tasks like writing a program downloading or debugging are handled the same way in APT regardless of your controller type The way APT treats direct memory addressin
22. PM550 Series 500 Series 505 TISOFT TISTAR TIWAY CVU1000 CVU10000 PM 550 and Unilink are trademarks of Siemens Energy amp Automation Inc AST is a registered trademark of Bank of America National Trust and Savings Association IBM and AT are registered trademarks of International Business Machines Corporation TUTSIM is a trademark of Actuality Corporation Pentium is a registered trademark of the Intel Corporation UNIX is a registered trademark of Novell Inc Windows Windows 95 Windows NT9 Windows 2000 Microsoft and MS DOS are registered trademarks of Microsoft Corporation Preface Contents Chapter 1 Approach to APT Program Design 0200eceeeeeeeeee 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 What This Chapter PresentS ooococcoccccnnc eee eee Develop a Perspective for the Overall Process 0 00ee cece eee ee ee eee Do a Top Down AnNalySiS 0 0 cee ec cece eee eee eee eee e eee eee eeneeee Consider the Whole Problem Then Subdivide 0 0 0 ccc cence eee eens Determine What the Process Does 0 ccc ence tte eee e ene Determine How the Process Is To Be Done 1 ene teens Determine Control Needs 0 0c ee teen enn een teen een eaes Example Mental Exercise for Top Down Analysis ocoooccooccoocccancc Plan the Bottom Up Implementation 00 cece eee eee eee e eee eneeee Use
23. Program Design 1 3 1 2 Develop a Perspective for the Overall Process When you develop a perspective of a control problem you develop a clear understanding of the process and its operation This phase of the design process includes the following considerations Information Collect all the relevant information that you need for a thorough understanding of the project such as Need batch logs P amp IDs functional specifications operator station Water in Water out drain Power Gas in Soap Washing machine requirements I O lists etc DOAAA People Get all the interested parties involved in the planning stages the project engineer representatives from management testing personnel the operator station graphics designers You also need to include the process operators These people are the final customers the ones who need to be fi Operator satisfied in order for the process control to run smoothly after startup Understand that the people most affected by the solution Operations are the ones who are often the most Maintenance Engineer unwilling to get involved at this stage However for a process retrofit these are the people with the most knowledge about how the process actually runs Process area Be certain that you know the area of the factory for which you are planning a control design Are you Process Area Water heat x working on a plan for the entire factory or a portion of it N
24. Read Write Boolean Read Write Integer Read Write Real ENABL INA IN1 NRDY 1IN2 IN2 INS IN3 1IN4 IN4 Dynamic Blocks Dead Time Delay Extensions Read only Boolean Read only Integer Read only Real ENABLD IOUT OUT Read Write Boolean Read Write Integer Read Write Real ENABL IN NRDY OUTIC GAIN DTIME Extensions Fixed by the Compile B 3 Extensions Fixed by the Compile continued Dynamic Blocks continued Derivative Extensions Read only Boolean Read only Integer Read only Real ENABLD IOUT Read Write Boolean Read Write Integer OUT Read Write Real ENABL NRDY Integrator Extensions Read only Boolean Read only Integer IN Read only Real ENABLD IOUT Read Write Boolean Read Write Integer OUT Read Write Real ENABL NRDY First Order Lag Extensions Read only Boolean Read only Integer IN OUTIC TAU1 DTIME GAIN Read only Real ENABLD IOUT Read Write Boolean Read Write Integer OUT Read Write Real ENABL NRDY IN OUTIC GAIN TAU1 DTIME First Order Lead Lag Extensions Same as 1st Order Lag Second Order Lag Extensions Same as 1st Order Lag Second Order Lead Lag Extensions Same as 1st Order Lag B 4 Extensions Fixed by the Compile Valve Control Blocks Motor Position Control Extensions Read only Boolean Read only Integer Read only Real Read Write Boolean Read Write Inte
25. STL controllers execute boolean logic faster and require less when Possible code than IF THEN ELSE statements Figure 3 3 use boolean logic instead of conditional statements Do This Not This b z or q or r If ae al r then true b temp gt 25 0 If temp gt 25 0 then b true Figure 3 3 Use Boolean Logic for Speed There are times when your application requires that a boolean entity remain turned on latched See Figure 3 4 Do This Nat This b b or temp gt 25 0 If temp gt 25 0 then b true Endif Figure 3 4 Logic Differences between If Then and Boolean Logic SIMATIC APT Applications Manual Programming Hints 3 3 Math Hints continued Write Clear and In Figure 3 5 calculation A is processed as quickly as calculation B but is Readable Code easier to read and to debug Although calculation B requires less code it is better that your code be readable and understandable B Not This G A B D F Figure 3 5 Write Code Clearly Use parentheses freely to make math code easy to understand Figure 3 6 The use of parentheses also removes any doubt about the order of execution Do This Not This If not t and S then If not t and S then Endif Endif Figure 3 6 Use Parentheses in Math Indent program code when appropriate Figure 3 7 This makes it easier to identify code sections such as IF THEN statements
26. Selector INCAS E INC MAME E NECE Peale ais Table C 40 Threshold Selector Bock control bi a EIN EL DISCRETE OUTPUT THRESHOLD LIMIT C 30 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Standard Blocks Valve Control Blocks The OSx tag types and extensions for the standard blocks are listed in Table C 41 through Table C 43 Table C 41 PID CFB name no extension PID loop Table C 42 On Off CFB name no extension PID loop Table C 43 Analog Alarm CFB name no extension Analog alarm block The OSx type for each valve block APT extension is listed in Table C 44 through Table C 47 Table C 44 Split Range do ENABL Block control bit BREA SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 31 CFB Extensions continued Table C 45 Valve Sequencer Ee EEC IICA ECO E Table C 46 Proportional Time Control Co EG CT INICIAN ECO ET Table C 47 Motor Position Control C 32 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual A Address controller report creating from object file required for COM 155H Append tag file 7 11 B Booleans translating C 19 Bottom up implementation defined layers level 1 controll 1 12 level 3 controll 1 13 operator interface design 1 18 steps 1 18 automatic start 1 24 controller addresses 1 28 controller selection 1 21 data dictionar T O modules menor a
27. a Layered Approach ooooccoccooco ete ete eee eens Study the Example Program WASH_DEM for Series 505 Controllers Coordinating With Operator Interface Design 0 00 eect eete eens Create the Code First StepS 00 cece eee eee eee eee eee eee Plan Memory Allocation 0 cc cect ent n eee eens Select Naming Convention 00 eee eee enn e eee Plan Testing and Simulation 0 0 00 cece eee eee ene Partition the Process into Units 0 cece enn teens select Controller aiii i noii ahah peered ae de dae de eed a ed Determine I O Module Layout 000 cee eee eee eens Gonfig re WO eiii cian ope ta wie tbat diet eae aida Sinaia eae Mae Define Discrete Devices 0 cece tne t nett e nee Create the Code Continuous Control Logic 0 cece cence eee eee Program the Simulation Math 000 cece cette eee eens Program Loops Analog Alarms On Off Control 0 00 cece cece cent nee Program Other Continuous Functions 0 00 ccc cece eee tne e eee n eens Program Automatic Start sesers asiaasi a iaga Kaa aadi a abg aaoi aaah a Ka a DS eee ene Program Other Alarms issan aiana a aa a aoada aia iiare iiaae aaa as Program Safety and Shutdown Interlocks 0 0 cece nnana Create the Code Operator Interface Addresses Graphics ooooooooommmm Identify Addresses for Operator Interface Database
28. a bb hems id anton gece Advanced BIOCKS o o ooooor ent ent nee n eee n teen eens Dynamic BlOCKS erais sedate dak ieee eee edie Oi aet ii ey Limiter BlOCKS oorp isos oia ai a ba Math BlocCkS o o oooooro en en ene nen teen teen eee n eee n eens Other BIOCKS is doz ici ee iain dr deine a A ata Ab Re aca ane aod dria aa td ae Welles Selector BIOCKS 1 0 0 0 ccc nent een e teen edin aaa Standard BlOCKS cuac a eWeek A A A a EONS Valve Control BIOCKS 0 0 ccc eee een e teen ene nen ene ene nnes SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation e 1 C 1 Translating APT Objects to OSx PCS and TISTAR Overview APT allows you to translate APT names to OSx 4 x PCS 3 x and TISTAR 1 x and 2 x In this appendix the name OSx refers to OSx 4 x PCS Rel 3 x and TISTAR Rel 1 x and 2 x unless otherwise noted The translation process involves the following steps e Specify the names you want to translate to OSx Once you mark a tag APT provides default names for the OSx name and the OSx object e Mark complicated tags such as devices I O points or declarations with more than one associated tag e Specify scan status upload autoload OSx 4 x and PCS 3 x and download TISTAR 1 x and 2 x or 20 offset for each point APT does provide defaults depending on the object type C 2 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual After tags are translated to OSx they are
29. an efficient and understandable way The code designer maintains the overall perspective and structure while laying out the detailed tasks When problems occur the code designer redesigns a program so as to maintain cohesiveness and structure A hacker writes and rewrites code until it works Select names carefully Use descriptive meaningful names to identify items in the program This will avoid confusion makes it easier to maintain a program and to transfer it to the next programmer Verify Requirements Communicate often with the other people who are involved in the system development This helps ensure that you fully understood the operations people for example when they gave you their list of needs SIMATIC APT Applications Manual 1 15 What Can APT Do for Me There are many reasons for creating your application program with APT Choose APT for your programming tool if any of these reasons apply to you SIMATIC APT Applications Manual You prefer to use a structured top down approach to design your program You do not like to be concerned with the details of RLL or Special Function programming Series 505 or STL S5 You prefer to use meaningful names in your program such as Tank_1 Drain instead of V213 You intend to monitor your process with OSx You like to select and use pre designed and tested solutions within your program instead of designing your own You find it easier to use a pre designed menu driven
30. and Analog Alarms oooccocccccc nent ete Chapter 5 Dynamic Program Simulation o 0oooooooommmmmmmo 5 1 5 2 Testing the Application Program Manual Testing ooooococconccnnc ee eee ene eens Repeatable Logic Testing 0 cece cect eee eee eee eee Dynamic Simulation aseessa cent nn n ete e eee nee APT and the TUTSIM Dynamic Simulation Package Series 505 ooooooo o AV AMA DINLY ass ria tar wee Ree ene tae ae ee te ae APT TUTSIM BIOGR iai aiina aadi menaam a trai A e EA TUTSIM USR File v se rirenigeni peia sa OAAR ENTERA eee tenets Example TUTSIM Program for Series 505 ooccccocccccconocnn Block Diagram Examples 00 0 cece eee een RAEAN Chapter 6 Redundant Configuration for S5 0 eee eee eee eee 6 1 6 2 6 3 vi Configuring an S5 155H Redundant System for APT 0020 cece cece eee OVEN IEW iaae aa a Ai vised dive chchintracted EE aca ge anavlanw aranane a jane ur bindee Ab a mare Options for Setting Up Your Redundant Configuration 0 cece eee eens Generating an APT Address Report and Configuring COM 155H 20 0005 Generating an APT Address Report oocoococcccoccnn eee eee eee eee Configuring Operating System Parameters from COM 155H 22 002e0ee Operating System SYSTEM Parameters 0 00 0 cece cnet n eens Contents 6 4 Configuring Data Block Transfer Lists from COM 155H
31. and the TUTSIM Dynamic Simulation Package continued TUTSIM USR File The APT TUTSIM USR block has an associated file called tutsim usr that defines communication information and the Series 505 controller addresses The APT utility program usrapt exe preprocesses the tutsim usr file and updates addresses from an APT program tutsim usr must be located in the same directory on your computer as the TUTSIM files The APT program must be on the same drive as the tutsim usr file when you run usrapt exe unless you use the APT LOCAL DOS environment variable to set the path for a different drive The format of the tutsim usr file is shown in Figure 5 2 COMM lt comm path gt lt comm name gt lt comm port gt lt secondary gt COMM lt comm path gt lt comm name gt lt comm port gt lt secondary gt PROGRAM lt APT program name gt UNIT lt APT unit name gt BLOCK lt tutsim block number gt lt address gt lt APT symbol name gt BLOCK lt tutsim block number gt lt address gt lt APT symbol name gt BLOCK lt tutsim block number gt lt address gt lt APT symbol name gt UNIT lt APT unit name gt BLOCK lt tutsim block number gt lt address gt lt APT symbol name gt Figure 5 2 TUTSIM USR File Format COMM command The COMM command allows TUTSIM to communicate with multiple controllers each with different communication requirements All four parameters for COMM are required even if they do not apply
32. be an ongoing process that extends beyond initial commissioning Approach to APT Program Design 1 13 Plan the Bottom Up Implementation continued 1 14 Layers There is a set of related tasks that logically you need to do first This set of related tasks comprise a layer in the level of control defined above Each task in the layer represents a degree of accomplishment When you complete the first layer of tasks you proceed to subsequent logical groups of tasks or layers until the process control design is finished Figure 1 4 illustrates the levels and layers that make up the bottom up implementation Layers of tasks represent more and more structure and increasing dependency upon lower layers of design to function correctly The addition of each layer adds more automatic controls and consequently less reliance on an operator to handle control functions Figure 1 4 shows how the levels of control change as you proceed in the development of your program Note however that as you climb the stairs that represent each layer of tasks your progress is not strictly linear Typically you must do some backtracking and translate tags again or program some more continuous control after having worked on structural control for example As you work on each layer of tasks never lose sight of the top down goals and the associated internal model described in Section 1 2 Continue to partition your work Divide a problem into small sub prob
33. can be added later coordinates the loading of product recipes In the laundry program an example of the Main SFC is shown in Figure 1 20 The steps and transitions are described below Step S1 Op_mode d in_auto sets the operation mode to automatic Transition T1 is always true because there is no need to wait Step S2 contains no code but is required because the parallel construction does not allow a loop to return directly below the top crossbar Transition T2 is always true because there is no need to wait Step S3 SFC Phases calls the procedure activator SFC Phases Transition T6 is always false so that this path never terminates Step S4 Op_strt true sets the boolean entity Op_strt to true Op_strt is used to inform the operator that the process is ready to start The operator s acknowledgement sets Op_strt to false which allows program flow to advance past transition T3 Step S5 SFC Download calls the SFC Download which downloads recipe information to the working recipe Transition T4 is always true because program flow does not advance until the exit step of Download is active Step S6 SFC Batch calls the SFC Batch which acts as a scheduler for the operational SFCs Transition T5 is always true This path loops back and program flow waits for an acknowledgement from the operator to continue 1 42 Approach to APT Program Design SIMATIC APT Applications Manual Main SFC Op_mode d in_auto set mode
34. controller APT fixes controller addresses for objects during the compile procedure It is not essential to mark all objects before you compile a program because you can append tag information to the file containing the tag data However you should decide which objects are required by the operator interface and mark them all before compiling You can use the APT Compile option for any type of operator interface The first time you compile a program after marking objects select these options in the Compiler Control File Force compile X Build translate table No Append Yes Units to compile Include all X 1 of 1 included SIMATIC APT Applications Manual APT and the OSx Operator Interface 7 9 Compiling the Program continued Recommendations Keep these points in mind when you fill out the Compiler Control Form for Compiling a Program Force Compile After a successful compile subsequent compiles may execute more quickly after you make minor code changes This is because some sections may not be revalidated Refer to the Compiling an APT Program chapter of the SIMATIC APT User Manual for a complete discussion about the program compile operation Build Translate Table When you do not want addresses for the marked objects to change after the initial program compile do not select Yes for the Build Translate Table option during subsequent program compilations If you need to recompile the program s
35. current DOS path environment includes the path to the APT executables directory For example if APT is installed at D APT enter the following command PATH If D APT is not included in the list output by PATH add it by entering the following command PATH PATH D APT 3 Ifyou are loading HX DEMO from the CD enter the following command substituting your diskette drive for E and your disk drive containing the APT database for D E DISK8 LOADDEMO E DISK8 HX_DEMO D If you are loading HX_ DEMO from diskette enter the following command substituting your diskette drive for A and your disk drive containing the APT database for D A LOADDEMO A HX_DEMO D 2 14 Program Descriptions SIMATIC APT Applications Manual The APT database is typically on the drive where you installed the APT software unless you selected the Configure Directories option during installation or reconfigured your system at a later time If you have configured APT so that the APT software is installed on multiple drives and or in non standard directories then you must ensure that the environment variables APT DB and APT COMMON exist and are assigned appropriate values See page 1 17 for more information If these environment variables are properly set and you are loading from CD drive G enter the following command G DISK8 LOADDEMO G DISK8 HX_DEMO If you are loading from diskette drive B enter the followin
36. description of the bit shifting that is performed when you scale an S5 analog input If you have an integer input to a loop you can perform an int_to_real calculation on the input before it is sent to the loop Use the result of the int_to_real as the process variable in the loop SIMATIC APT Applications Manual APT and Controller Memory 4 9 5 1 5 2 Chapter 5 Dynamic Program Simulation Testing the Application Program Manual Testing ovina ti a ta tt da ie dot ad dd AE Repeatable Logic Testing cooocccocconcconccr n ete teen nee Dynamic Simulation 00 0 c ce no APT and the TUTSIM Dynamic Simulation Package Series 505 oooooo o Avallabuiity eo cite a oa el be eles We eat pete ncaa eee en be eed eee ea APT TUTSIM Block TUTSIM USR File o inor rea dat sas aiia iai cee a wd A ee ea A aera ws Example TUTSIM Program for Series 505 ooccccocccccconncnnc Block Diagram Examples 00 00 cece anaana SIMATIC APT Applications Manual Dynamic Program Simulation 5 1 5 1 Testing the Application Program Manual Testing Repeatable Logic Testing There are three general approaches to testing the application program Manual testing Repeatable logic testing based on software routines e Dynamic simulation As you develop your application program the first testing task consists of the basic manual tests In these tests you change the digital and analog inputs manually and observe the r
37. design and execute a test program for an application program e SIMATIC APT Release Notes have important information not included in the manual set e The APT manual set is available both in paper form APT 8200 T and in electronic form on CD ROM APT 8200 CD NOTE Unless otherwise specified the term OSx is used throughout this manual to designate SIMATIC TISTAR Releases 1 x and 2 x in addition to SIMATIC PCS Release 3 x and SIMATIC PCS 7 OSx Release 4 x xiv Preface SIMATIC APT Applications Manual Chapter 1 Approach to APT Program Design 1 1 What This Chapter PresentS coococcoccccnnc eee eee 1 2 Develop a Perspective for the Overall Process 00ceeee eee ee eee eee eee 1 3 Do a Top Down Analysis 00 cece cece eee eee eee eee ene eeneeeneeee 1 4 Plan the Bottom Up Implementation 00 cece eee eee eee eee eens 1 5 Create the Code First StepS ccc cece eee eee eee 1 6 Create the Code Continuous Control Logic 0 cc cece eee eee 1 7 Create the Code Operator Interface Addresses Graphics ooooooooommmmo 1 8 Create the Code Templates for Procedural Control 00eeeeeeeeee 1 9 Create the Code Recipes and Recipe Templates 00eeeeeeeeeee eens 1 10 Create the Code Procedural Control Logic ooooooccrcocnncnror 1 11 Create the Code Structural Control Logic o oooooooocrcocnnrrror 1 12 Create the Code Obje
38. downloaded to the STANDBY ON LINE controller e For Series 505 a new program with the I O configuration cannot be downloaded to a STANDBY OFF LINE controller A new program without the I O configuration can be downloaded to the STANDBY OFF LINE controller SIMATIC APT Applications Manual Programming Hints 3 19 Miscellaneous Hints continued If You Need More L Memory or Faster RLL Execution for Series 505 Controllers If You Need Faster STL Execution for S5 Controllers 3 20 Programming Hints When you need to reduce RLL scan time in Series 505 controllers consider these options Force math calculations to be made in an SF program instead of RLL The consequences are described on page 3 6 e Use a faster controller such as a 545 545L 555 560T 565P or a 575 The 555 is the fastest controller e Use the guidelines suggested in this chapter to make your code more efficient When you need to remove RLL code from L memory force math to be executed in an SF program Use the PRAGMA code specifier statement in the math code This forces the math code into SFPGM code and causes a compile error to be generated if you inadvertently use RLL code in math that you intend to be SFPGM only PRAGMA SF causes math to be executed in an SF program and reduces RLL scan time When you need to reduce STL scan time in S5 controllers consider these options e Use a faster controller such as a 948 The 948 is
39. ffff means that the tag was assigned to all 32 process groups The PCS OSx install tag file shown in Figure A 2 and Figure A 3 is for a Series 505 controller An install tag file for an S5 controller is exactly the same except that the memory addresses follow S5 conventions A 14 Defining a Variable s Address SIMATIC APT Applications Manual INSTALL TAG File First Line The first line of a section starts with a field description line and contains a description of the data in the columns Compare the first line in Figure A 2 with the material in the first row in Figure A 3 INSTALL TAG File Second Line The second line of the section determines the amount of information associated with each tag Compare the second line in Figure A 2 with the second row in Figure A 3 This line starts with a T P or R identifier to identify it as a tag process group or recipe as shown in Table A 4 Table A 4 Identifiers for Tag Types T Ta Controller Type Tag Name Description Manual Set 5 Process Group Number in Hex and Parent EAN final ail di i ics a group DCI EC eee O INSTALL TAG File Subsequent Lines The next several lines of a section start with different identifiers depending upon the tag type A or C and contain attribute information for the tag or recipe listed in the install tag file See Table A 5 The number of lines for each tag varies with the tag type Table A 5 Identifiers for Attributes of Tags Identif
40. for a specified period of time When the flow rate is too low a timer begins to time down The boolean value becomes true and triggers interlocks when the timer times out Note that the timer does not time down unless the flow rate is low Remember to validate compile and test code as you develop it The code that handles interlocks and other safety related concerns is another example of logic that is best programmed in the form of continuous rather than sequential control As with loops and analog alarms you need to group interlocks by logical function It can be very difficult to determine the reason for the failure of a device for example when you must search through all the program interlocks for the one that has stopped operation of that device It is also best to place all the interlock code for an object in one location of the program It is much less difficult to troubleshoot an interlocked object when the interlock code is not in several different places Dedicate one CFC in each unit to contain the interlock code for that unit Consider dedicating one interlock CFB to handle interlock operations for each device and each CFB as shown in Figure 1 7 below Interlock CFC Unit 1 Valve 1 Interlock Valve 2 Interlock Temperature Loop 1 Interlock CFB Valve 3 Interlock Valve 4 Interlock Temperature Loop 2 Interlock CFB Temperature Loop 3 Pump 1 Interlock ump 1 Interl
41. functions This point in the process design marks the beginning of the work on the Sequential Function Chart SFC structures Begin by examining the continuous control strategies that you have already defined Refer to your top down analysis and determine what the procedures are These procedures are handled by the individual SFCs used in a unit Identify what the order of execution for these SFCs must be and how they interact with the continuously executing functions Give the SFCs meaningful names Choose a naming convention that has meaning to your process and then use it consistently In the laundry example the subordinate procedures may have names such as Fill Add_Soap Agitate and so on Think in terms of designing only SFC templates at this stage of the process design You are laying only the foundation of a design structure You will be coming back later in the design process to fill in the details This means that you do not want to write complete and fully functional SFCs yet Each SFC template must have a defined function and each SFC must be activated by a temporary Main SFC but it need not actually do any useful tasks yet However the program must be able to compile successfully Figure 1 9 shows SFC templates for the laundry example Subordinate SFCs Agitate E TT Start_Fill True Start_Agit True TT Start_Drain True On Fill_Done On Agit_Done On Drain_Done
42. in E APT As above ensure that the PATH includes D APT and then set the other environment variables by entering the following commands SET APT_DB C DATABASE SET APT_COMMON E APT If you are loading from CD drive G enter the following command G DISK8 LOADDEMO G DISK8 WASH_DEM If you are loading from diskette drive B enter the following command B LOADDEMO B WASH_DEM To install the other example programs substitute the program names APT_SIM FOOD545N HX DEMO or WASH_S5 for WASH DEM SIMATIC APT Applications Manual Approach to APT Program Design 1 17 Plan the Bottom Up Implementation continued Coordinating With Operator Interface Design On the left side of Figure 1 5 you can see a list of the typical tasks involved in creating a process control program The right side includes the tasks involved in creating a corresponding operator interface Ideally you do these two sets of tasks in parallel Develop a Perspective Do a Top Down Analysis y Execute Bottom Up Implementation Level 1 Tasks Control Software Design Do These Tasks in Parallel Operator Interface Design i Plan Memory Allocation Design Process Graphics i Select Naming Convention Create Dynamic Plan Testing and Simulation Symbols Y Create Shapes Partition Process into Units Create Animation for
43. is 0 or 1 PROFESSIONAL VERSION OF TUTSIM Model File test1 SIM Date 2 15 1992 Time 11 56 Timing 0 1000000 DELTA 10 0000 RANGE PlotBlocks and Scales Format BlockNo Plot MINimum Plot MAXimum Comment Horz 0 0 0000 10 0000 Time Y1 10 0 0000 1 0000 READ FROM PLC AT CLK BLK 1 SAMP Y2 11 0 0000 32 767E 3 READ FROM PLC AT CLK BLK 2 SAMP Y3 Y4 9999 0 0000 1 0000 REAL TIME SYNC PERFORMANCE 0 2000000 1 CLK SAMPLE RATE CLOCK 0 4000000 2 CLK SAMPLE RATE CLOCK 0 0000 10 USR READ FROM PLC AT CLK BLK 1 SAMP 1 0000 0 0000 0 0000 11 USR READ FROM PLC AT CLK BLK 2 SAMP 1 0000 0 0000 999 SYC REAL TIME SYNC PERFORMANCE TUTSIM Program COMM 1 DIRECT 1 2 BLOCK10 C1 BLOCK 11 V1 TUTSIM USR File Figure 5 4 Example TUTSIM Program and TUTSIM USR File 5 8 Dynamic Program Simulation SIMATIC APT Applications Manual Block Diagram Useful example algorithms are shown below in block diagram format Examples Figure 5 5 is an example of a program that simulates mass balance control for a tank The simulation varies the analog input level based on valve positions in the feed and exit streams Each valve has an associated gain to convert the boolean value to a scaled flow An increase in the gain fills or empties the tank faster The LMI integrator block clamps the tank at empty full or a range between The GAI between the LMI and AI USR block converts a scale level to an appropriate AI ra
44. names symbol rpt and address rpt You can examine a report within the APT environment or have APT send the report to a printer These reports are usually quite long and you may not want to wait for them to print You can also examine a report by using any text editor in the DOS environment The file names are symbol rpt and address rpt located under the following subdirectory apt program program_name prr where program_name is the name of your APT program SIMATIC APT Applications Manual Defining a Variable s Address A 3 Determining a Variable s Address continued Using the APT DC The DC utility performs all the functions that the APT Report option Utility provides for an object as well as resolving individual symbol addresses The DC Resolve Symbol option is very useful for determining addresses when only a few locations are needed When you want to work in the DOS environment use the DC utility rather than using the Debug Direct Address Follow the steps below 1 and press Enter 2 3 Type the program name and press 4 For a global variable just press 5 Type the APT symbol name and press 6 Type 0 to quit At the DOS prompt for the drive containing the APT program type DC At the menu prompt type 5 Resolve Symbol and press Enter For a local variable type the unit name and press Enter Enter Enter Enter Be sure you in
45. need to have this contingency in mind when you design the operational SFCs Start by determining what all the various steps of the execution pattern are List these in simple meaningful terms but enter more generic terms into the element field of the template Figure 1 18 shows the steps that are appropriate for the laundry example and their corresponding entries in a template called Sequence Enter steps into the template Process Steps gt Recipe Template Element Type Description Eng Units Set to wash cycle Step_1 Step 1 N A Fill the tank Step_2 Step 2 N A Add the soap Step_3 Step 3 N A Wait for the soap to be added Step_4 Step 4 N A Wait for the fill to complete Step_5 Step 5 N A Start the agitator Step_6 Step 6 N A Wait for the agitation to complete Step_7 Step 7 N A Step 8 N A Step 9 N A Start the drain Step_8 Wait for the drain to complete Step_9 Figure 1 18 Example Sequence Recipe Template 1 40 Approach to APT Program Design SIMATIC APT Applications Manual Define the Sequence Recipe Value Names Build the Sequence Recipe Before creating the sequence recipe choose carefully the names that you use for the recipe values There is an implied action associated with every name For example the word initialize means latch the start command for the associated operational SFC to true The word wait_init means monitor a done flag until the message is true and then reset the start command
46. needed to perform the appropriate connections between the control node and the operations node OSx uses its database to log batch changes and to create batch reports Making batch requests in the controller by way of unit_name BCH_REQ allows OSx to notify its database of the actions taking place in the controller and keep appropriate records of what is happening during the batch The unit_name BCH_REQ inputs the numerical equivalents of the commands for the batches These numbers are listed in the SIMATIC PCS 7 OSx Batch Programming Manual C 4 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Table C 2 Batch Unit Tag Attributes DES integer value BCH_REQ batch request 32768 to 32767 successful transfer 8000H BCH_REQ RESP batch request response failed transfer 4000H no command 0000H BCH_REQ INFO batch request information up to 16 characters Each time the BCH_REQ is sent to a batch or unit command the OSx batch manager processes the command and then writes successful 8000H or failed 4000H to the unit_name BCH_REQ_RESP A value of 8000H successful does not mean that the requested command was actually successfully executed it means that the batch manager successfully read the request and passed it along to the batch and or unit Typically the controller sets BCH_REQ_RESP to no command 0000H before a batch request If you need to send additional information with the BCH_REQ through the BCH_REQ
47. numbers for the reserved memory and APT does not use these areas If you reserve DB 6 7 10 and 160 165 then the APT program will not use these DBs that you listed NOTE If your application requires additional logic above and beyond the code created with APT then reserve APT memory Although APT allows you to reserve memory for your own use this is meant only for special cases and should be attempted only by experienced controller users You can reserve any type of controller memory for your own use in the Compiler Control File During the compile APT does not use these specified areas when assembling the object code for download After you have successfully compiled a program and begin to download APT APT establishes the controller memory configuration Any reserved areas remain untouched and the APT program is inserted outside the reserved areas 4 4 APT and Controller Memory SIMATIC APT Applications Manual Guidelines for If you need to reserve SF programs or SF subroutines be certain that you Series 505 also reserve enough Series 505 S memory in words in the Compiler Controllers Control File to allow room for the SF programs or SF subroutines that you reserved If you configure a loop or analog alarm in APT follow these guidelines Reserve the number of loops or analog alarms that you need in the Compiler Control File e Use the user assigned addresses for the loops LOOP or analog alarms AALM If you configur
48. tag Although tailored for the PCS OSx database the information can be used for any operator station package to determine the controller address of a variable The install tag file is located under the apt program program_name directory where program_name is the name of your APT program You can examine install tag by using an ASCII text editor as shown in Figure A 2 or you can examine install tag using a spreadsheet program as shown in Figure A 3 The format for release 3 x is comma delimited to be easily used in a spreadsheet program The information contained in install tag has the organization described below The install tag file for PCS 3 x and OSx 4 x is organized in sections as follows Tags and Attributes Recipes and Components and then Process Groups There is a field description line for each section one for tags one for recipes and one for process groups to identify the information in each column The subsequent lines in the section describe the data A 10 Defining a Variable s Address SIMATIC APT Applications Manual Record ControlNode TagType Tag Description ProcessGroup ManualSet Parent Attribute Memory Locations Upload Twenty Autolog Init T 575 LOOP TLOOP temperatu rerrrrrr CHANGE 171 1 rerrrrSP V 1 1 N N 0 rrereey STATUS LSTATUS1 1 rrrr1 rr MODE LModel 1 N The Record line wraps to the second line in this figure rrrrrrrL_RANGE LPVL1 1 Y rrrrorrr H_ RANGE LPVH1 1 Y rrrorrr P
49. the fastest S5 controller that APT supports e Use the guidelines suggested in this chapter to make your code more efficient e Use global variable instead of passing parameters into a subroutine SIMATIC APT Applications Manual Program Recovery from Controller Power Loss If there is a possibility of power loss to your controller provide alternative uninterruptible sources of power for your system At the least make sure that the battery backup to your controller is good If the controller loses power and the battery switch is off or the battery is low the APT program is lost You must download the program again This section describes how the APT program responds to a power loss to your controller Units All units become inactive and remain inactive until the power returns When power returns each unit starts up in the initial step of the main SFC If you want to control the response to a power loss use a retentive safe state SFC Place an SSARM command in the initial step of the main SFC Use the prog_name PWRFL extension as a trigger in the SSTRIGGER command SFCs When a unit is disabled by a controller power loss or when the unit_name ENABL bit is set to false all active SFC steps in that unit become inactive On a return from the power loss the initial step in the main SFC becomes active CFBs Continuous function blocks enter the state that they were in before the power loss Declaration Values For Series 505 ret
50. the order of operations Treat the recipe as a tool that can help provide meaning and structure to a program Recipes are associated with a template that defines the element name data type description and engineering units for the element You define the template at the program content level of the hierarchy You define values for the individual recipe elements through the Recipe Usage Table editor Build the Template To create a recipe begin by defining a template Try to think of all the possible setpoints that you may need and include them in your list Figure 1 11 shows the setpoints for the laundry example and their corresponding entries in a template Enter setpoints Operational Setpoints into the template gt Recipe Template Element Type Description Eng Units Temperature setpoint 1 Hot Warm Cold Tmp_sp1 Temp SP 1 Celsius Temperature setpoint 2 Hot Warm Cold Tmp_sp2 Temp SP 2 Celsius Temperature setpoint 3 Hot Warm Cold Tmp_sp3 Temp SP 3 Celsius Fill level 1 High Medium Low Fill_lev4 Fill level 1 Gallons Fill level 2 High Medium Low Fill_lev2 Fill level 2 Gallons Wash agitate time 1 Average Extra long Wsh_agi_tim1 Wash agitate time 2 Average Extra long Wsh_agi_tim2 Rinse agitate time 1 Average Extra long Rns_agi_tim1 Rinse agitate time 2 Average Extra long Rns_agi_tim2 Wash agitate time 1 Minutes Wash agitate time 42 Minutes Rinse agitate time 1 Minutes Rinse agitate time 2 Minutes
51. to false For the laundry example the word R_fill means latch the strt_fill command Create a recipe within the main unit of the process This will be the Sequence Working Recipe the recipe that contains the current recipe element values when the process is active Assign the working recipe a short name e g SWR for Sequence Working Recipe and associate it with the template Sequence Figure 1 19 shows the step action values for the laundry example Remember that the recipe values must be declared integer constants because APT only accepts text in recipe value fields when the text is the name of an integer constant Recipe Values Value Units Element Name Description Set_wash Step_1 First step R_fill Step_2 Second step R_soap Step_3 Third step Wait_soap Step _4 Fourth step Wait_fill Step_5 Fifth step R_agit Step_6 Sixth step Wait_agit Step_7 Seventh step R_drain Step_8 Eighth step Wait_drain Ninth step Figure 1 19 Example Sequence Recipe SIMATIC APT Applications Manual Approach to APT Program Design 1 41 Create the Code Objective Control Logic continued Create the Permanent Main SFC At this point it is time to create the SFC that will be the Main SFC for the unit The Main SFC controls the startup of the Procedure Activator SFC Phases and another SFC to be created later as a part of Objective Control that will act as a scheduler for the operational SFCs Another SFC that the Main SFC can control and which
52. to automatic T1 True SFC Phases True False Inform operator process ready to start Op_strt true Op_Strt false Load the working recipes SFC Download True SFC Batch True Figure 1 20 Example Main SFC Create the The sequence array is essentially a sequential data table A table pointer Sequence Array with a PTR extension can be advanced to read the next data point or reset to move to the beginning of the data table The table IOUT extension is loaded with the current data point after an advance command The table EMPTY extension is true when the pointer reaches the end of the table The sequence array has these functions e Hold the values of the working sequence recipe SWR Determine when to set the start command for operational SFCs e Determine when to wait for done responses from the operational SFCs Set the size of the sequence array to the same number of elements in the sequence recipe SIMATIC APT Applications Manual Approach to APT Program Design 1 43 Create the Code Objective Control Logic continued Create the Procedure Manager SFC The procedure manager operates as a graphical while loop which is initiated by the operator and provides these services Advance the pointer through the sequence array move data into the sequence array from the sequence recipe and reset the pointer
53. 2100220 VALUE V 232110020 A 6 Defining a Variable s Address SIMATIC APT Applications Manual Table A 1 INSTALL TAG File Example for TISTAR Release 1 x and 2 x continued temperature control DEADBAND 0 1 SP V 13 1100 2 40 STATUS LSTATUS 1110220 MODE LMODE 1100020 L RANGE LPVL 11 21 0 2 40 H_RANGE LPVH 1 1 2 1 0 2 212 PV LPV 111022 40 ROC_ALM V 255101021 L DEV V 2531010205 H_DEV V 251 1 0 1 0 2 2 5 LL ALM V 2491010250 L ALM V 2471010260 H_ALM V 245 101 0 2 180 HH_ALM V 243 10 1 0 2 205 RATE V 241101020 RESET V 239101024 GAIN V 2371010210 OUT V 15110020 P temperature control S V DEADBAND OH ON spvts1i1roozwm ON stATUSISTATUS1110220_ N MODE IMODE 1100020 000 N GRANGE LPVL11210240 N HRANGELPVH112102212 ON Pvirviiriozzs PON rocAmvesiotoz4 gt PON LbEvves1otoz0os PON HbEvvesiiorozs PON amv 291010250 PON tAmveiorozso PON HaAmvesioto2z1so0 PON Hhamves1iorozes PON RAarEvemiorozoo N RESET v 239101024 ON cAwvesziotozto PON ur 544002000 A A SIMATIC APT Applications Manual Defining a Variable s Address A 7 Determining a Variable s Address continued INSTALL TAG File First Line The first line of the file starts with a S identifier and contains the number of tags in the file and the name of the TISTAR secondary Table A 1 INSTALL TAG File Second Line The second line of the file starts with a T identifie
54. 5 C 16 C 17 C 18 C 19 C 20 C 21 C 22 C 23 CFCs Reflect Control Strategies 0 cee tenet eee eae 1 22 Uses for the NRDY Extension 0 cece teens 1 27 Washer Example I O o oooccoooccccccccc e nee tenet eee 2 6 Cooker Example W O coccion A la dda un dae ae eee 2 13 Heat Exchanger Example I O 000 cece cece ene es 2 18 How APT I O Types Map to S5 1 6 anaana aaea 6 11 OSX lag TYPES icine al tides wot ele e Diane ac nde Sew eile 7 5 Objects Used as Special Configuration Tools for OSX 0 cece ees 7 6 RBE Memory Requirements for Series 505 Controllers 000c cece eee eee eee 7 13 INSTALL TAG File Example for TISTAR Release 1 x and 2 x 0 00 c cee eee A 6 TISTAR Tag TYPES sretan dead ee eed ee a ek eden hae edad A 8 Tag Type Attribute Identifiers 0 0 nett nes A 8 Identifiers for Tag Types 00 eect t ne eee A 15 Identifiers for Attributes Of Tags 2 eect tenet neen eee A 15 PCS OSX Tag TYPES ass nens ah aces Reed cae dan ea ae a aoe Re eee a A 16 Unit Tag Types and Extensions 00 cece tenet e eee C 4 Batch Unit Tag Attributes 2 0 teen teens C 5 VAVO india daa C 6 CYIINGCSic as ore ic A Ad ee wd ee C 6 MOTOS tasca ii a eae ea ee ue eae ea ee uae es pein eee ea Pee ee C 6 POSO so bascimee rane hag taker ee A tA Ree a RAR A C 7 Stopwatch TiIMEF 22202 cata drapes Aelia dee eee eens Gaia erage ee C 7 APT Tag Correlation with OSx MTR1 Attribute
55. 60 cceee eee ee eee eee e eens Recipe HINS uote tad Avoid Using Boolean Variables as Recipe Elements 0 00 cece eee eee ees Hints for Using Debug 20 cece cece eee cence eee eee eee eee eee eeneees A awe Rib ad aoa dees hidebeaadaan hang Keene aon ha ale Miscellaneous Hints 2 000 c cece eee eee eee eee eee eee eee eeeeneees Guidelines for More Efficient Use of APT 0 0 ccc cee tne eens Avoid Overuse of Timers in SFCS 0 0 nett nent nee nnes Control Relay Allocation for Series 505 Controllers 0 0 0 cc cece ene o Using Commands Flags and Extensions 00 cece eee eee eens Group the Interlock Functions 0 0c cece o Programming Safe State SFCs 000 cece tenet eee eens Program Download Redundancy Constraints 00 cee eee eee If You Need More L Memory or Faster RLL Execution for Series 505 Controllers If You Need Faster STL Execution for S5 Controllers 00 cece eee eee Program Recovery from Controller Power LOSS 0000 ee cece eee eee eens Configuring DEVICES eisioes Caren dt ieee ew ee tate ieee terse been dees Configuring Simple Devices Using Pseudo Devices 00 cece nnn e tent t eens Table and V O HINIS 2i 2tes 0c c8iehees Sede ey pete Oedhends elie ee cee eke Working im Tables serite pao Dec idea bine beware d baw ghia dha ake dohaw abe Configuring Unlisted I O Modules for Series 505
56. 9 OSX HINIS accio toda ttienateeaded a a a 3 10 Relating APT and the Non OSx Operator Interface Database 3 11 Recommendations to the CVU1000 10000 User SIMATIC APT Applications Manual Chapter 3 Programming Hints Programming Hints 3 1 3 1 Organization of APT Logic Understand the When APT generates Relay Ladder Logic RLL for Series 505 or Statement Logic Structure List STL for S5 the logic sequence follows the organization shown in Figure 3 1 Be aware of this logic sequence when you design your program code to ensure that execution occurs when you expect it Address 1 System Logic APT Usage Interlock Logic High Priority Interlocks SFC Control SFC Transitions SFC Steps Flags Device Logic CFB Activation Logic CFB Math Logic Interlock Logic Low Priority Interlocks End of Scan APT Generated RLL or STL subroutines Figure 3 1 Organization of APT Logic in RLL or STL 3 2 Programming Hints SIMATIC APT Applications Manual 3 2 Math Hints Avoid Making Same You can improve performance in the controller by not testing a condition Comparison Twice repeatedly Test the condition once and assign the condition to a boolean entity then test the boolean entity Figure 3 2 Do This Not This B l 1 If I 1 Then If B Then ses wee Endif Endif If I 1 Then If B Then i wid Endif Endif Figure 3 2 Example of Reducing Math Comparisons Use Boolean Logic In RLL and
57. A Exactly what are the boundaries to your portion of the Kitchen Garage an process Utility E Washer Dryer BR BR Equipment areas Identify the major areas to be included in the design As you determine these areas weighing systems blenders packaging systems boilers etc you are also partitioning the process into more manageable units Equipment areas represent major processing equipment not operational tasks such as Clean in Place CIP The CIP often includes multiple equipment areas and should be viewed as an operational mode Dryer unit Washer unit 1 4 Approach to APT Program Design SIMATIC APT Applications Manual Clean clothes in less than 1 hour Manual draining not Y A required Push button operation Automated transfer to dryer Add water soap i othes in AN Agitate oy A Ca 1 1 y 200 J tay Al AMAN Clothes out SIMATIC APT Applications Manual Goals Identify the goals of the control system e You want to design an efficient and effective means of producing a product The process needs to produce a variety of products e The design solution must be flexible e The operator must be able to advance to the next process step easily e The operator must be able to abort a batch Model Develop and maintain an internal operatio
58. D Valve Types Valve Types PDD PDD PDD PDD PDD PDD PDD PDD PDD PDD PDD PDD PMD PMD PMD PMD PMD PMD PMD PMD PMD PMD PMD PMD CSD CSD CSD CSD CSD CSD CSD CSD CSD CSD CSD PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 PS1 2 Stopwatch Commands and Extensions Read only Boolean RUNNG HOLD MAXC TOUT Read Write Boolean Read only Integer Read only Real Read Write Integer Read Write Real B 2 CUR PSET Extensions Fixed by the Compile CUD CUD CUD CUD CUD CUD CUD CUD CUD CUD CUD PUD PUD PUD PUD PUD PUD PUD PUD PUD PUD PUD PUD PUD PUD Standard Blocks Analog Alarm Extensions Read only Boolean Read only Integer Read only Real DSABL INHHA INHA INLA INLLA INYDA INODA INRCA INBTA OVRUN Read Write Boolean Read Write Integer Read Write Real ENABL NRDY PID Extensions Read only Boolean Read only Integer APV Read only Real IOUT Read Write Boolean Read Write Integer OUT Read Write Real NRDY AWS On Off Extensions Same as PID with following exceptions Read only Boolean Read only Integer HLIM LIM VH VL TIA UE 5 gt uO gt D lt XOFE o gt Read only Real minus IOUT SIMATIC APT Applications Manual Advanced Blocks Dead Time Compensator Extensions Sam
59. DOS path environment includes the path to the APT executables directory For example if APT is installed at D APT enter the following command PATH If D APT is not included in the list output by PATH add it by entering the following command PATH PATH D APT If you are loading FOOD545N from the CD enter the following command substituting your diskette drive for E and your disk drive containing the APT database for D E DISK8 LOADDEMO E DISK8 FOOD545N D If you are loading FOOD545N from diskette enter the following command substituting your diskette drive for A and your disk drive containing the APT database for D A LOADDEMO A FOOD545N D Program Descriptions 2 7 Examining the Cooker Example continued 2 8 The APT database is typically on the drive where you installed the APT software unless you selected the Configure Directories option during installation or reconfigured your system at a later time If you have configured APT so that the APT software is installed on multiple drives and or in non standard directories then you must ensure that the environment variables APT DB and APT COMMON exist and are assigned appropriate values See page 1 17 for more information If these environment variables are properly set and you are loading from CD drive G enter the following command G DISK8 LOADDEMO G DISK8 FOOD545N If you are loading from diskette drive B enter the follow
60. DX20 DWO PROC FLAG Cyclic DX Figure 6 5 Analysis of DBs DXs for COM 155H Figure 6 5 shows that DB5 and DB6 need to be entered into the Cyclic DB table and that DX5 DX11 and DX20 need to be entered into the Cyclic DX table DB7 is used to program an interrupt OB and is also used in the cyclic program since it is shared by both interrupt and cyclic it must be placed in the Interrupt DB section See the section entitled Initializing Activation of the Standby in the S5 155H Programmable Controller CPU948R Manual for information on how to use TRAFDAT to enter these DBs and DXs SIMATIC APT Applications Manual Redundant Configuration for 5 6 9 6 5 Configuring Expansion Units from COM 155H Configuring APT does not contain any information about which expansion units are Expansion Units connected to the controller You need to enter your expansion units in VO 314 COM 155H by using I O 314 To configure I O 314 see the section entitled Initializing the I O Areas in the S5 155H Programmable Controller CPU948R Manual for more information 6 10 Redundant Configuration for 5 SIMATIC APT Applications Manual 6 6 Configuring I O from COM 155H IOCONF The 155H redundant system does not operate properly until you configure every I O point and channel using IOCONF from within COM 155H ACAUTION 7 You must specify all I O points and channels in a redundant system If you do not specify all of your I O points
61. Example P amp ID 000 c cc o 2 12 2 3 Heat Exchanger Example P amp ID 0 cece ent e nee 2 17 3 1 Organization of APT Logic in RLL or STL 1 teas 3 2 3 2 Example of Reducing Math Comparisons 0 c cece eee eee 3 3 3 3 Use Boolean Logic for Speed 0 0 ccc ananuna annen 3 3 3 4 Logic Differences between If Then and Boolean Logic 00 c cece eee eee 3 3 3 5 Write Code Clearly 0 cece eee n eee eee eee 3 4 3 6 Use Parentheses in Math 0 000 cece eee eee eens 3 4 3 7 Indent Math Code 0 c cece tenet e nee tenet eee 3 4 3 8 Use Event Math Blocks to Create Cyclic Events 000 2 0 cece cence ees 3 5 3 9 Calculation Requiring SF Program 00 cece eee eee tenes 3 6 3 10 Consolidate CFB Math 0 ccc nett eee e eae 3 7 3 11 Status Word 162 sa saates vs eataa ianed aaan a a a ala a ee 3 10 3 12 Consolidate Math Functions 00 ccc tenet eee 3 12 3 13 Use a Timer More than Once 0 0 c ccc tenet eee eae 3 16 Contents ix List of Figures continued 3 14 Example of Interlock Logic 0 eens 3 18 3 15 Example of a Pseudo Device 0 eee 3 24 5 1 APT TUTSIM USR Block a oia aa anai irna cc eect a aa ete ene eee 5 5 5 2 TUTSIM USR File Format 00600 c cece tenet eens 5 6 5 3 Example TUTSIM USR File 0 000 eee e eee ene 5 7 5 4 Example TUTSIM Program and TUTSIM USR File
62. FCs SFC 2 Subordinate SFCs Provide Procedural Control Figure 1 17 Relationship of the Procedure Activator to Procedural SFCs When you finish the code for the procedure activator SFC exit and validate the SFC Correct any errors and then compile the program and test it with the APT Debug Utility SIMATIC APT Applications Manual Approach to APT Program Design 1 39 1 12 Create the Code Objective Control Logic Objective Control ai ne Finish the Level 2 control by writing the code for objective cold weef knits control In this you are imposing upon the structural control a S ho araid cottons flexible execution pattern The execution pattern is defined by l j f a data set that is loaded from a sequence recipe The sequence recipe controls the start commands for the operational SFCs and defines when to test their done flags _ Wan Implementation of objective control comprises four tasks e Build a sequence recipe and template e Create the permanent Main SFC e Create a sequence array to hold the values contained in the sequence recipe e Create the procedure manager SFC Build the Sequence The sequence recipe defines the execution order of the various operational Recipe Template SFCs The recipe may call for the multiple execution by certain SFCs and not call some SFCs at all Note that if multiple executions are needed then you
63. INO EI AA ar JAN INPUT neg SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 27 CFB Extensions continued Other Blocks The OSx types for the anti reset windup scale and correlated lookup table block APT extensions are listed in Table C 31 through Table C 34 Table C 31 Anti Reset Windup Constraint Type do ENABL Block control bit HLIM High constraint Tm Table C 32 Anti Reset Windup Select Type Oo e o Table C 33 Scale MISCO EI MC OUTPUT EB CB Table C 34 Correlated Lookup Table ES CET OUTPUT Coat a BT OUTPUT imieger OO o O j C 28 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Selector Blocks The OSx type for each selector block APT extension is listed in Table C 35 through Table C 40 Table C 35 Average Selector do ENABL Block control bit DAINESE ECC ANECCCETT calc Series 505 STAT Number of inputs used ivar S5 OUTPUT a POLA INICIO EA INEA ale ms PO Table C 36 High and Low Selector Blocks Cao E AN INIESTA EGO NECE OUTPUT eae a IN OS IAN CON ESC INS INICIAN ECO IN A ENABIE pr a NE Table C 37 Inswitch Selector o ea l pos cedinpa OUTPUT e ROTA e IRPOS Peale IRIS Hale NP SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 29 CFB Extensions continued Table C 38 Median Selector Cao EG MEL MECA EG NECE OUTPUT epa ele nN E AA Table C 39 Outswitch
64. L ACCUM1 NTEGER FLOW_1 TEGER FLOW_2 TEGER FLOW_C TEGER EXCEP_CNT TEGER A_RATE EAL TOTALIZ NTEGER STOP_ALL BOOLEAN GLOBTBL C_TEMP1 TEGER U1 C_TEMP2 TEGER U2 C_TEMP43 TEGER U6 VLV_1_OLS IS IN Ut VLV_1_CLS S IN U1 VLV_2 OLS IS IN U2 VLV_2 CLS SIN U2 INTRLK1 SIN Ut REAC1_TEMP REAC1_VOL REAC1 PRES TOTALIZE 1 THERM1 VLV1_OPEN VLV1_CLOSE VLV2 OPEN VLV2 CLOSE SHUTI WORD IN OUT WORD IN OUT WORD IN OUT WORD IN OUT WORD IN OUT DIS OUT DIS OUT DIS OUT DIS OUT DIS OUT U3 U3 U3 GLOBTBL GLOBTBL U1 U1 U2 U2 U3 Figure 6 2 Analysis of DBs DXs for COM 155H Once you have a hard copy of the address report you are ready to invoke COM 155H and define your operating system parameters SIMATIC APT Applications Manual Redundant Configuration for 5 6 5 6 3 Configuring Operating System Parameters from COM 155H Operating System To configure your SYSTEM parameters you must first invoke COM 155H SYSTEM from STEP 5 Once you are in COM 155H go to the Initialize Operating Parameters System screen The operating system defaults that are used to program DX1 are shown in Figure 6 3 Initialize Operating System COM 155H PEC16 Initializing the H operating system No of test slices n 2ms H error DB number RAM DB for variable data H system flag word Time stamp F doubleword Standard discrepancy time Readback delay IR DI byte available Behavior followin
65. MS GA AC L_RANGE gt E BEER zy iT gt gt gt z z E E E oO a o gt lt Zz gt E E Hb A o 2 Zz ji ER Hc VALUE STATUS CHANGE Figure A 3 INSTALL TAG File Spreadsheet Example for PCS 3 x and OSx 4 x A 12 Defining a Variable s Address SIMATIC APT Applications Manual os i piers E e COMMAND ma a IE EA E A ea EN EA OS TOO ELO RE PEO E COMMAND ee GA E ooo aa STATUS 1 E IA CIC O O 0 O E Ea COMMAND AAA A S CE al A AA AE A AT T To UE E E FEA ew S ee ee ee ME ppp ep l a EN PO _ 4 E met 1 _ Ei El MO IA E CA D IS II IS SS E E IS pepe pipi eej A A S A IS E E fo ea EC E O RI IS A a pe e Ec 0 O A IE SS A E IS MR E ACC Cc 0 O II IS SS E IS swo e Ec S IS A IS ES A A MO CIO ACC E 0 O A IS SS A E E AC O AC 0 CC US O O IO IS A II PA E AAA AEREA Pe E E a AE ALA EA AAA Figure A 3 INSTALL TAG File Spreadsheet Example for PCS 3 x and OSx 4 x continued E e O SIMATIC APT Applications Manual Defining a Variable s Address A 13 Determining a Variable s Address continued An Analysis of the Consider the install tag file example shown in Figure A 2 and Figure A 3 INSTALL TAG File There are 12 process tags one recipe and one process group The recipe Examples for RT1 is an area tag with eight components The process group is called PCS OSx Clean Tank The two tags
66. Manual Figure 7 1 shows the install tag file for a 575 which is a Series 505 controller For an S5 controller the Memory column displays S5 memory types for example DB3 DW1 for data word 1 in data block 3 Control Tag Process Manual Twenty AE A En ou ka ia vale E z z Ce CC IR es O CI A A E MO IE AAA o HE SOM AE AS RB EE TF lt rd gt gt E EE E E L_DEV V 25 E E A gt E o LL_ALM v 21 E E V 19 eS S oo AA AAA ESE a oo AE So ee o E E ie y V 17 E T E e E V 13 oO a o L_ALM EME SAS a EE z 3 m Q 00 o EE EE EE RESET V 11 DA O ej amp a4 at wo o E E 7 a EA AAA AA ME STATUS C22 of H HRANGE E A RANGE VALUE Pe a II A CI Figure 7 1 Portion of an Example INSTALL TAG File for PCS 3 x SIMATIC APT Applications Manual APT and the OSx Operator Interface 7 3 Using APT to Configure an OSx Database continued The following procedure summarizes the three steps required to place APT object data into the OSx compatible database Steps 1 and 2 ensure that controller addresses remain constant for the operator interface 1 Mark objects for translation Section 7 2 In this step you select objects tags that are to be used by the operator interface and that must have unchanging controller addresses 2 Compile the program Section 7 3 This step builds the executable code
67. NOTE Before you read the information that follows you need to become familiar with the TUTSIM programming language The APT utilities that were written for the TUTSIM package are only for Series 505 controllers 5 4 Dynamic Program Simulation SIMATIC APT Applications Manual APT TUTSIM Block The APT utility usrblk exe operates in conjunction with the TUTSIM USR block to create a customized APT block for communication with a Series 505 controller usrblk exe must be located in the same directory on your computer as the TUTSIM files The graphical representation of the APT TUTSIM block is shown in Figure 5 1 Figure 5 1 APT TUTSIM USR Block Parameters The APT TUTSIM USR block has three parameters e Parameter 1 indicates type of communication 0 read from the controller 1 write to the controller 2 forced write to controller e Parameter 2 indicates the communication path number used in the TUTSIM USR file described on page 5 6 0 the default APT environment communication Parameter 3 indicates the initial value to be used in the block Inputs The APT TUTSIM USR block has two inputs e Input 1 enables disables the block 0 no read writes are done 1 a read write to controller is done on a 0 to 1 transition 2 aread write to the controller occurs on every TUTSIM iteration Input 2 contains a value for a write operation SIMATIC APT Applications Manual Dynamic Program Simulation 5 5 APT
68. RBE definitions in the controller as demand scan tags The system scans these tags continually at the Event Scan Period Refer to the OSx System Architecture chapter in the SIMATIC PCS 7 OSx System Administration Manual for more information about RBE and demand scan 7 12 APT and the OSx Operator Interface SIMATIC APT Applications Manual After compiling you can view the compile report that contains OSx Tag Type Usage in Phase 7 Translate File Builds or create a tag report from the object file reports The tag report lists the OSx tag types and information about the attributes The report is not as detailed as the install tag file but you can view it in APT These reports give you the total number of tags for each tag type that you can use in your calculations for memory requirements Table 7 3 RBE Memory Requirements for Series 505 Controllers Ta Controller Memory Ta Controller Memory g Typ IA Era Bytes g Typ O i i Bytes Bytes SIMATIC APT Applications Manual APT and the OSx Operator Interface 7 13 7 4 Translating Tags The last phase of setting up the connections to the operator interface involves tag translation In this phase tag data is moved into a formatted database that can be used by the operator interface For a non OSx operator interface this is a manual procedure Refer to Section 3 9 for recommendations about how to proceed For OSx tag translation is an automated procedure You can choose from five pr
69. Reverse RMx MREV 1 Stop RMx MSTRT 0 RMx MREV 0 Timeout_1 P C Memory Location X 0 1 sec TCP Not implemented in RMx RTCP OSx status word Timeout_2 3 P C Memory Location Integer X 0 1 sec TCP Not implemented in RMx STCP OSx status word 1 Refer to Figure C 2 2 RMx represents RM1 or RM2 3 For OSx the Timeout_1 and Timeout_2 attributes are reflected in the status word via the combination of the running and stopped bits as shown below RMTR Running Stopped State 1 0 Running 0 1 Stopped 0 0 Travel 1 1 Failed SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 11 Translating APT Objects to OSx PCS and TISTAR continued Translating Tags The OSx MTR2 corresponds to the APT BV1 and BV2 valve types PS1 and for OSx PCS MTR2 PS2 press types and TS1 and TS2 motor types Figure C 3 shows the MTR2 status word OSx Status Set in OSx Running Interlocked A Not Stopped stopped Mode Ovrd low Manual set In use Alrm UnAck Not Travel running Attribute Setpoint Ovrd high Failed Active Bit Positions APT OVRDL Extensions LOCKD OVRDH TRVL FTS DSBLD MHIGH FAILD NRDY MSTRT Figure C 3 APT Tag Correlation with OSx MTR2 Status Word C 12 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Table C 10 shows the OSx MTR2 status correlation with APT extensions Table C 10 OSx MTR2 Status Correlation wi
70. SFC templates test simulation Process control requirements 1 10 Process groups Pcs 7 7 Process partitions 1 7 Process perspective defined 1 2 Process perspective development steps 1 4 Process tasks 1 8 Process variable PV valid S5 values 4 9 Program compiling 7 9 7 12 downloaded modifying 4 2 testing 5 2 Programming hints 1 50 Q Queue priority 3 8 R RBE memory needed for Series 505 7 13 reserving memory Recipe data dictionar template 1 32 Recipe hints Recipes translated extensions Redundant S5 system operator interface database configuring 6 2 defining I O Report by exception See RBE a cw APT address required for COM 155H 6 4 RLL execution hints organization of logic S Safe state SFC hints Sequence recipe SFC permanent main SFC code procedure manager SFC code subordinate SFC code subordinate SFC templates temporary main SFC code 1 38 temporary main SFC templates SFPGM loop analog alarm hints loop associated math 3 12 queue priority task overruns Simulation program 5 2 Stopwatch translated to PCS C 4 C 6 translated to TISTAR C 4 C 6 Structural control defined temporary main SFC code 1 38 Symbol address report controller address A 3 SYSTEM 55 operating system configuring for redundancy Index 5 1 Table hints configuring HSPI and HSC configuring PEERLINK 3 unliste
71. SIEMENS SIMATIC APT Applications Manual Order Number PPX APT 8103 8 Text Assembly Number 2592843 0008 Eighth Edition A DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury DANGER is limited to the most extreme situations a WARNING WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury and or property damage ACAUTION CAUTION used with a safety alert symbol indicates a potentially hazardous situ ation that if not avoided could result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation that if not avoided could result in property damage NOTICE NOTICE indicates a potential situation that if not avoided could result in an undesirable result or state Copyright 2001 by Siemens Energy amp Automation Inc All Rights Reserved Printed in USA Reproduction transmission or use of this document or its contents is not permitted without express consent of Siemens Energy amp Automation Inc All rights including rights created by patent grant or registration of a utility model or design are reserved Since Siemens Energy amp Automation Inc does not possess full access to data concerning all of the uses and applications of customer s products we do not assume responsibility either for
72. SIMATIC APT Applications Manual Animating Non Standard Symbols Validation Failure Often there are times when you need symbols with forms and animations that are not standard in the OSx library e A control valve symbol animates the bonnet of the valve to red manual or green automatic indicating the mode of the associated PID loop e Acontrol valve symbol animates the body of the valve to red closed or green not closed indicating whether the control valve is opened or not To achieve these animations you can create a single integer and manipulate it from the associated math of the corresponding PID loop to provide the status information for OSx In this case two tags may be needed for each PID loop created in APT If the tag installation procedure fails the problem is often due to an initial value that falls outside the H RANGE and L_ RANGE values For a temporary correction you can edit the INSTALL TAG file and either change the initial value or the high and low ranges Refer to Appendix A of this manual for a description of the INSTALL TAG file Unless you make the correction in the APT program and then recompile however the error will continue to occur during installation SIMATIC APT Applications Manual Programming Hints 3 29 3 10 Relating APT and the Non OSx Operator Interface Database Chapter 7 describes the link between the operator interface and the application program The creation of this link involves fou
73. T database for D A LOADDEMO A WASH_DEM D NOTE You must have at least 539K free conventional memory to load this demo program 2 2 Program Descriptions SIMATIC APT Applications Manual The APT database is typically on the drive where you installed the APT software unless you selected the Configure Directories option during installation or reconfigured your system at a later time If you have configured APT so that the APT software is installed on multiple drives and or in non standard directories then you must ensure that the environment variables APT DB and APT COMMON exist and are assigned appropriate values See page 1 17 for more information If these environment variables are properly set and you are loading from CD drive G enter the following command G DISK8 LOADDEMO G DISK8 WASH_ DEM If you are loading from diskette drive B enter the following command B LOADDEMO B WASH_ DEM NOTE The WASH DEM example program accesses direct memory addresses to simulate an actual process For this reason warnings are generated the first time that you compile the program On subsequent compiles no warnings occur if you do not choose a forced compile SIMATIC APT Applications Manual Program Descriptions 2 3 Examining the Washer Example continued Process The process consists of a tub with level and temperature sensors and has Description for the the following components Washer Hot and cold water valve
74. Turn on off the start commands to the operational SFCs Provide for bad data in the recipe In the laundry example the SFC called Batch acts as the procedure manager The steps and transitions are shown in Figure 1 21 and are described below Step S1 Reset seq_selector resets the sequence selector The sequence selector pointer contains zero and Select IOUT will be unaffected by the reset Transition T1 is always true because there is no need to wait Step S2 SFC mode_ctrl calls the SFC that controls the mode and the sequence advance Transition T2 Seq_selector IOUT set_wash is true when the current recipe points to the wash operation Step S3 Wash_op wash loads wash_op with the wash variable Transition T3 is always true Transition T4 Seq_selector IOUT end_wash OR seq_selector empty detects the end of the batch Step S4 Enable dat_reset enables a CFB that clears all the batch data before allowing another batch to run Transition T5 Seq_selector IOUT set_rinse is true when the current recipe points to the rinse operation Step S5 Wash_op rinse loads wash_op with the rinse variable Transition T6 is always true Transition T7 Seq_selector IOUT r_fill is true when the current recipe points to the Fill SFC Step S6 Latch strt_fill sets the request to fill flag to true Transition T8 is always true Transition T9 Seq_selector IOUT wait_fill AND strt_fill is true when the tank has started t
75. UE COMMAND SETPOINT OVERRIDE MODE_CMMD L_RANGE H_RANGE MODE PV SP OUT ROC_ALM L DEV H_DEV etc For each attribute eight types of data are stored The format for a line with an N identifier is shown in Figure A 1 One Line in the INSTALL TAG File Identifier Attribute Attribute Data n arr MEM_TYP MEM_LOC LOC SCAN UPLD DNLD 20 IN_VAL Initial value 20 or not Download value to controller initially Upload value from controller initially Network scan or no scan Number of locations device STATUS has 10 or more C locations included Memory location Memory type V C V Memory LPVL etc 0 No 1 Yes 2 N A Figure A 1 Format for an N Line in the INSTALL TAG File for TISTAR 1 x and 2 x Following the first tag information for the second tag is listed The first line for the second tag contains a T identifier and contains the tag type and name of the second tag Following the attribute information for the second tag information for subsequent tags is listed INSTALL TAG File Last Line The last line of the file starts with an E identifier shown in Table A 1 SIMATIC APT Applications Manual Defining a Variable s Address A 9 Determining a Variable s Address continued Reading the INSTALL TAG File for PCS Rel 3 x and OSx Rel 4 x During a program compile operation APT stores tag information in an ASCII file install
76. V LEVI rrrrrr ROC rrr rrrrort rrrroro rrerrrrh All nor La rrrrorr HH_ALM V v 1 rrrorrRATE V reo RESET V reer GAL rrrrarrO0UT V 3 3975 DO TLOOP NRDY rrrrrrr y COMMAND C22 N 0 rrrrrrr STATUS C22 10 975 IVAR RT1 NUM_RUN number of batches Oxffffffff N rerrrrrr E RANGE 11132767 rrrrrrrl_ RANGE pp yr rerrrrr VALUE VS 1 N N 5 rorrrrr STATUS V5 1 N N 5 1575 IVAR RT1 FILL _SP level in tank Oxffffffff N rerrrrrr H RANGE 111132767 rrorrrrrL_RANGE 1rr0 rorrrrr VALUE V6 1 N N 50 rrrrrrr STATUS V6 1 N N 50 975 CALC RT1 TEMP temp of tank Oxffffffff N rorrrr CHANGE 777111 rerrrr E RANGE 111132767 rrrrrrh RANGE 71151 rrrrr STATUS 111155 nor VALUE V 7 1 Y N 220 DO GYLCOL what is in tank Oxffffffff N Pre COMMAND C17 1 N N 1 1 STATUS C17 N DO TEG what is in tank Oxffffffff N 7 1 y COMMAND C18 1 N N 1 1 STATUS CIS DO OIL what is in nk OXffffffff N r r COMMAND C19 N 1 1 STATUS C19 1 DO AIR what is i nk Oxffffffff N r COMMAND C20 1 N 1 1 STATUS C20 1 DO WATER what is in tank Oxffffffff N IMAND C21 1 N 1 rrrrrrrr STATUS C21 1 N N 975 AREA RT1 recipe to test tistar tags 0Oxffffffff N rrrrrrrr SCALE_HIGH 1110 0 rrorrrrrr SCALE_LOW 0 0 rrrrrrrr SCALE_FACTOR 17 1 1 0 T 575 DO RT1 INUSE recipe to test tistar tags Oxffffffff N Arrrrrrrr COMMAND C23 2 N N 0 Arrrrrrrr STATUS C23 2 N N 0 R
77. _INFO you can enter up to 16 characters in BCH_REQ_INFO SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 5 Translating APT Objects to OSx PCS and TISTAR continued Devices When you translate devices to OSx APT automatically creates the associated extensions Table C 3 through Table C 7 list the devices and how they translate to OSx Table C 3 Valves Single or Nall Feedback Valve Single or Null Feedback Valve Dual Feedback Valve vlv2 Dual Feedback Valve Dual Feedback Vave 7 Table C 4 Cylinders 12 O CUD User defined Cylinder Table C 5 Motors MDN Non Reversible Motor Nos Reversible Motor Nos Reversible Motor Nos Reversible Motor Reversible Motor Reversible Motor User defined Motor Two Speed Motor Two Speed Motor C 6 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Table C 6 Presses Single or Nall Feedback Press Single or Nall Feedback Press Hand operated Press Dual Feedback Dual Feedback Press PD Dual Feedback Press Table C 7 Stopwatch Timer di RON Rann HOLD SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 7 Translating APT Objects to OSx PCS and TISTAR continued Correlating APT The information in this section provides bit by bit correspondence between Device Types with APT device types and OSx tag type attribute OSx PCS Attributes Translating Tags The OSx MTR1 corresponds to the APT MSN MSS
78. a particular step Any step can be cancelled during execution During a batch run the effect of cancelling a step is to advance the recipe to the next logical step SIMATIC APT Applications Manual Program Descriptions 2 9 Examining the Cooker Example continued Process Functions of the Cooker 2 10 The process makes product according to a product recipe that specifies the sequence of operations the quantities of materials and the processing time for a particular product The following operations are provided for all products Program Descriptions The operator initiates the process by selecting one of three strategies A Download a recipe from the operator console The recipe specifies the number of batches B A recipe stored in the controller is used as the active recipe The recipe contains the number of runs for a batch The operator can modify the number of runs before executing the recipe C The operator selects a campaign a series of runs that uses a collection of recipes stored internally The operator selects the recipes their order of execution and the number of times that they are executed When a run begins the weigh tank weighs an amount of material and then transfers the material to one of the cookers While the weigh tank weighs material water is added to the cooker The cooker heats up to a temperature which must be stable for two minutes SIMATIC APT Applications Manual SIMATIC APT Appli
79. ada cde da aa ge bb bees PEE DEE eee Add Sate Siat SFCS suicida does died Chad ed ae dd dd eda eed eal ee aie Send Additional Data to the Operator Interface Allow Operator to Cancel Operations 0 00 cece eee When You Create Code ccicoocco ir o a ew det dats data DUQQCSUONS arado ds A AA a What Can APT Do for Me cocococccocccc ee eee eee Chapter 2 Program Descriptions 0 002 cece eee eee eee 2 1 2 2 2 3 Examining the Washer Example 0 0eee cece eee eee eee e ene ee ne eeneeee Loading the Washer Example for Series 505 Controllers 0 0 cece eee eens Process Description for the Washer oocoooccccccoccc Process Functions of the Washer 02 ccc cece e tee ete tenes P amp ID for the Washer 0 0 ccc een en en ene tenet eee e eens Process I O forthe Washer acc ciciei cede dea ciencia da da dade dade Examining the Cooker Example 00 0 cee e cece cence eee eee ee eeeeeee Loading the Cooker Example for Series 505 ControllerS o ooooooooommomm o Process Description for the Cooker cece eee eee eee e eee eee Process Functions of the Cooker 0 0 c cece rannan annern nnana P amp ID for the Cooker 0 0 ccc ce eee ene n oaser anria Process I O for the Cooker 1 0 0 0 ccc ccc cette enn e ene n eee neaes Examining the Heat Exchanger Example 0 0eee cece cece een eeneeeneeee Loading the Heat
80. alysis of the process from the viewpoint of process automation In this phase your design team is attempting to understand and develop a systems view of the process A top down analysis looks at the process and attempts to answer these questions first 1 What are the major process steps involved in producing a product or family of products 2 What role does the process equipment play After the major process steps are identified analyze each of the major equipment areas and break them down into the essential processing steps involved Next break down each process step into its components Finally analyze the various components of each process step and look for possible further sub division In this step focus on the tasks that you need to do Do not be overly concerned with the details of how to do them 3 Doa bottom up implementation This is the step in which you address the details Bottom up implementation is the process of developing the code for the functional subsystems identified in the top down analysis phase starting at the lowest level in the hierarchy the I O subsystem These are the actual programming and configuration steps involved in program development These tasks range from assigning the symbolic names to equipment to configuring the operator interface and merging all aspects of the design control solution Develop the program incrementally and test it thoroughly at each stage of development Approach to APT
81. amming language that you can use to write an external simulation SIMATIC APT Applications Manual Dynamic Program Simulation 5 3 5 2 APT and the TUTSIM Dynamic Simulation Package Series 505 Availability APT includes two utility programs that enable you to use TUTSIM a commercially available dynamic simulation programming language TUTSIM is a high level language that simulates the functions of an analog computer on a personal computer This language consists of pre defined blocks that enable you to use simple math integral calculus Laplace functions thermodynamic equations logic functions etc to simulate field inputs to the controller One block SYC can be used to synchronize the TUTSIM simulation with the real time clock of the personal computer Another block USR allows you to incorporate C language code into the TUTSIM environment The two APT utility programs usrblk exe and usrapt exe in the apt subdirectory together with the TUTSIM USR block allow the TUTSIM simulation program to read and write controller addresses The following pages explain how to use these APT utility programs with TUTSIM for the purpose of testing your APT application program Additional information about TUTSIM and the software package itself can be obtained from TUTSIM Products at this address ACTUALity Corporation TUTSIM Software US Mail P O Box 640 Morgan Hill CA 95037 E mail tutsimpa aol com Phone 408 778 7773 FAX 408 778 8277
82. and channels in COM 155H when you are setting up your redundant system the standby unit does not come online Ensure that you have specified your I O in its entirety using IOCONF The address report that you generated from APT see Section 6 2 contains information on each I O point used within APT For every I O location APT stores the address and APT type word or discrete input or output APT does not attempt to keep up with the I O mode switch redundant etc You must define all points that are on the I O cards whether they are used in APT or not when you use IOCONF in COM 155H You also need to specify the I O mode based upon your hardware configuration Table 6 1 shows the correspondence between APT I O types and S5 I O types Table 6 1 How APT I O Types Map to S5 APT I O Type from Address Report I O Type from COM 155H IOCONF CPs and IPs are not configured within APT If your system is using them it is your responsibility to assure they are configured correctly See the section entitled Configuring the I O in the S5 155H Programmable Controller CPU948R Manual for more information about IOCONF If your controller is to be connected to OSx see the section entitled S5 155H Configuration in the SIMATIC PCS 7 OSx Interface to S5 Controllers User Manual for important configuration information SIMATIC APT Applications Manual Redundant Configuration for 5 6 11 Chapter 7 APT and the OSx Operator In
83. and stopped bits as shown below MTR1 Running Stopped State 0 Running 1 Stopped 0 Travel SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 9 Translating APT Objects to OSx PCS and TISTAR continued Translating Tags The OSx RMTR corresponds to the APT RM1 and RM2 motor types for OSx PCS RMTR Figure C 2 shows the RMTR status word OSx Status Set in OSx Running Interlocked pe aan Stopped Not Mode Setpoint a Ovrd reverse Manual set Not In use Direction Alrm UnAck running Travel Active Attribute Ovrd fwd Failed Bit Positions APT OVRDR Extensions LOCKD OVRDF TRVL FTS DSBLD MREV FAILD NRDY MSTRT Figure C 2 APT Tag Correlation with OSx RMTR Status Word C 10 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Table C 9 shows the APT extension correlation with OSx RMTR attributes Table C 9 APT Tag Correlation with OSx RMTR Attributes OSx Status Bit OSx Attribute OSx Command Form Data Data Read APT Extension 2 Written to Controller 1 from Controller Override P C Memory Location Forward RMx OVRDF 1 C of Length 2 Reverse RMx OVRDR 1 Both RMx OVRDF 1 RMx OVRDR 1 Neither RMx OVRDF 0 RMx OVRDR 0 Mode_Cmd P C Memory Location C of Length 2 Disable RMx DSBLD 1 Lock RMx LOCKD 1 Unlock RMx LOCKD 0 Setpoint PC Memory Location Forward RMx MSTRT 1 C of Length 2
84. cations Manual The cooker ramps the temperature to the cook setpoint The product cooks soaks while maintaining the temperature Water is added to the cooker to begin the cool down step At the end of the cool down step three minutes the operator is notified that the product is ready for transfer The operator initiates the procedure of pumping out the cooker If a change in product is made or if no more runs are specified the cooker is cleaned Water is added to the cooker which is then heated The tank agitator starts automatically whenever the tank level is greater than 20 of its maximum value The agitator shuts off if a low level occurs for more than one minute The pump out pump stops on a low level time out Programmed interlocks protect all tanks from overheating and overfilling Program Descriptions 2 11 Examining the Cooker Example continued P amp ID for the Figure 2 2 shows the P amp ID for the Cooker Example program Cooker Site 1 Production Line FEED_PMP FEED_VLV eigh w WS_DMP_VLV Unit 1 Weigh System C1_DVLV C2_DVLV C2_FEED_VLV C2_FEED_PMP m C2 AGITATOR C1_LEVEL C2_LEVEL lt D STM_VLV C2_DMP_VLV Unit 2 Cooker 1 Unit 3 Cooker 2 Figu
85. ce cette e eee eee Examining the Heat Exchanger Example 0 eees cece eee eee eeneeeneees Loading the Heat Exchanger Example for Series 505 Controllers Process Description for the Heat Exchanger cooocccccccoccccncc naaraana Process Functions of the Heat Exchanger cece eee eee eee eee nee P amp ID for the Heat Exchanger 0 0 ccc eee eet eee Process I O for the Heat Exchanger ccc cece eee e ete eee SIMATIC APT Applications Manual Program Descriptions 2 1 2 1 Examining the Washer Example Loading the To install WASH DEM follow these steps Washer Example for Series 505 1 Insert the APT software CD in your CD ROM drive or if you created Controllers diskettes from the CD insert DISK8 in your diskette drive 2 Ensure that the current DOS path environment includes the path to the APT executables directory For example if APT is installed at D APT enter the following command PATH If D APT is not included in the list output by PATH add it by entering the following command PATH PATH D APT 3 Ifyou are loading WASH DEM from the CD enter the following command substituting your diskette drive for E and your disk drive containing the APT database for D E DISK8 LOADDEMO E DISK8 WASH_DEM D If you are loading WASH DEM from diskette enter the following command substituting your diskette drive for A and your disk drive containing the AP
86. clic category because they are used by code that is called by OB1 The only DB DX used by APT that falls in the interrupt category is RBED100 You must determine the actual DB or DX used for RBED100 from the address report DB DXs that are used by an interrupt OB that you have programmed OB2 through OB18 fall into the interrupt category You are responsible for keeping track of all the DBs and DXs that are used in your interrupt OBs and for determining whether a given DB DX belongs to a cyclic OB or else to an interrupt OB If a DB or DX is shared by both interrupt and cyclic enter it only in the interrupt area NOTE All DBs and DXs in the address report must be entered in TRAFDAT 6 8 Redundant Configuration for 5 SIMATIC APT Applications Manual Figure 6 5 shows how to analyze an APT address report and how to determine whether a DB DX belongs in the cyclic table or the interrupt table Even though the address report enumerates all the data words within a given data block you need to make only one entry for the entire data block to indicate whether it is interrupt or cyclic Data from APT Address Report Analysis Address Symbol Name COM 155H Location DB5 D0 0 A_STRTA Cyclic DB DB5 D0 1 B_STRT1 DB5 DW10 TOTAL A DB5 DD30 A BIAS DB5 DW100 ACCUM1 DB6 DWO FLOW_1 Cyclic DB DB6 DW1 FLOW_2 DB7 DW1 FLOW_C DB7 DW3 EXCEP_CNT IRDB DB7 DD40 A_RATE DX5 DWO TOTALIZ Cyclic DX DX11 DDO Cyclic DX DX11 DD1 DX11 DW4 J
87. clude the extension The system displays the address assigned to the variable For example consider the symbol Tk1_a opnd with the controller address C88 in unit Tank_1 of a program called BLENDER Use the DC utility following the steps below 1 2 At the DOS prompt type DC and press At the menu prompt type 5 and press Type Blender and press Enter Type Tank_1 and press Enter Type Tk1_a opnd and press Enter Series 505 Controllers The system displays the message Resolved C88 S5 Controllers Enter Enter The system displays the message Resolved DB10 D6 0 A 4 Defining a Variable s Address SIMATIC APT Applications Manual Reading the During a program compile operation APT stores tag information in an INSTALL TAG File ASCII file install tag Although tailored for the TISTAR database the for TISTAR Release information can be used for any operator station package to determine the 1 x and 2 x controller address of a variable Series 505 The install tag file is located under the apt program program_name directory where program_name is the name of your APT program You can examine install tag by using any ASCII text editor An example of an install tag file for a Series 505 controller is shown in Table A 1 The S identifier informs TISTAR that the install tag file contains six tags and that they are to be insta
88. ctive Control Logic 00ccc cece ener eee 1 13 Create the Code Level 3 Control 00 0 cece eee eee eee eee 1 14 When You Create Code 0 2 ccc cece eee eee 1 15 What Can APT Do for Me SIMATIC APT Applications Manual Approach to APT Program Design 1 1 1 1 What This Chapter Presents This chapter discusses a method for designing a process control application program There are many ways to approach the problem The procedure summarized below is a proven method that leads to a well structured and easily maintained program The most important concept to remember is that a well designed control solution is structured and modular A well designed system is structured using an approach called top down analysis and is executed using a methodology called bottom up implementation The following general topics are discussed in this chapter 1 Develop a perspective for the process Examine the 13 process in its entirety and understand the equipment i I involved View the process as a system and understand the role of all the major processing components such as reactors distillation columns weighing systems mixers packaging 2 eae T N systems etc Identify equipment that is or may become a need to wash my clothes shared resource For example a weighing system can be shared by several mixers Determine whether or not you can follow a distributed approach or you need to u
89. customer product design or for any infringements of patents or rights of others which may result from our assistance MANUAL PUBLICATION HISTORY SIMATIC APT Applications Manual Order Manual Number PPX APT 8103 8 Refer to this history in all correspondence and or discussion about this manual Event Date Description Original Issue 07 91 Original Issue 2592843 0001 Second Edition 11 92 Second Edition 2592843 0002 Third Edition 02 94 Third Edition 2592843 0003 Fourth Edition 10 94 Fourth Edition 2592843 0004 Fifth Edition 05 95 Fifth Edition 2592843 0005 Sixth Edition 10 96 Sixth Edition 2592843 0006 Seventh Edition 12 98 Seventh Edition 2592843 0007 Eighth Edition 04 01 Eighth Edition 2592843 0008 LIST OF EFFECTIVE PAGES Pages Cover Copyright History Effective Pages ili xiv 1 1 1 53 2 1 2 18 3 1 3 31 4 1 4 9 5 1 5 9 6 1 6 11 7 1 7 14 A 1 A 16 B 1 B 6 C 1 C 32 Index 1 Index 6 Registration Description Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Eighth Edition Pages Description Trademarks and Copyrights SIMATIC and SINEC are registered trademarks and S5 and STEP are trademarks of Siemens AG 386 ATM APT PCS Peerlink Program Master 550
90. d I O modules TAG RPT controller address Tags controller address dc get address utilit A 4 4 install tag file A 5 A 10 identifiers and attributes A PCS example analysis A 14 PCS spreadsheet can iA PCS tag typ es A 16 marking symboladdress reports A 3 tag rpt file translated to 7 14 advanced blocks C 23 C 24 dynamic blocks C 25 limiter blocks math blocks other blocks C math blocks C 27 other blocks C 28 Task overruns 3 10 Tasks of a process 1 8 Test simulation 5 2 code 1 20 Testing I O image register option 1 21 Timer declaration table translated extensions Index 6 Timer hints 3 16 TISTAR attributes APT devices and C 8 C 10 C 12 C 15 C 17 entering alarm values 7 8 install tag file 7 2 A 5 translating tags advanced blocks C 23 C 24 C 25 dynamic blocks limiter blocks TISTAR hints array names non standard R object names recipe element names unit names validation failure Top down analysis defined 1 112 steps TRAFDAT configuration for rd da cyclic and interrupt DB DXs Translating memory types from APT to PCS Series 505 7 2 TUTSIM simulation package 5 4 U Unit translated extensions C 2 V Valve translated to PCS C 4 C 6 translated to TISTAR C 4 C 6 Customer Response We would like to know what you think about our user manuals so that we can se
91. d in the controller All other code can be viewed but the source and object code may differ Refer to the SIMATIC APT User Manual for more information about using Debug Programming Hints 3 15 Miscellaneous Hints continued Avoid Overuse of Timers in SFCs Control Relay Allocation for Series 505 Controllers 3 16 Programming Hints When you need to use a timer in two or more sequential steps of an SFC you usually can change the preset and reuse one timer repeatedly Figure 3 13 Unless you need multiple timers for parallel operations use this programming practice instead of declaring and using several timers Do This Not This T1 TCP 5 Delay T1 T1 TOUT T1 TOUT Delay T1 T1 TCP 10 Delay T1 T1 TOUT T2 TOUT Delay T2 Figure 3 13 Use a Timer More than Once NOTE You cannot use the same timer in two consecutive steps of an SFC Control relays numbered greater than 512 require more controller memory To conserve memory APT assigns reference numbers less than 512 to the most frequently used control relays If you reserve a large number of non retentive control relays some of the most frequently used control relays can be assigned reference numbers greater than 512 Release 6 0 of the 560T 565T 565P has additional RLL instructions that use 1024 non retentive control relays The control relays numbered from 56321 to 57344 are no longer ava
92. d math 3 12 parentheses 3 4 RLL SFPGM math 3 6 miscellaneous commands control relays L memory RLL execution 3 20 programming apela SFPGM loop analog alarm loop associated math 3 12 queue priority task overruns 3 10 Hints continued tables configuring HSPI and HSC configuring PEERLINK unlisted I O modules TISTAR array names 3 27 non standard seals 3 29 object names 3 26 recipe element names unit names validation failure T O addresses conserving memory 4 7 loop and analog alarms PCS tags C 19 point definition redundant S5 system 6 11 translated to PCS C 19 translated to TISTAR C 19 I O modules configuring HSPI and HSC configuring PEERLINK configuring unlisted modules layout T O types mapping APT to S Image register 1 21 Install tag file controller address A 5 A 10 identifiers and attributes PCS example analysis A 14 PCS spreadsheet example PCS tag types A 16 TISTAR L L memory hints 3 20 Layers process code implementation Level 1 control defined 1 12 Level 2 control defined objective control defined procedural control defined 1 12 structural control defined Level 3 control defined 1 13 LOADDEMO 2 2 Logic organization RLL 3 2 Loop process variable 4 9 M Math hints active continuous option 3 5 CFB math 3 7 comparisons 3 3 event math CFBs 3 5 inde
93. d testing as much of your code as possible on a stand alone 948R You save the time that would be required to reconfigure with COM 155H after each program download Follow this sequence 1 Define your 948R CPU in the APT Compiler Control File by selecting CPU948 2 Write your APT program and ensure that all code and I O operates correctly for a stand alone 948R 3 Configure your operating system parameters in COM 155H COM 155H writes to DX1 in the controller 4 Bring your second controller online as the standby If you are expanding or changing an existing process follow this sequence 1 Define your 948R CPU in the APT Compiler Control File by selecting CPU948 2 Configure your operating system parameters in COM 155H You must configure the I O at this point however you can incorporate your DB DXs later if you wish 3 Bring your second controller online as the standby 4 Make changes in APT and use incremental download to put the changes in the active controller 6 2 Redundant Configuration for 5 SIMATIC APT Applications Manual ACAUTION If you select the Clear P C before download option when you download your program the operating system parameters that you selected using COM 155H are removed from the controller If the operating system parameters are removed from the controller your redundant system does not function You must use COM 155H to transfer DX1 if you clear the operating system parame
94. ddress e APT symbol APT symbol name for the block If the symbol name is not defined TUTSIM uses the absolute address The utility aptusr exe can update the address from the latest APT compile Use the PROGRAM and UNIT commands when necessary to change the scoping of the symbol Figure 5 3 shows a sample tutsim usr file In this example TUTSIM communicates through serial port COM1 of the personal computer The APT compiled program is called TESTO1 with units called BLENDER and PACKAGE The example shows that the usrapt exe utility was executed when only the BLENDER blocks were present The next execution of usrapt exe will update the BLENDER block addresses and insert the PACKAGE block addresses COMM 1 DIRECT 1 1 PROGRAM TESTO UNIT BLENDER BLOCK 10 C40 BL_HOT_BVLV OPND BLOCK 11 C50 BL_CLD_BVLV OPND BLOCK 12 V1 BL_TC SP BLOCK 13 WX9 BL_TEMP UNIT PACKAGE BLOCK 20 PK_PRD_DVLV OPND BLOCK 21 PK_LEVEL Figure 5 3 Example tutsim usr File SIMATIC APT Applications Manual Dynamic Program Simulation 5 7 APT and the TUTSIM Dynamic Simulation Package continued Example TUTSIM Figure 5 4 shows the listing for a simple TUTSIM program and an Program for Series associated tutsim usr file From the tutsim usr file you can see that block 10 505 points to the Series 505 controller address C1 and block 11 points to address V1 The program reads C1 every 0 2 seconds and V1 every 0 4 seconds since the magnitude of USR input 1
95. debug utility to test your program Your application is flexible and needs to be recipe controlled Your application is relatively large and detailed The more complicated a program is the easier it is to use APT to create it You need a means of coding both continuous and sequential control within the program APT provides a regulatory control language CFC and a language SFC for scheduling and coordinating control of the application You need to document your program APT makes it easy to provide comments and descriptions to reference when it is time to update the program Approach to APT Program Design 1 53 2 1 2 2 2 3 Chapter 2 Program Descriptions Examining the Washer Example 0 00 ee cee eee eee eee ee nee ee eeneeee Loading the Washer Example for Series 505 Controllers Process Description for the Washer 0 0 0 cece eee eet ene eens Process Functions of the Washer 0 ccc e cence tte ene P amp ID for the Washer 0 cece naaran Process I O for the Washer 000 eee e eee eet tenet eee eens Examining the Cooker Example 0 eeee cece eee cece eee eee eee Loading the Cooker Example for Series 505 Controllers Process Description for the Cooker cece cece eee eee tenets Process Functions of the Cooker 00 0 cece cece eee e eet eens P amp ID forthe COOKE ocio AR A A AA RARA AAA AAA Process I O for the Cooker 0 c ce
96. does not catch this error SIMATIC APT Applications Manual Programming Hints 3 7 3 3 SF Program Loop Analog Alarm Hints for Series 505 Controllers How Priority for SF You cannot easily predict the order in which the Series 505 controller Tasks Is processes loops analog alarms and other blocks that use SF programs The Determined for controller follows these rules Series 505 Controllers PID loops and analog alarms have the highest priority for processing Refer to the appropriate programming reference manual for your controller for information about when associated math for loops and analog alarms is processed The processor program execution time dedicated to associated math SF programs is determined by the time allocated to loop and analog alarm processing For the 545 545L 555 and 575 these time slices are user configurable When you set the time slices you are also affecting the length of the overall controller scan Shorter analog time slices reduce the overall scan time and the 1 O is updated faster Typically you want to reduce the analog portion of the scan as much as possible to reduce the overall scan time However do not allow too little time for the analog portion Loops and analog alarms will begin to overrun and the time for SF programs to execute after scheduling will be longer For the 565 565T 565P 60 of the processor s program execution time is allocated for loops and 15 for analog alarms e Cyclic SF
97. done even 505 Controllers if you do not want to define each of module points with APT symbolic names After an I O Module is placed in the Module Table you can reference the I O points with direct controller address e g WY1 X12 For Series 505 controllers APT locates the last I O address used by an I O Module in a channel and uses the remaining points as overflow CRs if necessary If you need to conserve memory eliminate gaps in your I O addresses where possible Configure modules consecutively beginning with low starting addresses To conserve memory and to save the need for additional RCCs multiple channel controllers APT uses any unconfigured I O locations as overflow CRs This is transparent to your program For multiple channel controllers each RCC card contains two I O channels Each channel contains 1024 configurable I O locations 768 non retentive CRs and 256 retentive CRs A WARNING TISOFT and other tools allow you to change the I O configuration of your controller During the APT download APT will overwrite the memory and I O configuration in your controller with those specified in the Compiler Control File and the I O Module Table APT uses certain unconfigured Y locations to supplement requirements for CR locations Changes to the I O configurations that are in use by APT as supplemental CRs could cause unpredictable operations that could result in death or injury to personnel and or damage to equipme
98. e a loop or analog alarm in TISOFT follow these guidelines e Reserve the number of loops or analog alarms that you need in the Compiler Control File e Reserve enough S memory in words in the Compiler Control File to allow room for the loops or analog alarms that you reserved a WARNING Many tools including TISOFT for Series 505 controllers allow you to change the controller memory configuration of an APT program after the program has been downloaded to the controller Changing the controller memory configuration may result in unpredictable operations that could result in death or injury to personnel and or damage to equipment Do not change the controller memory configuration of an APT program using TISOFT use APT instead In APT you can get the memory configuration that you want either by analyzing your reserved memory and making adjustments or else by analyzing your memory usage which is shown in the Compiler Conirol File and then adjusting your coding methods RLL versus SFPGM V versus K memory and so forth SIMATIC APT Applications Manual APT and Controller Memory 4 5 Memory and I O Usage continued Changing Values in After you have a program downloaded to the controller you need to take Memory some precautions before you attempt to change values Constant values should be set only from within APT Real and integer values can be set as constants in the Declaration Table If you need a Boolean constant
99. e as PID plus the following Read Write Boolean Read Write Integer Read Write Real GAIN TAU1 TAU2 DTIME Dual Mode Extensions Same as PID plus the following Read Write Boolean Read Write Intege Read Write Real DMODE PRSET DLY1 DLY2 Feedforward Output Adjust Extensions Same as PID plus the following Read only Boolean Read only Integer Read only Real SOUT Read Write Integer Read Write Integer Read Write Real FMODE GAIN TAU1 TAU2 TLEAD DTIME Feedforward Setpoint Adjust Extensions Same as PID plus the following Read Write Integer Read Write Integer Read Write Real GAIN TAU1 TAU2 TLEAD DTIME Ratio Station Extensions Same as PID plus the following Read only Boolean Read only Integer Read only Real RATIO Read Write Boolean Read Write Integer Read Write Real OFFST SIMATIC APT Applications Manual Math Control Blocks Absolute Value Square Square Root Extensions Read only Boolean Read only Integer Read only Real IOUT OUT Read Write Boolean Read Write Integer Read Write Real JIN IN Divider Multiplier Subtractor Summer Extensions Read only Boolean Read only Integer Read only Real IOUT OUT Read Write Boolean Read Write Integer Read Write Real INA IN1 1IN2 IN2 Math Block Extensions Read only Boolean Read only Integer Read only Real ENABLD IOUT1 OUT1 IOUT2 OUT2 IOUT3 OUT3 IOUT4 OUT4
100. e for PCS Release 3 x or OSx Rel 4 x An Analysis of the INSTALL TAG File Examples for PCS OSx Translating APT Objects to OSx PCS and TISTAR Overview UNS ese dele a ade hee eae peas A PAR eae Rip eco eae ae gaged Batch Unit Tags DEVICES its cide wae eee OE ORT Ene AAA ARA ee eee Ree Correlating APT Device Types with OSx PCS Attributes Translating Tags for OSx PCS MTR1 Translating Tags for OSx PCS RMTR Translating Tags for OSx PCS MTR2 Translating Tags for OSx PCS VLV1 Translating Tags for OSx PCS VLV2 VO A ascetics Sheahan e a E r cute ae to alee mop E ee ee eee ae ete Me oes Declarations Recipes Contents vii C 2 CFB Extensions 0 ci wise a tanad aia cid a 0 A cb ew oe cd Advanced BIOCKS vex edie ds Ae aad wea hers Dynamic BIOCKS cios hcinicca Maar eet Ma aac Satara aa eee Maa aoe Mead ae ae Limiter BIOCKS siii eae ace Soa ela eA eared ea ow wake aah IVEY BLOGS ib EA Other BIOCKS erursan ene ene e teen teen nee ene ene E Selector BIOCKS iia al ida a in o aa Gavel da Mea eked Standard BlOCKS 200 ia dd cdas Valve Control Blocks viii Contents List of Figures 1 1 Partitioning by Function or by TaSkK ooooccooccoccccncc eee eee 1 7 1 2 Determine the Process Tasks 0 0c ccc eect eects 1 9 1 3 Example of Control Determination 00 cece eee tenes 1 11 1 4 Tasks Comprising the Bottom Up Implementation ococcooccccocccccc eee eee eee 1 15 1 5 Steps of Designing Process Control
101. e time for an SF module is an order of magnitude faster when you install the module in the local base for a 545 as opposed to a remote base If all SF modules cannot be installed in the local base consider placing low activity SF modules such as the ASCII BASIC or DCP modules in a remote base Locate high activity modules such as the NIM or PEERLINK in the local base SIMATIC APT Applications Manual Programming Hints 3 11 SF Program Loop Analog Alarm Hints for Series 505 Controllers continued Correlating Loop You can ensure that the math processing is done at the appropriate time by and Real Math placing all math calculations for the loop into the associated math section Processing for the loop The SF program that executes this math executes with the highest priority Note these other considerations e The controller always executes the split range and scale blocks in Figure 3 12 as quickly as possible However the frequency of execution for code that is processed in the 545 545L 555 or 575 analog time slice or the 565 565T 565P controller is determined by a task queueing algorithm Frequency depends upon the number of SF programs scheduled their execution time priority of other SF tasks scheduled for processing etc e Since APT Rel 1 4 the algorithm that controls object download affects the execution flow of CFBs Although the exact order in which blocks are executed is not predictable the order does not change fr
102. eady bit Scale Recipe Scale High attribute em Scale Low attribute Scale Factor recipe_name SCALE 3 Scale_Factor attribute Hold Hold Recipe Pp recipe name HOLDREQ 3 Hold_req attribute Controller Request ari recipe_name RECREQ 3 PLC rec req attribute EXI CE A EXEC A 172770020 CO EX A AN CES A CE RENO ron aO The status attribute is available for integers scaled integers booleans and text eatin To get the status attribute for a real number you must choose Create Unique Status on the Real Declaration Form Refer to the Recipes chapter Chapter 9 in the SIMATIC APT Programming Reference Tables Manual for how to use recipes with OSx These extensions are assigned when you choose Create Unique Scale Factor Create Unique Hold Request or Create Unique Controller Request in the Recipe Usage Table Refer to Appendix C for how to use the batch control with OSx 7 6 APT and the OSx Operator Interface SIMATIC APT Applications Manual APT provides four editors for marking objects for translation the Tag Translate editor the Tag Translate sub editor the Tag Attribute sub editor and the Process Group sub editor The Tag Translate editor allows you to mark simple APT objects such as declarations for translation to OSx The Tag Translate sub editor also allows you to mark complex objects such as CFBs recipes or declarations with more than one associated extension for translation After marking a complex object you th
103. ecord Recipe Component Tag Attribute R RT1 C NUM_RUNS RT1 NUM_RUNS VALUE C FILL_SP RT1 FILL_SP VALUE C TEMP RT1 TEMP STATUS C BATCHES 1 GYLCOL COMMAND C BATCHES 2 TEG COMMAND C BATCHES 3 OIL COMMAND 4 5 US ss a Secqcbecbe na Q O A A A A A A A A A A A A A A A A A A T A A T A A A A T A A A A T A A A A A T A A T A A T A A T A A T A A T A A A C BATCHES 4 AIR COMMAND C BATCHES 5 WATER COMMAND C RT1 RT1 INUSE COMMAND Record GroupNumber Description P 1 CLEANING TAN E Figure A 2 INSTALL TAG File Example for PCS 3 x and OSx 4 x SIMATIC APT Applications Manual Defining a Variable s Address A 11 Determining a Variable s Address continued Pee orl mr few CIO Tet TT a E O A E a E EL A AO IO IO IO IO IO O O E CG E II AAA ppp Ap Papa Ae A pe DCI E AER E O A A LA EC PO E E A EC DECS IE E RICAS AL RENN A ON A A CO O E ES E E E IA E a E L_DEV E z z z z y lt Zz E lt z gt gt lt V2 is m lt HON LL_ALM v 21 E EE V 19 E halo AE le A A Ep ee ae APA o A RATE V 13 e E ee E e ee eee eee pee AAA apparel 2 ene pS STATUS pa AAA H HRANGE Ooo EA AHH HA au i a A CE A E A A
104. ect However before you can compile remember that the field I O associated with the APT device must be defined in the Module Definition Table and in the I O Table for analog inputs SIMATIC APT Applications Manual Approach to APT Program Design 1 21 1 6 Create the Code Continuous Control Logic At this stage of the process design you begin writing the actual program code Try to use continuous control logic to handle as many functions of your process as possible and allow the sequential control code to do the scheduling for these functions For this reason it is best to begin work on the continuous control first As you design the continuous control code determine the various control strategies and group them appropriately The categories for the groups depend upon your own process and what is most convenient not only for the current programmers but also for those who must maintain and update the program Use different Continuous Function Charts CFCs for the different functional control strategies as shown in Table 1 1 Table 1 1 CFCs Reflect Control Strategies CRC Name Program the You can program the math for the optional simulation as a continuously Simulation Math operating function The simulation math is not necessarily the first code that you need to write but you can develop it in parallel with the other continuous control logic Place the simulation math in one or more math Continuous Function Blocks CFBs locat
105. ect Address function e Read the symbol address reports e Use the APT DC utility Read the install tag file Reading Translated You can have APT generate a report for translated tags Place the cursor on Tag Reports the Object icon and select Report Then select the Translated Tag option If you save the report APT places it under the Saved Report Level of the hierarchy with the name tag rpt The following information appears in tag rpt for each marked object e APT and OSx tag names e Controller address e Selected OSx attributes and their status tag rpt is located in this subdirectory apt program program_name prr where program_name is the name of your APT program Using Debug You can determine the controller address for a variable while running the Debug utility Press Lat D or use the OPTs icon to select Direct Address APT prompts you to enter the unit and variable names and then reports the controller address A 2 Defining a Variable s Address SIMATIC APT Applications Manual Reading Symbol You can have APT generate a report on the compile operation Place the Address Reports cursor on the Object icon and select the Report function You can choose from two types of report on variable addresses e APT symbol name to P C address e P C address to APT symbol name Select one of these two options If you save the reports APT places them under the Saved Report Level of the hierarchy with these
106. ed in a CFC dedicated to program testing 1 22 Approach to APT Program Design SIMATIC APT Applications Manual Program Loops Begin to write the code for those objects located under the APT Standard Analog Alarms CFC icon Think in terms of control strategies Group the loops for example On Off Control by logical function and avoid being bound by artificial boundaries Two cascaded loops in which temperature control drives flow control are best placed in their own unique group Examine the CFC groupings in Figure 1 6 below Group CFBs like this Not like this Ramped Temperature Control Strategy CFC T_CTRL Temperature Control CFC Heat Exchanger Temperature Saiit Temperature Control Temperature Control Ramp CFB CFB Loop 1 CFB Loop 2 Temperature Control Heat Exchanger CFB Loop 3 Temperature Control Temperature Control Temperature Control CFB CFB Loop 4 CFB Loop 5 Heat Exchanger Flow Control CFB Pressure Control CFC Pressure Control Pressure Control CFB Loop 1 CFB Loop 2 CFC LEV_ALARM Tank Level Alarm CFB Figure 1 6 Example of CFC Groupings For analog alarms focus on programming the code that detects the alarm condition Wait until you work on the interlock code discussed on page 1 25 Program Safety and Shutdown Interlocks to program the code to correc
107. ed the process during the top down analysis Each partition represents a portion of the functional organization of the physical plant Dedicate one APT unit to each partition and begin adding the units to the APT hierarchy Determine which units can be copied and used elsewhere in the program Define only the original unit 1 20 Approach to APT Program Design SIMATIC APT Applications Manual Select Controller The controller that you use must be able to support the number of I O points that you are planning for your process Remember that the 560 560T and 565 565T 565P controllers support up to eight I O channels and as many as 8192 I O points The 555 and the 575 support up to 8192 I O points in one T O channel The 545 supports 2048 I O points in one I O channel and the 545L supports 1024 I O points in the local base The S5 928B 948 and 948R CPUs support 2048 inputs and outputs with process image and 384 analog inputs and outputs through the periphery Determine I O Determine the kinds and numbers of modules that you need Plan their Module Layout location carefully Allow for expansion If you try to reduce costs by using fewer modules and bases you may ultimately increase the expense of expanding the system When you use APT to develop the program remember that for a Series 505 controller the module table determines the address space but the object belongs to the I O Table This allows you to test code even when the I O configuration is
108. efficient Verify code manually Do not base your understanding of the operation of a program section solely on your belief in your code generation capabilities and the descriptions of the functions in the controller user manuals Prove to yourself that the code does the task that you intend Manipulate the T O and or the control words to see if the devices respond appropriately Take small steps Write your program in small sections and then test each section When you successfully test a section of the program do not create several sections of code assuming that they will test successfully Subsequent testing can be difficult and time consuming SIMATIC APT Applications Manual Drain water from washing machine E Es Add soap ndd comes and water to washer A ee Commands Wash Clothes Clothes in Clothes out Status SIMATIC APT Applications Manual Verify communications path Use the operator station to control the field equipment as soon as possible during the process control design It is best to identify communications problems between the operator station controller and field devices early Program structure reflects process The application program is a window into the process and the program s structure should be similar to the process Be sure to make the appropriate functional partitions in the process When you write code the program wil
109. egin fill_at_sp ws_level in gt fill_setpt compute the shutdown condition valve_nrdy fill_at_sp OR ws_level inhha OR hold_washer OR stop_spin cold_water nrdy valve_nrdy hot_water nrdy valve_nrdy Figure 3 14 Example of Interlock Logic 3 18 Programming Hints SIMATIC APT Applications Manual Programming Safe State SFCs Program Download Redundancy Constraints The RETENTIVE option specifies that an armed safe state SFC remains armed when a power failure occurs If you do not include the RETENTIVE option a power failure effectively disarms a safe state SFC If you define a safe state SFC with the RETENTIVE option you do not have to enable the unit to restart the process If you specify the power failure detection bit as the trigger condition SSTRIGGER program_name PWREL program execution begins with the initial step of that safe state SFC assuming that the SFC was armed at the time of the power failure The HBU Hot Backup Unit or standby unit presents several points to consider when you download programs e For APT certain incremental program downloads cannot occur with the STANDBY unit ON LINE You must set the STANDBY unit to the OFF LINE state before doing the download e When the process is running correctly one controller is ACTIVE and the other controller is STANDBY ON LINE e Anew program can always be downloaded to the ACTIVE controller but a new program cannot be
110. elect No for Build Translate Table To include additional tag data see the Adding Tags section which follows If you select Yes for the Build Translate Table option when you compile a program take note If you have already compiled the program using the Yes option addresses for objects which were fixed by the earlier compilation in the file install tag will change Refer to the APT OSx TISTAR and TISOFT STEP 5 chapter of the SIMATIC APT User Manual and to Appendix A of this SIMATIC APT Applications Manual for more information about the Build Translate Table option and the install tag file Mark Units The Units to Compile Include All option must remain selected if you do not want the addresses of previously marked objects to change 7 10 APT and the OSx Operator Interface SIMATIC APT Applications Manual Adding Tags You can add tags without affecting the addresses of previously marked objects To do this mark the objects and select Append for the Build Translate Table option when you recompile a program The Append selection adds new object addresses to the file append tag which contains tag data for appended tags without changing addresses of previously marked objects If you need to recompile the program after appending tag data select No in the Build Translate Table option and no object addresses are changed Refer to the APT and OSx TISTAR and TISOFT STEP 5 chapter of the SIMATIC APT User Manual and to Appendix A o
111. en edit the object to mark individual extensions of the object After marking an object the Tag Attribute sub editor allows you to specify scan status upload or 20 offset for the object You can specify autolog only for PCS 3 x and OSx 4 x download is only available for TISTAR 1 x and 2 x After marking an object you can use the Process Group sub editor to specify the OSx process group to which a tag belongs Consult the SIMATIC PCS 7 OSx Process Configuration Manual for more information about assigning tags to process groups You cannot delete objects that you mark for OSx without first unmarking the objects You also cannot change the contents of a field that sets address locations without unmarking the object containing the field For declarations these fields include the type of object and whether it is constant the number in an array the controller address or the unique status of the object All these fields affect the variable s address in the controller However you can change initial values high low ranges and engineering units without unmarking the object For recipes you can only change component values without unmarking recipe objects To change any other item you must first unmark the recipe SIMATIC APT Applications Manual APT and the OSx Operator Interface 1 7 Marking Tags for Translation continued Recommendations for Marking Objects Keep these points in mind when you mark objects for translation Take S
112. entive boolean entities retain their values the function suggested by their name Other boolean declarations are cleared All S5 booleans are retentive and retain their values Real and integer variables remain at their last state Constants are not changed VO Outputs are cleared and a full controller scan takes place before they are written again SIMATIC APT Applications Manual Programming Hints 3 21 Miscellaneous Hints continued 3 22 Programming Hints Devices For Series 505 controllers unless the Uninterruptible Power Supply option in the compile control file is selected power fail recovery logic for devices is included After returning from a power loss all devices go to their safe state position For Series 505 and S5 controllers all devices go to their safe state positions and are unlocked upon return from power loss For Series 505 the PFAIL control relays shown in the figures of the Device Operation Appendix of the SIMATIC APT Programming Reference Tables Manual are included in the code if you do not select the UPS option in the Compiler Control File This means that the device logic copies the states of the device status control relays into a V memory location every scan After the recovery from a power loss this data is copied from the V memory location back into the appropriate control relays For Series 505 if you do select the UPS option in the Compile Control File the states of the device status control re
113. erly concerned with the details or how they need to be handled For example consider the equipment functions in a laundry room Two operations comprise the process of washing clothes a wash operation and a rinse operation The following phases are common to both operations fill agitate drain and spin The four phases execute in both the wash and rinse operations The add soap phase is unique to the wash operation You also need to consider operations other than just the wash and rinse operations Will the system have to handle delicate clothes differently from normal loads of clothes Will permanent press cycles be included Will the system handle large medium small and extra small loads All these considerations can affect the complexity of the control solution The wash operation consists of the following steps fill add soap agitate drain and spin The rinse operation consists of these steps fill agitate drain and spin The primary differences among process cycles consist of cycle duration water levels and strength of agitation A well planned design differentiates the common process steps from the unique ones The common process steps are the building blocks for the total control solution A poorly planned design treats each phase in each operational mode as unique This design approach requires more coding and debug effort Also problems and errors typically have to be corrected in more than one place This leads to pote
114. ess For example for a sensor or controller if the address of a digital output is Y8 the address of both the status and command for that point is also Y8 For an S5 controller if the address of a digital output is Q8 0 the address of both the status and command for that point is placed in a data word in DB or DX Table C 14 1 0 se ECTS Ar ae pobedom Dita Once se FRO Werden Wot tr 1 The RAW extension can be translated as a OSx ai type Series 505 only 2 The maximum low range an RTD is 15 3 The maximum low range for a TC is 900 Declarations The OSx tag type and the corresponding declaration types are listed in Table C 15 When you translate a boolean the command and status of the translated tag both have the same controller address For example for a Series 505 controller if the address of a boolean is C9 the address of both the status and command for that point is also C9 For an S5 controller if the address of a boolean is F9 0 the address of both the status and command for that point is placed in a data word in DB or DX SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 19 Translating APT Objects to OSx PCS and TISTAR continued Table C 15 Declarations Seta Be a BR teen ra Boole IX Boolean Array pe aad e ERTS AA SI Scaled Integer Calculated Integer A WARNING Boolean array of two elements long must not have the second array element marked for translation to OSx
115. esults You can do hardware checks such as throwing switches or turning dials and monitor the results in APT to test inputs to the controller You can make software changes such as using APT to modify variables or to force I O and monitor the result in the field to test outputs from the controller Manual tests are an important means of finding errors in your program and in wiring but they can be tedious and time consuming since they are not automated You can write software test routines to check the application program Since software routines can be stored as files you can run them over and over very quickly and simply note the results APT includes MAITT Main Application Integration Test Tool a utility program that simplifies the task of repeatable logic testing You can design the test routines to generate reports that are stored or printed With MAITT it is very easy to test the control system response to variable inputs When you develop new code you can easily test the existing code to verify that it still executes correctly While software routines can simplify your program tests it is not likely that you would replace basic logic testing with software routines It would be more appropriate to use both types of tests 5 2 Dynamic Program Simulation SIMATIC APT Applications Manual Dynamic A good simulation is an excellent tool for discovering the problems that tend Simulation to remain hidden during program development W
116. f this manual for more information about the append tag file NOTE If you make changes to your system e g adding RCCs or changing controller models addresses may change even if you have selected the Append option See the Compiling an APT Program chapter of the SIMATIC APT User Manual for more details Handling Complex Tags When you mark a complex object such as a valve or motor only a subset of the object extension addresses is fixed A detailed list of these is given in Appendix B Extensions Fixed by the Compile SIMATIC APT Applications Manual APT and the OSx Operator Interface 7 11 Compiling the Program continued Report by Exception Reserving Memory for RBE Series 505 Some categories of information are reported by the controller automatically without a demand scan from an OSx operations station Examples include alarms and alarm acknowledgements the automatic logging of messages action requests BCL jobs and recipe handshaking exchanges This process is called Report By Exception RBE and is supported in PCS 3 x OSx 4 0 0 and later The RBE process is a data management system used in OSx The RBE capability exists in Release 3 x or greater firmware of the 545 1102 1103 545 Lite and 1104 555 1101 1102 1103 1104 1105 and 1106 and 575 2108 2104 2105 and 2106 controllers The S5 controller programs require a function block package for the RBE process which is included by selectin
117. fore the system can restart SIMATIC APT Applications Manual P amp ID for the Figure 2 1 shows the P amp ID for the Washer Example program Washer Clothes chute SOAP_VALVE gt PJ HOT_WATER COLD_WATER AGITATOR WASH_LEVEL LT C WASH_TEMP tr VIBRATION 01 a ME NE me Dx DRAIN_VALVE SPIN_MOTOR Figure 2 1 Washer Example P amp ID SIMATIC APT Applications Manual Program Descriptions 2 5 Examining the Washer Example continued Process I O for the Table 2 1 lists the Series 505 I O for the Washer Example program Washer Table 2 1 Washer Example I O Low High A A wee ar we 1 7 00 veses enem AT wos AI ACA O E NS maw o e IE E O FR EAN IEA or ECU A FR FE E EN Bore E ROT PR A FE E EN Dos or fea O O ee Previa ROY IS ER L Sw or e IR O O ER ELE Son m a O O O e Ymon or e O O EEN Pats oO ECC arte Crema E o A FF FR e Drema E WOO A A IE ER EN Picea BO WOO twat en comma Sopena BO Yous Y JO paces 2 6 Program Descriptions SIMATIC APT Applications Manual 2 2 Examining the Cooker Example Loading the Cooker To install FOOD545N follow these steps Example for Series 505 Controllers 1 SIMATIC APT Applications Manual Insert the APT software CD in your CD ROM drive or if you created diskettes from the CD insert DISK8 in your diskette drive Ensure that the current
118. g RAM PIQ comparison error 0 Error search mode assume master value 1 Standby stop assume master value 2 Error search mode delete odd bits PIQ 3 Standby stop delete odd bits PIQ 4 Collective stop Figure 6 3 Initialize Operating System Screen 6 6 Redundant Configuration for 5 SIMATIC APT Applications Manual APT anticipates the default values from the Initialize Operating System screen shown in Figure 6 4 All the other input fields on the Initialize Operating System screen can be configured as required for your application If you have already programmed DX1 check your SYSTEM parameters to make sure that the values you loaded conform to the items listed below and modify the parameters if necessary H error DB number RAM DB for variable data H system flag word Figure 6 4 Values Required by APT SIMATIC APT Applications Manual Redundant Configuration for 5 6 7 6 4 Configuring Data Block Transfer Lists from COM 155H Transfer Data for Activating Standby TRAFDAT After you have configured your operating system parameters you can use TRAFDAT to specify your DBs and DXs for redundant control For COM 155H data blocks are organized according to the following four categories e Cyclic DBs e Cyclic DXs Interrupt DBs Interrupt DXs The address report that you generated in APT described in Section 6 2 contains a list of all DBs and DXs in ascending order Most DBs and DXs used within APT fall in the cy
119. g RBE code included on the Compiler Control File Refer to the SIMATIC PCS 7 OSx Interface to S5 Controllers Manual for more information The Series 505 controllers have factory allocated memory to store 20K bytes of RBE definitions 20 Kbytes is the minimum memory allocation Any entry less than 20 Kbytes results in the minimum amount being allocated If the number of RBE tags in a given controller requires more than 20K you can determine the total memory required for all tags and enter the amount in the APT Compiler Control file or just allow the controller to use unconfigured user memory to hold additional RBE tag definitions Unconfigured user memory is the memory above the amount APT has configured for the program The memory configuration amounts are contained in the Compile Report The memory required for a given tag depends on the tag type Table 7 3 For a typical OSx tag mix the average memory requirement is 42 bytes per tag This means that you can define approximately 490 tags in a given controller before the RBE tag definitions require unconfigured user memory Depending on the memory requirements of the controller program it is possible to define a larger number of tags However the amount of unconfigured controller user memory available for RBE definitions can change over time if you make changes in the controller program If insufficient controller memory is available for RBE then OSx handles tags that could not be stored as
120. g and I O is determined by whether you have an S5 or a Series 505 controller How to Use This This manual has been arranged into four major sections Manual e Section One Chapter 1 presents a strategy that you can follow when you design an application program This strategy is general enough to be followed no matter what tool you use to write the program APT is however assumed to be the programming tool e Section Two Chapter 2 describes several specific APT program applications The examples exist on the distribution media for APT Software Release 1 9A e Section Three consists of four chapters Chapter 3 contains APT programming hints Chapter 4 includes some suggestions on handling controller memory Chapter 5 introduces you to a commercially available program language that can be used to create a dynamic simulation for testing the APT program Chapter 6 provides information for configuring an S5 155H redundant controller system using APT and COM 155H e Section Four consists of one chapter and three appendices Chapter 7 provides information on how to use APT to configure your SIMATIC OSx operator interface database Appendix A explains how to determine the controller address of an object This information is necessary when you are creating a database for a OSx or non OSx operator interface Appendix B shows the extensions that are fixed by the compile for OSx tags that you have marked Appendix C shows the information that is tra
121. g command B LOADDEMO B HX_DEMO NOTE The HX DEMO example program accesses direct memory addresses to simulate an actual process For this reason warnings are generated the first time that you compile the program On subsequent compiles no warnings occur if you do not choose a forced compile Process The process consists of a heat exchanger with flow and temperature analog Description sensors The system is made up of these components for the Heat Exchanger e On off water valve e Regulatory control valve e Pump SIMATIC APT Applications Manual Program Descriptions 2 15 Examining the Heat Exchanger Example continued Process Functions The process is flexible and recipe controlled The temperature control of the Heat strategy is based on a cascade control scheme with a temperature controller Exchanger and a flow controller The temperature controller must transition to automatic whenever the flow controller is placed into the remote or cascade mode of operation The process provides these services e A startup phase heats the process to an initial temperature e A shutdown phase shuts off the system and ensures that the process has cooled down e A ramp setpoint phase controls temperature ramping from an initial starting point to an endpoint at a controlled rate e The process includes a soak procedure that is a timed wait The process includes a profile procedure that uses a time temperature profile to specif
122. ger PV Read Write Real ENABL NRDY Valve Sequencer Extensions Read only Boolean Read only Integer SP DBAND Read only Real Read Write Boolean IOUT Read Write Integer OUT Read Write Real ENABL NRDY DOUT IN BRKPH BRKPL Proportional Time Control Extensions Read only Boolean Read only Integer Read Write Real DOUT Read Write Boolean Read Write Integer Read Write Real ENABL NRDY Split Range Extensions Read only Boolean Read only Integer IN DUTY Read only Real Read Write Boolean IOUT1 IOUT2 Read Write Integer OUT1 OUT2 Read Write Real ENABL NRDY IN BRKP1 BRKP2 SIMATIC APT Applications Manual Selector Blocks Average Selector Extensions Read only Boolean Read Write Boolean Read only Integer Read only Real IOUT POS STAT Read Write Integer OUT Read Write Real ENABL NRDY 11N1 1IN2 IINS High Selector Extensions Low Selector Extensions Read only Boolean Read Write Boolean Read only Integer IN1 IN2 IN3 TVAL Read only Real IOUT POS Read Write Integer OUT Read Write Real Selector Blocks continued Outswitch Selector Extensions Read Write Boolean Read Write Integer Read Write Real ENABL 11N1 IN NRDY POS PV1 PV2 PV3 PV4 Threshold Selector Extensions Read only Boolean DOUT Read only Inte
123. ger Read only Real Read Write Boolean Read Write Integer Read Write Real ENABL IIN IN NRDY LIMIT Other Control Blocks Anti reset Windup Constraint Extensions ENABL 11N1 IN1 NRDY IIN2 IN2 IINS IN3 11IN4 IN4 SW1 SW2 SW3 SW4 Inswitch Selector Extensions Read only Boolean Read only Integer Read only Real IOUT OUT Read Write Boolean Read Write Integer Read Write Real ENABL 11N1 IN1 NRDY IIN2 IN2 IIN3 IN3 IIN4 IN4 POS Median Selector Extensions Read only Integer Read only Real IOUT OUT POS Read only Boolean Read Write Boolean Read Write Integer Read Write Real ENABL 11N1 IN1 NRDY IIN2 IN2 INS IN3 SIMATIC APT Applications Manual Read Write Boolean Read Write Integer Read Write Real ENABL NRDY HLIM LLIM Anti reset Windup Select Extensions Read Write Boolean Read Write Integer Read Write Real ENABL NRDY Correlated Lookup Table Extensions Read only Boolean Read only Integer Read only Real Read Write Boolean IOUT Read Write Integer OUT Read Write Real ENABL NRDY Scale Extensions Read only Boolean Read only Integer IN Read only Real Read Write Boolean IOUT Read Write Integer OUT Read Write Real ENABL NRDY IIN IN HRIN LRIN HROUT LROUT Extensions Fixed by the Compile B 5 Extensions Fixed by the Compile contin
124. he object s name and description This is a manual procedure when your operator interface is not OSx You must enter the object s controller address into the operator interface database Consider writing a short program that can read the ASCII file generated by APT install tag when you compile the program and then write the object s address to your operator interface database Download the program and connect the operator interface to the controller Verify that the operator interface graphics are reflecting the operation of the controller program correctly Do the icons change colors as they should Are the correct messages being displayed Can you use the operator interface to interact with the controller program i e can you open a valve or turn on a motor You can use the APT Debug utility or MAITT along with the operator interface to do these tests After you verify the operator station graphics the Level 1 tasks are completed Section 1 8 describes the Level 2 tasks SIMATIC APT Applications Manual Approach to APT Program Design 1 29 1 8 Create the Code Templates for Procedural Control Procedural Control agitate Subordinate SFCs At this stage of the process design you start on the Level 2 tasks The continuous control logic is well defined Program code may not be complete but its development is under way It is time to begin work on scheduling the continuously executing
125. hen you have developed a good working dynamic simulation you can concentrate on developing the program code without being distracted by the actual execution of testing procedures You can watch the code as it runs and note problems as they occur This is preferable to the manual testing described above There are two approaches to designing a simulation procedure for testing your process control program Internal simulations consist of test algorithms that are executed within the controller This method can be quite an effective means of testing your program However your test program competes with the process control program for resources within the controller For examples of internal simulations refer to the example APT programs that are provided on the APT software CD A External simulations consist of test algorithms that are executed in a separate computer that communicates with the controller You can simulate virtually any mechanical or process control scenario and send the inputs to the controller just as if they were actual field inputs Since the external simulation does not reside within the controller your test program does not compete with the process control program for resources within the controller A simulation requires considerable effort However you need to consider the cost of developing a good simulation versus the cost of not having one Section 5 2 describes a commercially available dynamic simulation progr
126. ier Field Contents Attribute of Attribute Name Memory Location Number of T Memory Locations Upload 20 Offset Autolog and ag se Initial Value c Components Component Name Tag Name Attribute VALUE in a recipe STATUS or COMMAND Upload 20 Offset and Autolog can be a Y for yes N for no or blank for not applicable SIMATIC APT Applications Manual Defining a Variable s Address A 15 Determining a Variable s Address continued INSTALL TAG File Last Line The last line of the file starts with an E identifier which means end of file APT determines the PCS OSx tag types based on the type of variable the tag is See Table A 6 Table A 6 PCS OSx Tag Types TNR Integer variable APT valve device VLV1 Digital output DO O APT valve device VLV2 Digital input or APT flag APT motor device MTR1 PID PiDloop LOOP APT motor device MTR2 HET alarm or APT reversible RMTR analog input motor device Digital output Text TEXT Distal put DI10 array of 10 The PCS OSx attributes that are reported include STATUS VALUE COMMAND SETPOINT OVERRIDE MODE_CMMD L RANGE H_RANGE MODE PV SP OUT ROC _ALRM DEV H_DEV etc For each attribute six types of data are stored A 16 Defining a Variable s Address SIMATIC APT Applications Manual Appendix B Extensions Fixed by the Compile When you mark a complex object such as a valve or motor only a subset of the tag extension addresses is fixed A detailed
127. ilable for application programs Any release of the 545 555 or 575 which support the same additional RLL instructions will support the following number of control relays 4096 for 545L 32768 for 545 and 555 and 23558 for 575 NOTE The 560T 565P controllers have local control relays C10241 C56320 that can be used in APT programs These control relays are not completely supported in the 565T and are therefore not available for use in APT for this controller SIMATIC APT Applications Manual Using Commands Command bits i e read write boolean values allow you to change the Flags and condition of an object You can control these bits by the following methods Extensions Method Device Example PID Loop Example Use a command in an SFC Lock valve_1 Auto pid_1 Use a command in MATH Lock valve_1 Auto pid_1 Use an APT flag On valve_1 RTL On pid_1 RAUTO Use a boolean extension valve_1 LOCKD true pid_1 GAUTO true The command manipulates the APT flag and the boolean extensions in order to control the object Use the command rather than the extensions to control the mode of the object because APT can overwrite the boolean mode extensions Use the APT flags and boolean extensions to monitor the status of the object If you use an APT flag extension you must use the LATCH ON and CLEAR math procedures described in the chapter on Math Functions and Procedures in the SIMATIC APT Programming Reference Gra
128. ing command B LOADDEMO B FOOD545N NOTE The FOOD545N example program accesses direct memory addresses to simulate an actual process For this reason warnings are generated the first time that you compile the program On subsequent compiles no warnings occur if you do not choose a forced compile Program Descriptions SIMATIC APT Applications Manual Process The process consists of two cookers and a weigh tank The weigh tank is Description for the connected physically to the two cookers by means of a transportation Cooker network that consists of a blower fan and a screw auger Material moves along the auger until it either drops into an open diverter valve into a cooker or it passes beyond the boundary of the cooker network and falls into the waste bin The operator always has the option of placing the system into one of three execution modes Automatic The selected recipe automatically executes until finished Jog At the end of each operation the operator is prompted for permission before the recipe proceeds This is a semi automatic mode Manual The operator selects which operation to execute and provides a parameter s for the operation The operator can switch between any of the three modes at any time although the request may be ignored until a logical time in the recipe execution The system allows the operator to repeat the previous recipe step skip to the next recipe step or to restart the recipe at
129. interface is not OSx you can still mark objects and fix their addresses in the controller when you compile the APT program The next step building the operator interface database is a manual procedure You can use the file created in step 2 to identify the addresses that you must enter into the database If your operator interface is not OSx or even if it is OSx you do not have to mark tags for translation You can reserve controller memory and assign selected addresses to the objects that you want to monitor with your operator interface If you choose this method you must include code in the controller program that moves the necessary data into the address that the operator interface monitors 1 28 Approach to APT Program Design SIMATIC APT Applications Manual Build Operator Station Database Verify Operator Station Graphics Finish Level 1 Tasks Enter the controller addresses for objects that are monitored by the operator interface into the operator interface database Note that these addresses must remain unchanged in the controller program if the operator interface is to access data during run time If you alter an address for an object you need to make the appropriate change in the operator interface database You can use the APT Translate Tags utility to place the object s controller address into a database that is compatible with OSx This is an automated procedure that also places other data into the database including t
130. ion put in washing machine Unit soap Function add to washing machine Unit washing machine Unit water Functions clothes in Function add to washing machine add soap Unit washing machine add water Function agitate clothes agitate Unit drain drain Function release water from washing machine Figure 1 1 Partitioning by Function or by Task Identify interconnectivity among the equipment areas Within each partition note which pieces of equipment are to be shared by different areas These items are shared resources and are termed global because access to them is required in other equipment areas beyond the immediate equipment area Improper or task oriented partitioning results in the incorrect inclusion of many global objects in the system A common mistake is to make all I O and devices global due to uncertainty about which objects are needed by a unit This approach results in a system that is less maintainable and expandable Consider this It is easy to move the small number of objects that are truly global but mis identified as local It is more difficult and time consuming to move the massive number of truly local variables from global to local equipment areas SIMATIC APT Applications Manual Approach to APT Program Design 1 7 Do a Top Down Analysis continued Determine What the Process Does Determine How the Process Is To Be Done Ascertain the upper level tasks that the process must do Do not be ov
131. irement when you select the APT names See the example below APT Name WTR_PUMP 331 WTR_PUMP_331 WTR_PUMP_ 332 WTR_PUMP_ 332 WTR_PUMP_ 333 WTR_PUMP_ 333 When you mark names for translation APT allows you to choose different object names to be used by OSx These names may be altogether different from the APT names that you used However if you choose unique twelve character APT names when you create your APT program you may save time and avoid confusion when you translate them for OSx SIMATIC APT Applications Manual Selecting Array Observe the same twelve character name requirements when you create an Names array The array elements shown below cannot be fully translated because the OSx names would be identical APT Nae SEQARY MAPSI 1 SEQARY MAPS SEQARY MAPS 2 SEQARY MAPSI An error occurs when you mark the second name above for translation The array number in brackets is part of the name observe the OSx twelve character name requirements as shown below APT Name SEQ MPS 1 SEQ MPS 1 SEQ MPS 2 SEQ MPS 2 Selecting Recipe Observe the same name length requirements for recipe names The recipe Names elements shown below cannot be fully translated because the OSx names would be identical APT Nae WORKING_REC TEMP WORKING_REC WORKING_REC MIXT WORKING_REC Use the following recipe name conventions instead APT Name WR TEMP WR TEMP WR MIXT WR MIXT SIMATIC APT Applications Manual Progra
132. l be structurally sound and more efficient It will be easier to write since you will have small well defined functions to program Use black box design Almost any task can be viewed as a black box with a set of inputs and a set of outputs After you have analyzed the task and defined the external view then you can change the task any number of times without affecting other tasks that use it The external view changes only when the functional requirements of the task change When the external view changes then other tasks must be changed as well This approach is a very powerful and useful design approach Approach to APT Program Design 1 51 When You Create Code continued Designed Code Dirty clothes Clean clothes Unit water Was unit W Unit W n the water or a vs i Unit washer the washer Unit WA Hey Mac Pa gt need a light g X Coming right over here 4 U gt gt up Bud 1 52 Approach to APT Program Design Designed vs hacked code Recognize the difference between implementing a design and hacking code A designed system is highly structured and modular Designed code is well thought out and tasks are designed as black boxes Hacked code is typically disorganized is written quickly and with little planning The code designer thinks through the requirements and charts a course to meet the requirements in
133. larms on off control memor names operator interface database 1 29 operator interface graphics other alarms 1 251 other continuous functions 1 24 partition 1 20 permanent main SFC code procedure manager SFC code recipel 1 33 1 32 1 25 recipe template safety interlocks sequence array 1 43 sequence recipe sequence recipe tem plate 1 40 simulation math subordinate SFC code subordinate SFC templates temporary main SFC code 1 38 temporary main SFC templates test simulation Index C Coding hints 1 50 Command hints 3 17 Compile report memory type 4 8 reserving memory 4 4 Compiling programs 7 9 adding tags fixing extensions B 6 Configuration ET200 I O rack 3 25 redundant S5 system compatibility with APT 6 3 data transfers T O points and channels 6 11 mapping I O types 6 11 operating system parameters 6 6 setup sequence 6 2 using COM155H 6 2 Configure vo 1 21 Continuous control automatic start 1 24 loops analog alarms on off control 1 23 other continuous functions safety interlocks simulation math Control relay hints 3 16 Control requirements Controller address de get address utility A 4 debug direct address option A 2 install tag file LA 1O A 15 identifiers and attribures identifiers and attributes PCS example analysis PCS spreadsheet PCS tag types A 16 symbol address report memory pnl ing va
134. lays are not copied into V memory After recovery from power loss all devices enter the de energized state and are unlocked This action is not controlled by controller logic For S5 controllers since memory is retentive the states of the device status bits are not copied into VFLAG After a power fail the status of the devices is still in memory and the controller performs a controlled transition to the safe state condition all devices enter the de energized state and are unlocked SIMATIC APT Applications Manual 3 7 Configuring Devices Configuring Simple Devices It is unnecessary to enter simple devices e g no feedback or always manual or automatic into the Device Definition Table Instead you can define your own device with declaration tables I O tables and math blocks Enter a name in the I O Symbolic Name Table to represent the device and then use math statements to control the actions of the device This can save you approximately 100 words of L memory 10 13 control relays and two timers for Series 505 controllers or 200 words of STL code 10 13 flags and two timers for S5 controllers You may want to program a device such as a simple pump or valve as a digital output DO and not as an APT device under these conditions e The device starts quickly has no feedback and you do not care about a traveling state e The device always operates in manual mode e Your application does not require the controller to co
135. lems or modules that can be addressed independently and systematically This will enable you to minimize the number of complex issues to be dealt with at any point in the design cycle Sections 1 5 1 13 of this chapter describe the tasks in detail and give you some suggestions about how to do them You can create any application program by following the order in which they are presented Approach to APT Program Design SIMATIC APT Applications Manual Level 3 Control Level 2 Control Level 1 Control bail enhancements Sec 1 13 Layers 9 Layer 8 Layer 7 d gt Layer 6 gt Layer 5 gt Layer 4 gt Layer 2 Figure 1 4 Tasks Comprising the Bottom Up Implementation SIMATIC APT Applications Manual Approach to APT Program Design 1 15 Plan the Bottom Up Implementation continued Study the Example Program WASH_DEM for Series 505 Controllers 1 16 Approach to APT Program Design The example program WASH DEM illustrates the concepts that are emphasized in this chapter If you load it on your system you can follow along with the control strategy To install WASH DEM follow these steps 1 Insert the APT software CD in your CD ROM drive or if you created diskettes from the CD insert DISK8 in your diskette drive Ensure that the current DOS path environment includes the path to the APT exec
136. list of these appears in the pages that follow Declarations Devices Declaration Types Valve Extensions Type All declarations of the following types that were Boolean Extension Valve Types marked for translation Position bits read only Integer Shift Register Array OPND VND VSN VSS VSD VDD VMD BV1 2 VUD Sn pee Integer CLSD VND VSN VSS VSD VDD VMD BV1 2 VUD Flag DO10 TRVL VSN VSS VSD VDD VMD BV1 2 VUD ie A Text Array Fail bits read only Aaa FTO VSS VSD VDD VMD BV1 2 VUD Boolean Array FTC VSS VSD VDD VMD Bv1 2 VUD Sequence Array FAILD VND VSD VDD VMD BV1 2 VUD Operation bits read write DSBLD VSN VSS VSD VDD VMD BV1 2 VUD 3 7 LOCKD VSN VSS VSD VDD VMD BV1 2 VUD Fast Slow Timer Counter Extensions NRDY VSN VSS VSD VDD VMD BV1 2 VUD MOPEN VND VSN VSS VSD VDD VMD BV1 2 VUD Override bits read write Read only Boolean Read only Integer Read only Real OVRD vss TCC OVRDO VSD VDD VMD VUD OVRDC VSD VDD VMD VUD OVRDL BV1 2 Read Write Boolean Read Write Integer Read Write Real OVRDH BV1 2 RESET TCP ENABL INPUT Motor Extensions 1 O and Modules Al Extensions Boolean Extension Motor Types Position bits read only RUNNG MSN MSS MDN MDS RM1 2 TS1 2 MUD Read only Boolean Read only Integer Read only Real STPPD MSN MSS MDN MDS RM1 2 TS1 2 MUD RAW VO name TRVL MSN MSS MDN MDS RM1 2 TS1 2 MUD Fail bits read onl FTR MSS MDS RM1 2 TS1 2 MUD BI Ext FTS MSS MDS RM1 2 TS1 2 MUD x
137. ll task is finished and clears the stop command Transition T4 Not strt_fill waits for the start command Strt_fill to clear This path loops back and program flow waits for Strt_fill to become true again 1 36 Approach to APT Program Design SIMATIC APT Applications Manual Wait for start command Strt_fill Start command detected Use formula recipe to load level setpoint Increment Fill_s Change step counter animation Fill_level Wr fill_sp Temp_setpt Wr tempt_setpt True Wait for level to reach desired level Fill_at_sp Tank at desired level On Fill_done Indicate fill is done Clear Stop_fill Clear the stop command if set in stop_stp CFC Not Strt_fill Wait for start command to clearsired level gt Figure 1 15 Example Procedure SFC This example reinforces important concepts about the design of process control e Use continuous control functions to do the actual work in the process e Allow the sequential control functions to do the scheduling tasks In the laundry example the control of the valves is handled by CFBs while the factors that involve scheduling and setpoints are handled by the SFCs As you finish the code for each procedural SFC exit and validate the SFC Correct any errors and then compile the program and test it with the APT Debug Utility See Chapter 3 for suggestions about using Debug SIMATIC APT Applications Manual Approach to APT Prog
138. lled in the secondary called Blender The two tags BR ADD_A and D_SETPT are real numbers Each tag has several variables with initial values The address for BR ADD_A assigned to the VALUE attribute as V 23 is both V23 and V24 since the variable is a real number The address for D SETPT assigned as V 7 is both V7 and V8 The tag called TK1_RESTART is a Boolean entity The address for TK1_RESTART assigned to the COMMAND and STATUS attributes is C369 The tag called BATCH_MODE is an integer The address for BATCH_MODE assigned to the STATUS and VALUE attributes is V232 The name of the loop is TK1_TC The number immediately following the word LMode in the MODE attribute is the address of the loop in the controller that is Loop 1 The information contained in install tag has the organization described in Table A 1 SIMATIC APT Applications Manual Defining a Variable s Address A 5 Determining a Variable s Address continued Table A 1 INSTALL TAG File Example for TISTAR Release 1 x and 2 x 00000006 BLENDER AREA BR Blender recipe CALC BR ADD_A Amount of ingredient A UNITS lbs DEADBAND 0 1 H_RANGE 150 0 L_RANGE 0 ADD A VALUE V 23 1 1 0 0 2 85 0 CALC D_SETPT Setpoint of ingredient D DEADBAND 0 1 H_RANGE 10000 L_RANGE 0 VALUE V 71100 2 100 DO TK1_RESTART Restart the process COMMAND C 369100020 STATUS C 369110220 IVAR BATCH_MODE MODE auto man or jog H_RANGE 1000 L_RANGE 0 STATUS V 23
139. ller after you have downloaded an APT program to the controller A WARNING Incrementally downloading an APT program to the controller affects the current operation of your application A change in operation of your process could cause unpredictable operations that could result in death or injury to personnel and or equipment damage To minimize risk when downloading an APT program changes should only be made by qualified personnel who are fully aware of the possible consequences of any program modifications If your controller is a Series 505 use the Verify Option to check the program created by the last successful compile against the program in the controller The verify option indicates discrepancies caused by changes to the program in the controller but does not check contents of reserved memory areas The Verify Option is not supported for S5 SIMATIC APT Applications Manual APT and Controller Memory 4 3 4 2 Memory and I O Usage Overview Reserving Memory When the program is compiled APT uses the controller memory at the first location of each type i e SFPGM1 V1 for Series 505 FB1 DB3 for S5 unless you reserve memory in the Compiler Control File for Series 505 controllers If you reserve memory APT program use begins at the first location after the reserved area For example if you reserve 100 V memory locations for a Series 505 controller the APT program uses V101 and above For S5 controllers you reserve the
140. ller processes RLL math much faster than SF math When possible use RLL functions and procedures for math calculations The SIMATIC APT Programming Reference Graphics Math Manual lists RLL only and SF only math functions and procedures For those procedures that can be programmed in either RLL or an SF program APT generates and uses RLL logic For Series 505 Controllers if you use just one SF math function or procedure requiring SF programming in a calculation the entire calculation is done in an SF program The simple calculation in Figure 3 9 requires SF programming because a single variable F is a real number Programming Allowed Operators Integer Variables Real Variables RLL A B C D E SF Figure 3 9 Calculation Requiring SF Program For Series 505 Controllers use the PRAGMA statement in a math block that you are designing to be RLL or SFPGM only If you inadvertently use SFPGM code in math that you intend to be RLL only and vice versa a compile error is generated The PRAGMA statement is described in the Math Language Overview chapter of the SIMATIC APT Programming Reference Graphics Math Manual Use the Report option to see whether APT places the code for a calculation in RLL or an SF program 1 At the Program Content level of the hierarchy place the cursor on Object and select Report 2 When prompted for the type of report select the following option SFC CFB math to P C address 3 Examine the rep
141. lly or in parallel The sequence recipe specifies whether an operation must finish before the next operation is started or whether several operations are started simultaneously NOTE Although operations execute in parallel they are activated sequentially due to the nature of the graphical execution pattern If execution interlocking and synchronization is required include code for this within the various independent operational SFCs Approach to APT Program Design 1 45 Create the Code Objective Control Logic continued Figure 1 22 shows how the levels of control procedural structural and objective are implemented by the SFCs used in the laundry example Main SFC Inform Operator Process Call Procedure Is Ready to Start Activator Call Procedure Manager Main SFC and Procedure Procedure Manager Manager Provide Objective Control Load Recipe Procedure Activator Call Procedure Activator SFC Agitate Provides Structural Control SFC Agitate Subordinate SFCs SFC Provide Procedural Control Figure 1 22 Sequential Control Hierarchical Relationship 1 46 Approach to APT Prog
142. lues in 4 6 tag rpt file A 2 selection Index 1 CRs overflow 4 8 CVU recommendations for 3 31 Cyclic DB DXs specifying in TRAFDAT 6 8 Cylinder C 4 C 6 translated to PCS translated to TISTAR C 4 C 6 D Data block DB specifying for redundant control Data dictiona building reating 1 34 ns EE POSEES Data structure designating dictionary 1 35 DC get address utility controller address Debug direct address option A 2 Debug hints 3 14 Declaration types translated to PCS C 19 translated to TISTAR Demonstration programs loading Device C 4 C 6 extensions translated to PCS extensions translated to TISTAR C 4 C 6 PCS attributes and C 8 C 10 C 12 C 15 C 17 power fail recover TISTAR attributes and C 8 C 10 C 12 C 15 Device hints configuring pseudo devices Discrete device definition Downloaded program modifying 4 2 E ET200 I O rack configuring 3 25 Example programs loading loading the cooker 2 7 Index 2 Example programs continued loading the heat exchanger 2 14 loading the washer 2 2 Extensions fixed by compile B 1 B 6 F Flag hints 3 17 H HBU hints program download Hints coding debug utility 3 14 devices configuring pseudo devices math active continuous option 3 5 boolean logic CFB math 3 7 comparisons 3 3 event math CFBs 3 5 indenting 3 4 loop associate
143. mall Steps It is recommended you test objects in an incremental fashion That is develop a portion of your program and then test the objects Then develop the next portion of the program and test objects for that portion When you are certain that your code is correct then mark objects for translation Mark the Device Not the Elements When you want to mark a device you do not need to mark all the individual elements e g commands feedbacks etc Mark Loops When you mark a PID loop block most loop variables are included for translation It is unnecessary to mark analog inputs outputs for the loop separately in the I O Table When you mark analog inputs not associated with a PID loop or analog alarm remember these points A scaled real variable maps to the OSx CALC tag type with no alarm capabilities An integer raw variable maps to the OSx Al tag type with alarm capabilities APT does not fill in the alarm values To enter these values you must use the OSx tag configurator TISTAR Releases 1 x and 2 x or else edit the install tag file as described in Chapter 5 of the SIMATIC PCS 7 OSx Process Configuration Manual PCS 7 OSx 4 x NOTE Do not overload installation Limit the number of marked tags to 1 000 tags per program to speed up tag installation 7 8 APT and the OSx Operator Interface SIMATIC APT Applications Manual 7 3 Compiling the Program When you compile the program APT builds the executable code used by the
144. mming Hints 3 27 OSx Hints continued Selecting Unit Although APT can differentiate between identical names in different units Names OSx cannot The names shown below cannot be translated because the OSx names would be identical An error occurs when you mark the second name for translation APT Name TK_LEVEL Used in tank 1 unit TK LEVEL TK_LEVEL Used in tank 2 unit TK LEVEL Solution Use similar APT names but unique OSx names Choose short APT names that you can easily modify for the 12 character OSx name requirements Refer to the example below APT Name TK_LEVEL Used in tank 1 unit TK1_ LEVEL TK_LEVEL Used in tank 2 unit TK2_ LEVEL Other examples of appropriate OSx names are the ISA names used in your P amp ID drawings Alternative Solution Use unique APT names and unique OSx names An alternative is to use unique APT names that can be translated for OSx without error Refer to the example below APT Name TK1_LEVEL Used in tank 1 unit TK1_LEVEL TK2_LEVEL Used in tank 2 unit TK2_LEVEL The alternative solution makes unit copies in APT less simple to do because the general term LEVEL in Unit 1 is replaced with the specific term TK1 LEVEL When Unit 1 logic is copied to Unit 2 the name TK1_ LEVEL must be replaced with TK2_ LEVEL However if you choose unique APT names when you create your APT program you can save time and avoid confusion when you translate them for OSx 3 28 Programming Hints
145. modules or by configuring a User Module If you have an S5 controller you must program the IM308 card through the front panel of the card using COM ET200 the software that configures the IM308 card You cannot configure the IM308 card through APT After you configure the IM308 you can bring your ET200 I O into APT by defining them in the I O Table The I O Table will accept the following addresses IW0 126 QW0 126 PWO 254 and OW0 254 but will not accept page addresses Programming Hints 3 25 3 9 OSx Hints Selecting APT Object Names 3 26 Programming Hints APT allows you to translate APT names into OSx tags Detailed instructions for marking APT names and translating them are given in the SIMATIC APT User Manual APT permits you to use names having more than twelve characters However OSx uses names of twelve characters or less When APT translates a name as many characters as possible are used in the OSx name For example these names are translated as follows APT Name HORN HORN SIREN_23 SIREN_23 WATER_VALVE WATER_VALVE APT does not permit you to mark all the following water pump designations for translation because the OSx names for the water pumps would be identical APT Name WATER _PUMP_331 WATER PUMP 3 WATER_PUMP_ 332 WATER_PUMP_3 WATER PUMP 333 WATER PUMP 3 For the APT names representing Water Pumps 331 332 and 333 to be translated into unique OSx names remember the twelve character OSx requ
146. n_Rinse In_Rinse Clothes are rinsing N A In_Spin In_Spin l Tank is spinning N A Figure 1 13 Example Data Dictionary Template 1 34 Approach to APT Program Design SIMATIC APT Applications Manual Build the Dictionary Recipe Create a program level recipe named D Keep the name short so that anyone who examines the program will focus on the meaning of the extension and not the recipe name e g D IN_FILL D IN_SPIN See Figure 1 14 Recipe Units Element Name Description N A In_Fill Tank is filling N A In_Agitate Agitator is running N A In_Drain Tank is draining N A In_Rinse Clothes are rinsing N A In_Spin Tank is spinning Figure 1 14 Example Data Dictionary Recipe Keep values unique to avoid confusion Use multiples of eight if you intend to use OSx to animate tags that use values that are defined in the data dictionary NOTE You can designate that your data dictionary be only a data structure on the recipe usage table form A data structure does not get the handshaking code that recipes get but can be marked for tag translation SIMATIC APT Applications Manual Approach to APT Program Design 1 35 1 10 Create the Code Procedural Control Logic Continue your work on sequential control by writing the code to handle specific procedures Select one of the SFC templates that you developed for procedural control and the begin to enter the code that executes the appropriate tasks Do this for all the SFC templates Your priori
147. ne the program and add enhancements you may find the need to replace one Main SFC with another The Main SFC in the laundry example is named Phases Figure 1 10 Main SFC Procedure Activator Phases True SFC Agitate Drain True Figure 1 10 Example Procedure Activator SFC The temporary Main SFC the procedure activator has an initial step followed by a true transition Next is a parallel construction that contains a step for each subordinate SFC Within each of these parallel steps a call to one of the subordinate SFCs is made Note that none of the subordinate SFCs ever terminate each is in an endless loop Therefore the procedure activator never reaches the exit step This approach allows you to test and adjust event scheduling without being distracted by the details of what the SFCs must do The development of the actual SFC program code is discussed in Section 1 10 SIMATIC APT Applications Manual Approach to APT Program Design 1 31 1 9 Create the Code Recipes and Recipe Templates At this stage of the process design the program structure is in place It is time to return to the procedural control and complete this code This point in the process design marks the beginning of the work on recipes and recipe templates APT recipes are multi functional Recipes are used to assign meaningful names to values define operational setpoints or to specify
148. ned address to prevent the loop and analog alarm addresses from changing SIMATIC APT Applications Manual Programming Hints 3 31 4 1 4 2 Chapter 4 APT and Controller Memory OVGEFVICW ici ia Sa be de Source COG as cimas ada acid ta Acasa bane da id a da idas abide aw Randa dds bode ed a Ba Downloaded Program Memory and I O Usage 02 2c cece eee cee eee eee OVER aaa race veia Reserving Memory oooocccccc ent e nen nee eee Guidelines for Series 505 Controllers 00 0 cece eee eee Changing Values in Memory 00000 c cece eee ene ete eee Reserving I O Locations in Series 505 Controllers 000 0 cece eee Determining Memory and I O Usage oococcccccccccccc nett e eee eens Loops and Analog Alarms 0 ccc aka aach adaha dack a aaa A aak a a Aaaa aa R a aA A SIMATIC APT Applications Manual APT and Controller Memory 4 1 4 1 Overview Source Code When you compile your program APT uses the instructions and objects that you have defined to create RLL and SFPGM for Series 505 or STL for S5 To enhance scan performance the APT program includes an END statement at the end of the RLL for Series 505 controllers After you download a successfully compiled program to the controller do not make changes to that version of the program If you want to enhance the program copy the program and make changes to the copy You can put copies of the program on two different hard disk partitio
149. ng the entire unit or program and it takes longer Use the Verify option any time that you want to check for changes that may have been made to the controller program Series 505 only Select Force Compile in the Control File and recompile the program if you receive Internal Errors during a compile If you are still developing your program or making a lot of changes compile the program with the Force Compile option selected Do not select Force Compile when you make changes to only one portion of the program the system then compiles only those portions of the program that have changed since the last compile If the compile fails because you have incorrectly identified your controller configuration i e the size of memory or the number of RCCs for a 565 recompile without Force Compile selected after you correct the configuration in the Control File Archive your program frequently to protect against a loss due to a power failure Make changes to a copy of the program when you want to change a program that has been compiled and downloaded to the controller Consider placing copies of the program on two different hard disk partitions using one for editing compiling the other for debugging You are limited in the Debug features that you can use to test your controller program if you change the source code directly When you make changes in an SFC for example Debug does not display the SFC although the SFC code is still execute
150. nge 0 32000 A 20 offset analog input can be simulated by adding a SUM block with 6400 as an input feed valve 1 opened CLK gt USR feed valve 2 opened level analog CLK gt CLK gt USR pb gt exit valve opened CLK gt USR hb Figure 5 5 Example TUTSIM Algorithm for Mass Balance input Ll Figure 5 6 illustrates how to simulate a pressure or temperature response to a PID loop A first order lag FIO is placed between the output or setpoint and the process variable of the Series 505 controller PID loop PID setpoint CLK USR pb Figure 5 6 Example TUTSIM Algorithm for a PID Loop SIMATIC APT Applications Manual Dynamic Program Simulation 5 9 6 1 6 2 6 3 6 4 6 5 6 6 Chapter 6 Redundant Configuration for S5 Configuring an S5 155H Redundant System for APT 00 eee eee neces COVEIVIQW siii Track ee tt ad sai eden Ak aa a ee Options for Setting Up Your Redundant Configuration 0 0 0 ccc eens Generating an APT Address Report and Configuring COM 155H Generating an APT Address Report 02 00 cece cece e eee e eee eee eee Configuring Operating System Parameters from COM 155H Operating System SYSTEM Parameters 000 e cece eee e ete eens Configuring Data Block Transfer Lists from COM 155H 00e ee eeeeees Transfer
151. ngineers who have designed and developed process controls includes the elements described below Partition the process into units Try to divide the process along lines that represent the functional organization of the physical plant Then plan to dedicate one independent section of the application program to each equipment area When you partition a system you are promoting understanding as well as allowing for expansion Always think in terms of function when you choose the partitions Do not allow the physical size of the equipment or its representation on the P amp ID influence your decisions about partitioning For example a piece of equipment may be so complicated that it is drawn on a single sheet of the P amp ID This does not necessarily mean that you dedicate an APT unit to control that equipment It may functionally belong within another unit In the event that the equipment serves as an independent supplier to several other units function may dictate that you control this equipment through its own independent APT unit 1 6 Approach to APT Program Design SIMATIC APT Applications Manual You can improve the organization of your control program by partitioning the process by function not by task The simple process shown in Figure 1 1 is partitioned by function and by task to show the difference Partition by function Not by task clothes Funct
152. not yet known When you develop a program for an S5 controller you determine the addresses by setting the dipswitches on the I O modules You then use the I O Editor to enter these addresses into the I O Table For an S5 controller you can test code without the I O connected by selecting the image register in the I O Table Configure I O Enter the I O data into the I O Symbolic Name Table addresses alarm limits scaling data offset information etc Take the time to document the T O by including descriptive data and engineering units This saves time and avoids confusion for other people who need to understand your system When you make changes in the table remember to validate the I O after you exit the I O Table Define Discrete Enter the device data into the Device Definition Table type commands Devices alarm times limit switches etc Take the time to document the devices by including the descriptive data A Device Definition Table is available at both the Program Level and at the Unit Level Devices defined at the Program Level can be referenced in any unit in that program Devices defined at the Unit Level can be referenced only within that unit When you make changes in the table remember to validate the devices after you exit the Device Table Consider compiling the program and downloading it to the controller at this point Do this to verify that devices are connected to the correct I O points and that the alarm times are corr
153. ns oriented model of the system Be able to state in simple language what the system is supposed to do from the viewpoint of process operation If you are unable to explain it easily to another person you might ask yourself if you really understand it Keep in mind the next two steps top down analysis and bottom up implementation Approach to APT Program Design 1 5 1 3 Do a Top Down Analysis Consider the Whole Problem Then Subdivide At this stage of process control development you are concerned mostly with a system view of the process However be able to change your focus readily from the system view to a more detailed view so that you can anticipate and avoid as many problems as possible A design engineer who designs physical process equipment for a plant must subdivide the facility into functional units such as mixers or reactors Each unit is designed as an independent entity but with an underlying consideration for the process as a whole As a control engineer you can use the same tactic when designing the solution to a process control problem You can follow a structured modular approach by dividing a large control design problem into smaller more manageable sub systems You design each sub system independently keeping in mind the needs of the system as a whole and then integrate the separate results to provide the total design solution A systematic procedure that has worked well for Siemens Energy amp Automation e
154. ns using one for editing compiling the other for debugging A WARNING Debug allows you to modify the contents of variables in the controller However if the re compiled program has not yet been re downloaded the addresses the compiler assigned to the items you edited are not yet downloaded in the controller The address of an edited object may not be what you think and consequently your modifications could have unpredicted results Modifying re compiled objects with Debug could cause unpredictable operations that could result in death or injury to personnel and or equipment damage Fully understand what changes have been made to an APT object before modifying it with Debug APT supports limited debugging of a changed or non APT program If the program has been changed APT warns you that the program in the controller does not match the source code but allows you to debug the program in the controller If the program you wish to edit does not match the program in the controller or if the program was not originally created in APT you will only be allowed direct address capabilities in Debug If an SFC has been edited you cannot debug that SFC 4 2 APT and Controller Memory SIMATIC APT Applications Manual Downloaded After you have a downloaded program in the controller do not modify the Program downloaded program unless you fully understand the program logic In addition do not change the memory configuration of your contro
155. nsions for these dynamic blocks second order lead lag second order lag first order lead lag first order lag and dead time delay Table C 24 Dynamic Blocks Group 1 ae erase cont MIC EC ACI Table C 25 lists the extensions for the integrator and the derivative dynamic blocks Table C 25 Dynamic Blocks Group 2 do ENABL Block control bit Block sats Tapa oad Tapa eae SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 25 CFB Extensions continued Limiter Blocks The OSx type for each limiter block APT extension is listed in Table C 26 and Table C 27 Table C 26 Output Limiter do ENABL Block control bit OUTPUT INPUT INPUT Table C 27 Rate Limiter Block control bi OUTPUT INPUT Rate of change Tite C 26 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Math Blocks Table C 28 lists the OSx tag and extensions for the math CFB Table C 28 Math CFB Extensions IICA CT ENABLD Block status cle OUTPUT E OUTPUT F CY IO EB INPUT eno PO Table C 29 lists the OSx tag and extensions for the following math CFB types summer subtractor multiplier and divider Table C 29 Math Blocks Group 1 ke a INPUT a A INPUT tg 2 POr a var JE APOT tigo Table C 30 lists the OSx tag and extensions for the following math CFB types square square root and absolute value Table C 30 Math Blocks Group 2 OUTPUT Goad OUTPUT niegan D
156. nslated to OSx for each APT object SIMATIC APT Applications Manual Preface xiii Checklist In order to take advantage of the example programs described in Chapter 2 we suggest that you have the following hardware and software e Software release 1 9A of the Application Productivity Tool APT e IBMor compatible computer with an 80486 or Pentium processor with an EGA VGA or CVU graphics card e A SIMATIC 545 545L 545 Lite 555 565 565T 565P or 575 controller or an S5 Programmable Controller with a 928B 948 or 948R CPU See the APT Installation Appendix in the SIMATIC APT User Manual for cable pinouts and communication link options The Other Manuals This manual is not intended to be a primer on programming If you are not familiar with the techniques of programming with APT refer to the other manuals in this set e SIMATIC APT User Manual is a guide for using the operator interface to enter your program e SIMATIC APT Programming Reference Tables Manual and SIMATIC APT Programming Reference Graphics Math Manual provide the information that you need to design your process control solution These manuals describe the APT programming languages the characteristics of APT objects and the tables that you use to configure these objects Information is presented in the order that provides for the most efficient and logical design of an APT program e SIMATIC APT MAITT User Manual provides the information that you need to
157. nt Do not use TISOFT or any other external utility to change the I O configuration on your controller SIMATIC APT Applications Manual APT and Controller Memory 4 7 Memory and I O Usage continued Determining After a successful compile the compile rpt lists the amount of each memory Memory and I O type that is used to create the object code for a Series 505 controller or S5 Usage controller For a Series 505 controller this report also includes information on retentive and non retentive CRs and the number of Ys that are used as CRs overflow CRs To obtain information about the controller addresses that are used in the program create a report on the Object file The APT Symbol Name to P C Address Report indicates the exact P C locations used to store the APT variables Loops and Analog For both Series 505 and S5 controllers if you use a P or PI loop the Alarms Derivative time is set to zero on each scan If you use a P or PD loop the Integral time is effectively set to infinity on each scan to negate the integral portion of the PID equation If you want to change the loop type you must use APT and recompile and download the program again For Series 505 controllers only if you use any Standard or Advanced CFB the loop automatically includes one SFPGM to be called from PV SP and OUTPUT When you add the Associated Math option you create additional special function code As a result a large number of loops can cause lo
158. ntial long term problems At this stage you want to determine the high level requirements of the tasks identified in the previous step The analysis at this stage is intended to determine the essential elements of the task Consider the laundry room example again Figure 1 2 The fill phase adds water to the tank up to a predetermined level The add soap phase meters a predetermined quantity of soap into the washer The agitate phase runs the washer s agitator for a predetermined length of time The drain phase pumps water from the washer The spin phase runs the spin motor and injects water into the system during the initial phase of the spin phase Each of the previous statements represents a high level description of the task without specific details as to what is involved in accomplishing the task For each phase you need to specify functional requirements For example consider the fill phase 1 8 Approach to APT Program Design SIMATIC APT Applications Manual First determine whether the system will provide a single level several levels or a continuous range of level settings For a flexible system you may provide the operator a switch setting for selecting high medium low and extra low water levels This switch setting will be used to determine the level setpoint for the fill phase At this stage however the only requirement to consider is whether one or multiple level settings is required The temperature of the water in the
159. nting 3 4 loop associated math parentheses 3 4 RLL SFPGM math 3 6 Memory reserving for S5 for Series 505 reserving for RBE Memory allocation creating code Memory types translating from APT to PCS S5 Series 505 7 2 Installing APT example programs 1 16 2 2 E Interlock function hints 3 17 Interrupt DB DXs specifying in TRAFDAT 6 8 IOCONF configuration for redundanc Motor translated to PCS C 4 C 6 translated to TISTAR C 4 C 6 Index 3 N Naming convention code 1 20 O Objective control defined permanent main SFC code procedure manager SFC code sequence array 1 43 sequence recipe sequence recipe template Operating system S5 configuring parameters for redundancy 6 6 default parameter values Operator interface controller addresses 1 28 1 29 graphics 1 29 marking tags 7 5 translating tags Operator interface design bottom up implementation 1 18 Overflow CRs P Parameters S5 operating system configuring for redundancy default values Partition process code Partitioning a process 1 7 PCS attributes APT devices and C 8 C 10 C 12 C 15 C 17 creating database with APT 7 217 5 device tag translation C 6 entering alarm values 7 8 install tag example install tag file 7 2 A 10LA 15 example analysis A 14 A 19 identifiers and attribute A 20 spreadsheet example A 12LA 17 tag types A 16LA 21 process groups
160. ntrol the device through an interlock Program a device as an APT null feedback device e g VSN MSN when these conditions are true e There is no feedback from the device but you want to allow the device a certain length of time to react to a command A wait state is required before logic execution continues You can show a traveling state e Your application requires the controller to determine when the device cannot operate through an interlock The operator can still operate the device manually The APT VSN for example provides the OPND extension that becomes true after a specified period of time The NRDY extension interlocks to the fail safe condition You can also use the user defined devices VUD MUD CUD and PUD These devices use two timers and create extensions in V memory and C memory for Series 505 controllers or DB memory for S5 controllers Use math blocks for your customized math for controlling the devices SIMATIC APT Applications Manual Programming Hints 3 23 Configuring Devices continued Using Pseudo You can define a device to control any flow path Use math logic to operate a Devices combination of valves and motors All feedbacks can be ANDed to create a single feedback See Figure 3 15 Device Table Entry PATH_VLV Type VSD Valve single drive dual feedback Description Product drain system Energized State O Open Open Close command PATH_VLV_OC Open limit switch PATH_VLV_OLS Close limit swi
161. o fill and the process is waiting for the fill task to finish The recipe must set strt_fill to true before the wait is accepted At Step S7 the process waits for the Fill SFC to finish Transition T10 Fill_done is true when the Fill SFC has finished Step S8 Clear strt_fill clears the start fill flag Transition T11 is always true 1 44 Approach to APT Program Design SIMATIC APT Applications Manual Start Start Wash Cycle Rinse Cycle Fill Control Soap Control Soak Control Agitate Control Spin Control Drain Control e Step S9 contains no code but is required because a convergence must be followed by a step Transition T12 is always true Transitions T13 T37 and Steps S10 S24 handle scheduling for the Soap Soak Agitate Spin and Drain SFCs with code similar to that used for the Fill SFC e The branch containing transitions T38 and T39 always true and Step 25 no code allows the SFC to continue running if no other transitions evaluate to true in the event of bad recipe data Main SFC Ti S2 Bad I I Recipe Data T2 T5 T38 SIMATIC APT Applications Manual Figure 1 21 Example Procedure Manager SFC The procedure manager SFC activates operations sequentia
162. o validate compile and test code as you develop it Remember to do this in an incremental fashion to reduce the debug effort Use a test controller that has no connected I O SIMATIC APT Applications Manual Approach to APT Program Design 1 27 1 7 Create the Code Operator Interface Addresses Graphics Identify Addresses for Operator Interface Database Follow the steps below to identify the APT objects that are to be referenced by the operator interface This procedure was designed for an OSx system but you can use it for any operator interface Both steps can be done from the APT environment by selecting the appropriate options 1 Mark tags for translation In this step you select objects tags that are to be used by the operator interface and that must have unchanging controller addresses 2 Compile the program with the Yes option selected in the Build Translate File field of the Compile Control File If controller addresses are to remain fixed select the No or Append option in subsequent compile operations This step builds the executable code used by the controller and creates a file that contains controller addresses that are fixed unchanging for each object that you marked in Step 1 If your operator interface is an OSx system you can use the file that was created in step 2 to build the OSx database This is an automated process and is described on page 1 29 Build Operator Interface Database If your operator
163. oc Interlock CFB Pump 2 Interlock Figure 1 7 Example Interlock Blocks Approach to APT Program Design 1 25 Create the Code Continuous Control Logic continued Note that there is a practical limit to the number of interlock CFBs that you group within one CFC If you have a large number of interlocks in a unit consider placing all device interlocks of one device type into one CFB all loop interlocks for one loop type into another CFB etc as shown in Figure 1 8 Interlock CFC Unit 1 Valve Interlock CFB Valve 1 Valve 2 Valve 3 Valve 4 Pump Interlock CFB Pump 1 Pump 2 Pump 3 Temperature Loop Interlock CFB Loop 1 Loop 2 Loop 3 Loop 4 Pump 4 Pressure Loop Interlock CFB Loop 1 Loop 2 Loop 3 Loop 4 Figure 1 8 Example Interlock Groupings 1 26 Approach to APT Program Design SIMATIC APT Applications Manual Every APT device and CFB has a NRDY extension Use it in your interlock code as an indication of whether the device or CFB is ready for operation Table 1 2 lists some interlock conditions and shows how the NRDY extension can be used in the program code Table 1 2 Uses for the NRDY Extension Object to Go to ae Flow controller in FENRDY TCINHHA manual Sati oars The temperature is IF EDGE FC NRDY THEN output too high FC OUT 0 0 ENDIF Remember t
164. ocedures for translating tags into the OSx format The procedures vary depending upon your controller type and how your APT and OSx systems are configured Refer to the SIMATIC APT User Manual for instructions in following one of these procedures e Tags translated on a OSx APT engineering node using the Industrial Ethernet network Series 505 and S5 Tags translated on an APT workstation that is not in communication with OSx using the TRANSOFF option Series 505 and S5 e Tags translated outside the APT environment using the TRANSOFF option Series 505 and S5 Tags translated on a TISTAR operating station Series 505 only Tags translated on a non TISTAR operator station Series 505 only 7 14 APT and the OSx Operator Interface SIMATIC APT Applications Manual Appendix A Defining a Variable s Address A 1 Determining a Variable s Address Reading Translated Tag Reports Using DEBUG seccion ba e A a KERSEET ETES ad ao Reading Symbol Address Reports Using the APT DC Utility 0 02 naana Reading the INSTALL TAG File for TISTAR Release 1 x and 2 x Series 505 Reading the INSTALL TAG File for PCS Release 3 x or OSx Release 4 x An Analysis of the INSTALL TAG File Examples for PCS OSx SIMATIC APT Applications Manual Defining a Variable s Address A 1 A 1 Determining a Variable s Address To determine the address of a specific variable you can Read the report for translated tags e Use the Debug Dir
165. oller 1 OSx Command Form Data OB AEDU Written to Controller Override P C Memory Location Open Vxx OVRDO 1 C of Length 2 Close Vxx OVRDC 1 Both Vxx OVRDO 1 Vxx OVRDC 1 Neither Vxx OVRDO 0 Vxx OVRDC 0 Mode_Cmd P C Memory Location Disable Vxx DSBLD 1 C of Length 2 Lock Vxx LOCKD 1 Unlock Vxx LOCKD 0 Setpoint PC Memory Location Vxx MOPEN 1 C of Length 1 Timeout_1 3 P C Memory Location Xx 0 1 sec TCP Not implemented in OSx status word Timeout_2 3 na P C Memory Location Integer X 0 1 sec Not implemented in Vxx STCP OSx status word TCP 1 Refer to Figure C 5 2 Vxx represents VSD VDD VMD or VUD For the cylinder the override extensions are Cxx OVRDE and Cxx OVRDR The setpoint extension is Cxx MEXTEND The timeouts are Cxx ETCP and Cxx RTCP 3 For OSx the timeout_1 and timeout_2 attributes are reflected in the status word via the combination of the opened and closed bits as shown below VLV2 Opened Closed State 1 0 Opened 0 1 Closed 0 0 Travel 1 1 Failed C 18 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual 1 0 The OSx tag type and the corresponding I O types are listed in Table C 14 When you translate values that are defined with a high and low range the low range cannot be greater than the value that you enter in the form When you translate a digital output the command and status of the translated tag both have the same controller addr
166. om download to download e In Figure 3 12 execution for the PID block that is graphically connected to the split range and scale blocks requires at least an additional 0 5 second more time than the PID block that contains associated math e Additional SF blocks scale and split range in Figure 3 12 tend to increase the program execution time Not This PID With Associated Math HA Place Math Calculations in the PID Associated Math Figure 3 12 Consolidate Math Functions 3 12 Programming Hints SIMATIC APT Applications Manual 3 4 Recipe Hints Avoid Using Use integers instead of boolean variables as recipe elements Recipe Boolean Variables assignments use excessive code when boolean elements are included as Recipe Elements Use these math function procedures to move boolean entities to and from recipe elements and boolean arrays e BITS _TO_INT INT_TO BITS These operations generate more code in RLL code segments use PACK BITS procedure e BITTEST e BITSET e BITCLEAR PACK BITS SIMATIC APT Applications Manual Programming Hints 3 13 3 5 Charts 3 14 Hints for Using Debug Programming Hints Define the Debug charts under the chart heading in the Debug hierarchy that has the same name as the SFCs used in the program In these charts group all information of interest to you when troubleshooting that SFC Remember these functions
167. on consists of doing all the related tasks Approach concerned with designing and creating the application program Approach the design as a series of levels with a number of layers within each level Level and layer are defined as follows A level represents the degree of automation for a process ranging from operator control to full automatic control A layer represents the tasks that you have to complete in order to bring a process to a certain level of control On Off 7 NS agitate ES 1 12 Approach to APT Program Design Level 1 At Level 1 control the degree of automation is such that the operator can manipulate the control system easily Safety protection logic has been incorporated into the process and continuous control logic is in place At the operator station the operator must manually operate devices modify loop modes and change set points in order to run the process The system is ready for loop testing PID tuning and physical equipment testing You need to verify that an operator can successfully monitor and control the process from the operator station through the controller to the field equipment In the laundry example you have a washing machine that requires considerable manual control The water valves are connected but you open and close them manually The agitator can operate but you must start it and stop it You must also start and s
168. op overruns if you use small sample times For both Series 505 and S5 controllers the Dead Time Compensator Feedforward Output Adjust and Feedforward Setpoint Adjust typically require larger sample times than other CFBs These blocks automatically include a Lead Lag simulation which occurs on each scan The Feedforward Setpoint Adjust can be programmed without the Lead Lag option For Series 505 controllers if you do not select the Map Tuning and Alarm Data to S Memory field of the PID form all Loop and Analog Alarm information e g setpoints tuning parameters etc are stored by APT in V memory and written into S memory Any attempts to change S memory with an external device LAM TISOFT etc are overwritten You can use the APT Symbol Name to P C Address Report to determine the V memory locations for the Loop and Analog Alarm values 4 8 APT and Controller Memory SIMATIC APT Applications Manual For S5 controllers for loops and analog alarms set your sample time to a reasonable value The sample time cannot be less than the cyclic scan time The loop calculations occur either with each scan or when the sample time is reached For an S5 controller only scaled analog inputs and real values can be used as the process variable PV Analog inputs are scaled unless you select NO SCALING in the I O form See the chapter called Math Functions and Procedures in the SIMATIC APT Programming Reference Graphics Math Manual for a
169. or OSx Table 7 2 lists these objects An AREA tag is an APT recipe area A UNIT or OSx parent tag is the unit in APT to which the APT object belongs The non networked tag is an object in APT for which the controller address is selected as none This means that no controller address was assigned and that it cannot be downloaded to the controller The non networked tag is for OSx use only you cannot use it anywhere else in the APT program Table 7 1 OSx Tag Types APT Object OSx Tag APT Object OSx Tag APT Valve Device Real Variable Analog Input 2 VLV2 1 Digital Output Boolean DO MTR2 Digital Input or APT Flag APT Reversible Motor Device RMTR PID Loop LOOP APT Unit UNIT CTO CA AN 1 Used by many objetts in APT For a detailed list TtefeFto Appetidik C OSx and TISTAR Tag Translation 2 Analog Input can be translated as both a CALC and as an Al tag type Analog Inputs also include Thermocouple and RTD inputs SIMATIC APT Applications Manual APT and the OSx Operator Interface 7 5 Marking Tags for Translation continued Table 7 2 Objects Used as Special Configuration Tools for OSx APT ee OBESE APT Extension OSx L OOd Declarations Text array TEXT tag DI10 DI10 tag DO10 DO10 Unique status status variable _ name variable_name STATUS A E None is specified as Recipe Recipe recipe_name INUSE In_use bit Recipes recipe_name DSTBL Stable bit recipe_name DRDY DataR
170. ort If the report does not show that a calculation is assigned to an SF program it has been coded in RLL SIMATIC APT Applications Manual Consolidate CFB To reduce controller overhead consolidate Series 505 SF math into as few Math for Series 505 CFBs as possible For example it is preferable to use one math block Controllers instead of a combination of the Summer Subtractor Multiplier and Divider blocks Figure 3 10 Do This Not This Multiplier CFB D F Subtractor CFB e Figure 3 10 Consolidate CFB Math Consider these other points when you create code for math calculations Except for comparisons lt gt lt gt real number calculations are always done in an SF program Associated math calculations for PID loop and analog alarm processing are also done in SF programs e Arrays with simple number indexing array 1 are placed in RLL An array with an index composed of an expression array i is placed in an SF program e Read bit 14 in Status Word 1 STWO01 to see if the RLL scan is overrunning When the bit is true 1 the scan is too short to execute the entire program in the designated scan time The variable Program_name TSCAN contains the time in milliseconds for the last scan Do not mix RLL math functions and procedures with SF math functions and procedures The program does not compile and the validation utility
171. ou compile the program Choose names for your I O and devices that are meaningful so that you can easily identify their functions If you intend to copy these objects for use elsewhere in the program remember that names must be unique as well as meaningful Initially try to choose names that are less than nine characters in length Choose names that are easily transferred to the operator interface and avoid creating a cross reference to which you must continually refer Begin planning your code tests early to anticipate problems that may occur The simulation program is an optional task but is recommended as an excellent way to test your code before process startup The simulation allows you to concentrate on debugging the program without being concerned with the logistics of doing the tests A software simulation program allows you to test your process control program by simulating real time conditions Since software routines can be stored as files you can run them over and over very quickly and simply note the results APT includes a utility program called MAITT that simplifies the task of repeatable logic testing You can design the test routines to generate reports that are stored or printed With MAITT it is very easy to test the control system response to variable inputs When you develop new code you can easily test the existing code to verify that it still executes correctly Examine the partitions that you defined when you sub divid
172. phics Math Manual Group the Interlock Place all logic and events that set related devices or CFBs to the not ready Functions state into the same interlocked CFC During a debug session this enables you to avoid searching for all the various program sections that could set a device to not ready You need only check the inputs at the single location in which the NRDY bit is set One input bit can represent the logic of complex code executed elsewhere Use a comment to indicate location of the code refer to Figure 3 14 SIMATIC APT Applications Manual Programming Hints 3 17 Miscellaneous Hints continued Program Wash_dem Unit Washer CFC Interloc INTERLOCK INTERLOCK INTERLOCK INTERLOCK SPIN_IL H20_ILK AGIT_ILK DRN_ILK XXXXXX F1 F2 F3 INTERLOCK E OPTs mi E y Name _H20_ILK Description water valve interlocks Priority type HIGH LOW Press F10 to edit math text Purpose Shutdown the supply valves if the tank level is too high variables use cold_water nrdy cold water valve shutdown interlock hot_water nrdy hot water valve shutdown interlock ws_level inhha level reading is too high ws_level in level reading hold_washer place washer into pause step fill_setpt desired washer level strt_fill p fill cycle active fill_at_sp tank is at setpoint level stop_spin see CFC stop_stp boolean valve_nrdy b
173. process it for you Thank you I a ae SIMATIC APT Applications Manual Structural Control You plan the flexibility for the system structure A very rigid system has a fixed and definite execution pattern A flexible system has an open data driven pattern For this reason a flexible data driven design is recommended Consider this you can build a rigid system from a data driven pattern but you cannot build a flexible system that is based on a rigid structure In the laundry example each of the operational phases is independent and can be executed at any time with a pushbutton when procedural and structural controls are in place Interlocks are in place to prevent certain phases from executing simultaneously such as Fill Tank and Drain Tank Objective Control You impose a data driven execution pattern upon structural control The process operation becomes essentially automatic subject to operator intervention and has the full flexibility offered by many recipes In the laundry example you select the wash cycle that drives the various procedures Fill Agitate etc You can select from one or more wash cycles start the washing machine and leave knowing that when you return the clothes will be washed Level3 A process at Level 3 control has been developed and improved thoroughly All necessary and desired refinements e g report design operator help screens etc have been added Level 3 control may
174. programs have the second highest priority for execution A cyclic SF program is executed when the input to the RLL SF program instruction transitions from off to on When the cyclic SF program has terminated it is automatically re queued for execution based on the programmed cycle time 0 5 second increments This process continues as long as the input to the RLL SF program instruction is on When the input turns off the cyclic SF program is removed from the queue For the 545 545L 555 and 575 you can adjust the cyclic SF program time slice to your own specifications For the 565 565T 565P the processor allocates approximately 8 of the program execution time to cyclic SF programs 3 8 Programming Hints SIMATIC APT Applications Manual Priority and non priority SF programs have the third highest priority for execution APT allows you to create only non priority normal SF programs The difference between high and low priority Interlock blocks is their position in RLL All high priority blocks are placed near the top of the RLL If the code in the high priority Interlock block creates an SF program a normal SFPGM is created and called from RLL APT creates two priority SF control blocks for each unit The first control block is used to scale unfiltered analog inputs and most math CFBs exceptions Interlock and Math The second control block is used to scale and filter analog inputs that you have marked as filtered Both of these cont
175. queue is full Non priority SF program queue is full Cyclic SF programs are overrunning Analog alarms are overruning 1 Loops are overrunning All priority and then all non priority SF programs are executed in turn Figure 3 11 Status Word 162 The 545 545L 555 and 575 allow you to queue up to 32 cyclic SF programs at once If you create more than 32 cyclic SF programs only the first 32 that are queued will be executed Check bit 8 in Status Word 162 to see if the queue is full See the procedure on page 3 5 for a way to create more than 32 cyclic events 3 10 Programming Hints SIMATIC APT Applications Manual Handling Task To correct overruns consider the following options Overruns e Increase loop and analog alarm sample times where possible e Separate math that can be done in RLL from SF program math e Combine several SF programs into one An example of this is shown in Figure 3 12 For a 545 545L 555 and 575 you can also use the Peak Elapsed Time words For example you can check LPET to determine whether or not a loop is coming close to overrunning If the value in the LPET approaches the sample time you can increase the loop time slice Alternatively you can decrease the other time slices This reduces the overall scan allowing the loops to run more often in a given time When you determine the base location for SF modules consider the impact on the controller scan Updat
176. r In order to develop a working internal model of the system consider the following example The objective is to assign to yourself the task of task master manager and to delegate all the other tasks The example is built around the washer example and the task master manager will be the master washer Keep in mind the following considerations e Suppose that you had a large number of people whom you could ask to run your process Figure 1 3 You can employ as many as you like however they are not free They must be paid which means there is a cost to using them in your process Also consider that a diverse mixture of skills and abilities is available for you to utilize Some of the people are good supervisors and coordinators others perform detailed tasks well Each skill level has a certain cost Take care to match the skill level to the task e Consider the laundry room example again The washing machine has valves and motors that need to be controlled and monitored Control of a valve is a mundane and rote task but one which requires attention to detail and obedience The task of master washer on the other hand requires the ability to work with others and to coordinate their activities Skill with detailed tasks is less important You are wasting valuable resources when you select a master washer to handle valve control or select a valve controller to do wash coordination 1 10 Approach to APT Program Design SIMATIC APT Application
177. r Series 505 controllers select the User Module To configure the Peerlink Module in a Series 505 controller enter the appropriate information in the Module Table Then reserve at least sixteen V memory locations in the Compiler Control File for each node on the Peerlink network In addition you must assign values to the ALO and AHI T O points that represent the starting and ending addresses of the Peerlink Table Refer to the user manual for the Series 505 Peerlink Module for more information about configuring this module Module configuration for the Series 505 HSPI and HSC Modules is not fully supported No channel setup data that you enter is sent to the module The WY memory locations for an HSPI Module with the prefix HSPI1 can be initialized in an event math block as shown below 1111114 Bit position 1234567890123456 HSPI1_C1SET 2 001010000010001 1 Channel 1 Setup HSPI1_C2SET 2 001010011100001 1 Channel 2 Setup HSPI1_C1P1 32000 Channel 1 Preset 1 HSPI1_C1P2 1 Channel 1 Preset 2 HSPI1_C2P3 32000 Channel 2 Preset 3 HSPI1_C2P4 1 Channel 2 Preset 4 Refer to the user manuals for the Series 500 High Speed Pulse Input Module and the Series 505 High Speed Counter Encoder Module for more information about configuring these modules ET200 I O racks can be used by both controller families For Series 505 you configure ET200 from the Module Editor You can define the ET200 rack with existing APT
178. r and contains the tag type and name of the first tag shown in Table A 1 This line determines the amount of information associated with each tag Table A 2 lists the TISTAR tag types which are determined by APT Table A 2 TISTAR Tag Types MC BO EA VINE Digital input or APT flag APT motor device MTR1 PID loop LOOP APT motor device MTR2 Analog alarm or Al APT reversible RMTR analog input motor device Digital output Text TEXT Paital mpat DI10 array of 10 INSTALL TAG File Subsequent Lines The next several lines start with different identifiers depending upon the tag type P R V C or N and contain attribute information for the first tag listed in the install tag file shown in Table A 1 The number of lines for each tag varies with the tag type Table A 3 lists the attribute identifiers and a description of what is contained in each Table A 3 Tag Type Attribute Identifiers Identifier Field Contents Description of tag O R Name of TISTAR recipe area if tag is part of recipe Attribute with an initial value only may be zero one or more N Attribute with an address options and an initial value may be more than one c Component name in recipe area if the N attribute above is part of a recipe A 8 Defining a Variable s Address SIMATIC APT Applications Manual The N identifier precedes the TISTAR attributes that have a corresponding address in the controller TISTAR attributes include STATUS VAL
179. r major steps 1 Assign addresses to objects 2 Mark objects for translation Select objects that are to be used by the operator interface and that must have unchanging controller addresses 3 Compile the program Create a file that contains tag data 4 Translate the tags Place the tag data into a formatted database that can be used by the operator interface You must follow each step for any operator interface For OSx all four steps can be done by selecting the appropriate option while you are executing APT For a non OSx operator interface you can do Steps 1 3 while executing APT Step 4 is a manual procedure that requires you to enter data into the database used by the operator interface The format for the database depends upon the operator interface that you use One attribute that must appear in any operator interface database is the object s address in the controller 3 30 Programming Hints SIMATIC APT Applications Manual 3 11 Recommendations to the CVU1000 10000 User A Series 505 controller can have a CVU1000 10000 operator interface this feature is not currently supported for S5 The default displays created by the CVU for loops and analog alarms assume that all loop analog alarm information is located in Series 505 S memory Enter X in the Map tuning and alarm data to S Memory field of the PID form in order to use the default CVU Loop Tune Page for changing the tuning parameters or outputs Also use the user defi
180. ram Design 1 37 1 11 Create the Code Structural Control Logic Structural Control You completed most of the work that comprises the design of a structural control when you created the templates and procedure activator for procedural control Section 1 8 To finish the design of the structural control you need to finish the code for the procedure activator SFC and verify these items e The procedure activator SFC can successfully call each procedural SFC e Each procedural SFC operates correctly when called by the activator In the laundry example the temporary Main SFC called Phases coordinates the activation of the procedural SFCs The steps and transitions are shown in Figure 1 16 The actual operation of Phases is very simple Once called by an SFC at a higher management level which you program for Objective Control page 1 40 Phases activates all the procedural SFCs in parallel Procedure Activator SFC S1 r Td Figure 1 16 Example Procedure Activator SFC 1 38 Approach to APT Program Design SIMATIC APT Applications Manual The relationship between the procedure activator SFC and the procedural SFCs is shown in Figure 1 17 Procedure Activator Ld True Procedure Activator Provides Structural Control Procedural S
181. ram Design SIMATIC APT Applications Manual Figure 1 23 shows how the levels of control procedural structural and objective are reflected by the APT hierarchy PROGRAM HIERARCHY PROGRA PROGRAM UNIT CONTENT 2 crts opts 1 MM Esc F1 F2 FS WJ culi CONTROL OBJECT DECLARE RECIPE SUBROUTI WASHER SEQUENC OP_PARM D_DICT Finish Level 2 Tasks SIMATIC APT Applications Manual COMPILE DECLARE 1 0 DEVICE DECLARE RECIPE 1 0 symbolic name table Device definition table Declaration table Recipe usage table DOWNLOAD MAIN_SFC lt BATCH SPIN DRAIN AGIT SOAP SOAK PHASES FILL SFCs Recipe management The main calling structure Batch step program task mgr Timed spin cycle Drain the water Timed agitate cycle Add soap Soak the clothes Invoke the washer phases Fill washer CFCs Figure 1 23 APT Hierarchical Relationship After you create the logic for objective control the Level 2 tasks are completed Turn to Section 1 13 for a description of the Level 3 tasks Approach to APT Program Design 1 47 1 13 Create the Code Level 3 Control Level 3 Control Good morning Ralph Please insert your laundry and will be happy to process it for you Thank you Level 1 Control At this stage of the process design you start on the Level 3 tasks Although you can follow the
182. re 2 2 Cooker Example P amp ID 2 12 Program Descriptions SIMATIC APT Applications Manual Process I O for the Table 2 2 lists the Series 505 I O for the Cooker Example program Cooker Table 2 2 Cooker Example I O Cooker Number One Low High a as o ESC CS oa po 0 PO rre ICAC o ea AA PR II IR EEN we EL EC AR PR IR IR EEC rawe o ECC AA IR IO IR EEE SS 7 Pasar po po PT rro 7 Pasar 10 008 PO pra 7 erae o EI ARA PR IR IO ET ICC LO EC AR FR IR IR EEE reo foo fo rro reia po pa rro Fean fo es AR IR IR IR EE o Feared DO e AR PR IR IR ETE Fewn OK oe ARA FI E E Fisk ame DO fee AR IR IO IR ICA ero E A E octet fa ps 7 reo 1 e onw a was A f 00 fio EN Toe ar wo 7 fee foo 90000 ond eet reai se o w 7 fe O SSU Weigh Tank A A A Name ype Address Subivpe Units Range Range Description eee poe a oo mes o EC IEA FR O O CITAN IEC EL CC Paar ICAA 0 EIA AE FR O O ELE ICONO DO vous IR FR O IR EEC Fesa o EC IE FR E O EA ICO EL IC IR FR PR A EA ICON LN EC IR FR IA E EE Picea woo 700 9000 tocata SIMATIC APT Applications Manual Program Descriptions 2 13 2 3 Examining the Heat Exchanger Example Loading the To install HX_ DEMO follow these steps Heat Exchanger Example for Series 1 Insert the APT software CD in your CD ROM drive or if you created 505 Controllers diskettes from the CD insert DISK8 in your diskette drive 2 Ensure that the
183. rlocks for those devices that are manipulated by the SFC In the laundry example the Fill SFC spends nearly all its time waiting for the tank to fill with water To enable an operator to terminate this SFC declare the integer kill_step and provide the code that loads it with the name of the step to be terminated The following math in a CFB causes the Fill SFC to transition to its last step and clears the terminate flag If kill_step fill_tmp and start_fill then Latch kill_fill activate the kill fill step Kill_step 0 reset the kill command Endif You should also use the kill_fill flag in the appropriate interlock blocks to ensure that all devices that need to return to the de energized state respond to the kill_fill flag SIMATIC APT Applications Manual Approach to APT Program Design 1 49 1 14 When You Create Code Suggestions Consider these software design guidelines when you begin writing the program Do add the soap first or turn on the water Is this how this is supposed to work a i i 1 50 Approach to APT Program Design Understand the problem Do not write any code for a section of a program until you are certain that you know how this section is supposed to function and can explain it clearly to a colleague Otherwise you can do a considerable amount of rewriting Your program may become patched and in
184. rol blocks are executed as quickly as possible For the 545 545L 555 and 575 you can adjust the time slices yourself If necessary you can allocate equal processor time to the two types of SF programs For the 565 565T 565P the processor allocates approximately twice as much program execution time to priority SF programs as to non priority SF programs Your calculation of an SF program execution time based on the statement time s is the actual execution time required for the controller to run the SF program The time from when the SF program is placed in the queue until the execution begins can vary This wait depends upon the number of SF programs scheduled how long they take for execution how long the time slice SIMATIC APT Applications Manual is and the priority of other SF tasks scheduled for processing Programming Hints 3 9 SF Program Loop Analog Alarm Hints for Series 505 Controllers continued Detecting Task As the number of loops analog alarms and SF programs increases you Overruns need to test your program to see if any of these tasks are overrunning Create code to check the status of the bits in Status Word 162 STW162 shown in Figure 3 11 You can also check status by selecting the PC Diagnostics Cell Aux Function from the APT Debug utility Status Word 162 7 8 9 10 15 16 Cyclic SF program queue is full Priority SF program
185. rve you better How would you rate the quality of our manuals Excellent Good Fair Poor Accuracy Organization Clarity Completeness Graphics Examples Overall design Size Index Would you be interested in giving us more detailed comments about our manuals Yes Please send me a questionnaire No Thanks anyway Your Name Title Telephone Number Company Name Company Address Manual Name SIMATIC APT Applications Manual Edition Eighth Manual Assembly Number 2592843 0008 Date 4 01 Order Number PPX APT 8103 8 FOLD 3000 BILL GARLAND RD P O BOX 1255 JOHNSON CITY TN 37605 1255 SIEMENS ENERGY 8 AUTOMATION INC BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 3 JOHNSON CITY TN POSTAGE WILL BE PAID BY ADDRESSEE ATTN TECHNICAL COMMUNICATIONS M S 1255 SIEMENS ENERGY 8 AUTOMATION INC POBOX 1255 JOHNSON CITY TN 37605 1255 FOLD NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES
186. s 0 eee C 9 APT Tag Correlation with OSx RMTR Attributes o 0ooococococorororn C 11 OSx MTR2 Status Correlation with APT Extensions 0000 c cece eee e eee eee C 13 APT Tag Correlation with OSx MTR2 Attributes 0 00 eee C 14 APT Tag Correlation with OSx VLV1 Attributes 0 0 00 eee eee C 16 APT Tag Correlation with OSx VLV2 Attributes 000 ccc cee eee C 18 VOW et ece Moret O Mie eae ie ia es re teeta nye lee C 19 Declarations sion aca env aaa EREE acacia aval a aan A ara Aap a C 20 Declaration TIMGIS is cache aad Whew rd hae weed Aba aaa Gna waa he Made hae wea C 21 Declaration Counters 66 0 c ect eee tenet eee C 21 ROCES seca sida tts baa atten dS ned idee wise te da te AA AA C 22 Dead Time Compensator oooccccccccc tenet eens C 23 Feedforward Output Adjust 00 0 cece ent ene C 23 Feedforward Setpoint Adjust 0 00 cece cece tenet eee C 24 Ratio STO tic ia adda A tea Nae ie dae te Saaa its C 24 Dual MOE ii comicios saved a acne a casieta val A snags dave KENS KRESK RR C 24 Contents xi List of Tables continued C 24 C 25 C 26 C 27 C 28 C 29 C 30 C 31 C 32 C 33 C 34 C 35 C 36 C 37 C 38 C 39 C 40 C 41 C 42 C 43 C 44 C 45 C 46 C 47 xii Dynamic Blocks Group 1 0 0 eee cece tenet eens Dynamic Blocks Group 2 arri ie aa i ceed eee eens Output Limiter Rate Limiter Math CFB Extensions
187. s Soap dispenser Agitator motor Spin motor with an analog speed sensor Open door sensor Vibration monitor Process Functions The process is to be used to wash and rinse clothes and provides these of the Washer services 2 4 Program Descriptions The system provides the capability of washing large medium and small loads of clothes The fill level setpoint is user selectable The temperature of the wash and rinse cycles is user selectable The temperature of the wash cycle can be hot warm or cold The temperature of the rinse cycle can be warm or cold The process provides two wash cycles normal or permanent press The process sequence is identical for the two cycles but the setpoints such as agitation time are different The operator has the capability of placing the process on hold and of advancing the process to the next step in the cycle at any time The operator has the capability of aborting the process at any time The abort sequence empties the tank and spins the contents of the tank before resetting the system The operator has the capability of monitoring the state of the wash sequence and of modifying the steps in the sequence while the process is executing Programmed interlocks prevent the spin motor from running when the door is open or when the vibration sensor is tripped Alarms notify the operator when either of these two conditions are true The operator is required to acknowledge the vibration alarm be
188. s Fill_lev3 Fill level 3 Average Minutes Wsh_agi_tim1 Wash agitate time 1 Ex_long Minutes Wsh_agi_tim2 Wash agitate time 2 Average Minutes Rns_agi_timi Rinse agitate time 1 Ex_long Minutes Rns_agi_tim2 Rinse agitate time 2 Figure 1 12 Example Recipe Choose values for names as is appropriate for your program but always assign the following values to these loop modes so that they correspond to the loop extension SMODE For information about SMODE see the section on PID Chapter 2 in the SIMATIC APT Programming Reference Graphics Math Manual In Automatic 4 e In Cascade 6 e In Manual 2 SIMATIC APT Applications Manual Approach to APT Program Design 1 33 Create the Code Recipes and Recipe Templates continued Create Data Build the Dictionary Template Create a data dictionary as a structured Dictionary means of defining meaningful names for use in the program The recipe and template are preferable to multiple declaration tables for holding data dictionary values Using the recipe and template keeps all the information in one place makes it easy to reference and helps to avoid duplicate entries that can make troubleshooting difficult See Figure 1 13 Enter names into the template Process Dictionary Recipe Template Names Element Type Description Eng Units In_Fill In_Fill Tank is filling N A In_Agitate In_Agitate Agitator is running N A In_Drain In_Drain Tank is draining N A I
189. s Manual An efficient cost effective and understandable organization designed to execute the task of washing clothes consists of valve motor controllers a level controller a temperature controller a tank filler an agitator a drainer a spinner a soap dispenser and a master washer who coordinates the total wash activity A safety team which ensures the safety of the overall operation is also needed to work in conjunction with the wash team The safety team has the passive role of monitoring conditions until a fault occurs that demands immediate action When called to action the safety team works primarily with the valve motor controllers to ensure the safe shutdown of the washer system This exercise is simplistic but may give you ideas to consider as you study the control design for your process It can help you identify the tasks that make up a process determine the process partitions and to develop a feel for what the process is supposed to do washer U U Add water soap supervisor Mix supervisor Drain water supervisor Soap in lt lt A i ES SS 8 w A i Water on off Clothes in out lt iP aes Fr 8 8 S SS fi Drain water lt i D Agitate Figure 1 3 Example of Control Determination SIMATIC APT Applications Manual Approach to APT Program Design 1 11 1 4 Plan the Bottom Up Implementation Use a Layered The bottom up implementati
190. same general approach to designing controls for most types of processes each process is unique Consider the next step to be a series of steps an ongoing set of improvements to your program Add as many as you need to make your program more efficient or easier to use You can stop enhancing the program at any time or you can continue indefinitely See Figure 1 24 Level 2 Control Level 3 Control Procedural Structural Objective Top Down Symbol Config I O Analysis Names amp Devices More Time Here Makes Startup Easier Percent Program Design Completed Cont Tag Design Sequen Continuous Control Translate Recipes Control Improvements Can Start To More Recipes Make Product More Efficient Operation Faster Execution Improved Operator Interface More Statistics Use Debug Time Figure 1 24 P roject Development Time Relationship Add Normal SFCs As your process evolves you may want to add steps to the sequence control These steps may not have been important enough to hold up process startup but to improve production you want to add them now For example your quality control may determine that tank cleanings are necessary to increase output For this you need to write new SFCs and incorporate them into the current program 1 48 Approach to APT Program Design SIMATIC APT Applications Manual Add Safe State SFCs Send Additional Data to the Operator Interface Allow Operator to Cancel Opera
191. se a single controller If a single control node approach is followed address the problem of capacity What happens if the solution grows to exceed the capacity of the controller Will the solution be distributed easily to multiple control nodes or will a major effort be required Determine if a potential for future expansion exists Consider the possibility that the products made in the process will change over time to include new or expanded product lines All the above considerations should be addressed in the initial structuring of the problem Planning for expansion and growth in the initial design leads to a flexible expandable and often more understandable design solution 2 Do a top down analysis Break a system down into a hierarchical set of functional subsystems Control strategies such as temperature control or pressure control are at the lower levels in the hierarchy The goals are at the highest levels The requirement is to wash and dry 220 pound loads of clothes each week in five eight hour shifts 1 2 Approach to APT Program Design SIMATIC APT Applications Manual Wash System SIMATIC APT Applications Manual Starting with the requirements your process design team develops a physical and operational solution to the problem The process automation engineer puts a control solution in place to enable the system to achieve the stated process objective The automation engineer needs to do a top down an
192. set to automatic whenever the flow controller is in the cascade mode e The supply solenoid opens whenever the flow controller is placed in automatic or cascade modes e The supply pump starts whenever the supply valve opens Remember to use the flag variables which are objects that are similar to devices but which have only two states on or off The flag variable provides a useful way to control objects through math statements Objects respond to flags just as they would to commands Remember to validate compile and test code as you develop it Remember to do this in an incremental fashion to reduce the debug effort Use a test controller that has no connected I O 1 24 Approach to APT Program Design SIMATIC APT Applications Manual Program Other Alarms Program Safety and Shutdown Interlocks SIMATIC APT Applications Manual Other alarm conditions that you want to monitor may be too simple to be programmed as analog alarms or the analog alarm function is not appropriate These alarms typically have only one or two conditions that set off a signal to an interlock to handle the problem Consider these examples e Monitor tank level A declared boolean value is true when the level is greater than one value or less than another When the level is outside the range the boolean value becomes true and triggers interlocks e Monitor flow rate A declared boolean value is true when the flow rate is less than a certain value
193. stable that is they keep the same controller location when the program is changed or recompiled If you mark new tags change reserved memory locations or cause the compile phase six to force compile the tags must be translated again NOTE Objects that you mark for OSx cannot be deleted unless you unmark them and then select the Delete unused tags on secondary option during translate When you translate values that are defined with a high and low range the low range cannot be greater than the value that you enter in the APT form SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 3 Translating APT Objects to OSx PCS and TISTAR continued Units You can translate the unit extensions to OSx by marking the unit in the Program Content Directory Table C 1 lists the OSx tag type and the unit extensions Table C 1 Unit Tag Types and Extensions Unit enabled status ENABLE Command Unit enable disable command ABORT Unit abort clrabort command Unit name STATUS Current status Unit name BCH_REQ_INFO Bch_req_info Batch information Unit name BCH_REQ_RESP Bch_req_resp Response to batch request Batch Unit Tags The controller can retain the batch control in OSx but still allow OSx to assist in batch tracking reports through the use of three attributes available in the UNIT TAG See Table C 2 for the BCH_REQ BCH_REQ_RESP and BCH_REQ_INFO unit tag attributes The controller program can set these attributes as
194. t the alarm condition Always validate compile and test code as you develop it Do this in an incremental fashion to reduce the debug effort Use a test controller that has no connected I O SIMATIC APT Applications Manual Approach to APT Program Design 1 23 Create the Code Continuous Control Logic continued Program Other Continuous Functions Program Automatic Start Other forms of continuously operating functions include totalizers and code for a specific module such as PEERLINK communications Industrial Ethernet peer services HSPI control logic flashing lamps etc Focus on solving the problem not on analyzing the flow of events because the path can become very convoluted as you try to anticipate future events Remember to validate compile and test code as you develop it The automatic startup for some devices loops and analog alarms is another function that is frequently better handled as a form of continuous versus sequential control When you define the conditions that control an operation then you can create a continuous control strategy based on those conditions that handle the operation Remember that the way you approach the problem determines how you find the solution Think continuous control not sequential control Consider these typical process requirements for objects e The agitator starts whenever the water level is greater than 20 for more than a minute e The temperature controller is
195. t tag name is a recipe_name RECIPE ELEMENT name APT builds an area with all the elements as components of the area See Chapter 1 for a description of how to use recipes with OSx Table C 18 Recipes Recipe Extension Type Area Component Command Command Command ivar I Integer Value calc R Real Value calc RA Real Array Value 1 You must translate each array element individually 2 You must create these extensions on the Recipe form they are not among the default extensions They become attributes of the Area tag C 22 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual C 2 CFB Extensions Advanced Blocks The OSx tag type and extensions for the advanced blocks are listed in Table C 19 through Table C 23 Table C 19 Dead Time Compensator a CS ETT MMC ECO EAT DCI EC LITE Table C 20 Feedforward Output Adjust DICO CA ECT DEN ECO ETT DONE E ECT DCI EC SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 23 CFB Extensions continued Table C 21 Feedforward Setpoint Adjust ao RR testo eae SAN nae ec gainer Table C 22 Ratio Station a ERC eae RSP Biter ratio setpoint Table C 23 Dual Mode loop CFB name no extension PIDlop a ear as iran a oo rat sas Dual mode presei Dual mode delay Y C 24 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Dynamic Blocks Table C 24 lists the OSx tag and exte
196. t_2 attributes are reflected in the status word via the combination of the running and stopped bits as shown below MTR2 Running Stopped State 1 0 Running 0 1 Stopped 0 0 Travel 1 1 Failed C 14 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Translating Tags The OSx VLV1 corresponds to the APT VSN and VSS valve types and PSN for OSx PCS VLV1 and PSS press types Figure C 4 shows the VLV1 status word OSx Status Set in OSx Open Interlocked In use nn ss Close Not closed Mode Ovrd fdbk Manual set Alrm UnAck Not open Setpoint Travel Active Attribute Bit Positions APT Extensions CLSD OPND Not implemented in OSx Figure C 4 APT Tag Correlation with OSx VLV1 SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 15 Translating APT Objects to OSx PCS and TISTAR continued Table C 12 shows the APT extension correlation with OSx VLV1 attributes Table C 12 APT Tag Correlation with OSx VLV1 Attributes OSx Status Bit OSx Attribute OSx Command Form Data Data Read APT Extension 2 Written to Controller fom Controller Controller 1 Override P C Memory Location 32768 Disable VSx OVRD 1 C of Length 1 Mode_Cmd i Disable VSx DSBLD 1 P C Memory Location Lock VSx LOCKD 1 C of Length 2 Unlock VSx LOCKD 0 Setpoint PC Memory Location VSx MOPEN 1 C of Length 1 Timeout_1 7 P C Memory Loca
197. tch _PATH_VLV_CLS Open Close alarm time 10 seconds Declaration Table Entries PATH_VLV_OC Type B boolean Description Product drain control Retentive Value 0 PATH_VLV_OLS Type B boolean Description Product drain open limit switch Valve 1 Retentive Pseudo Value 0 Valve 2 Device PATH_VLV_CLS Type B boolean Path_vlv Description Product drain closed limit switch Valve 3 Retentive Value 0 Math Block Operate pseudo valve by ANDing valve1 valve 2 valve 3 viv1_oc path_viv cmmd Digital Outputs viv2_oc path_vlv cmma vlv3_oc path_vlv cmmd path_vlv ols viv1_ols AND vlv2_ols AND viv3_ols path_vlv cls viv1_cls AND vlv2_cls AND vlv3_cls Digital Inputs Figure 3 15 Example of a Pseudo Device 3 24 Programming Hints SIMATIC APT Applications Manual 3 8 Table and I O Hints Working in Tables Configuring Unlisted I O Modules for Series 505 Configuring the PEERLINK Module for Series 505 Controllers Configuring the HSPI and HSC Modules for Series 505 Controllers Configuring ET200 SIMATIC APT Applications Manual Use the SPLIT SCREEN function As you work on a table you can display a report to help you fill out the table Use the SORT function to organize table elements You can sort by type by name by description or by address When you need to configure a module that does not appear in the APT Module Definition Table fo
198. tensions Operation bits read write DSBLD MSN MSS MDN MDS RM1 2 TS1 2 MUD Read only Bool Read only Read only Real LOCKD MSN MSS MDN MDS RM1 2 TS1 2 MUD Read only Boolean ead only Integer gad only Rea NRDY MSN MSS MDN MDS RM1 2 TS1 2 MUD RAW 1 O name MSTRT MSN MSS MDN MDS RM1 2 TS1 2 MUD MREV RM1 2 MHIGH TS1 2 I O Symbolic Names I O Point All I O points of the following types that were marked for translation Analog Input Analog Output Binary coded Decimal Input Binary coded Decimal Output Digital Flag Digital Input Digital Output Resistance Temperature Detector Thermocouple Word Input Word Output SIMATIC APT Applications Manual Extensions Fixed by the Compile B 1 Extensions Fixed by the Compile continued Devices continued Cylinder Extensions Boolean Extension Position bits read only EXTENDED RETRACTED TRVL Fail bits read only ETE FTR FAILD Operation bits read write DSBLD LOCKD NRDY MEXTEND Override bits read write OVRDE OVRDE Press Extensions Boolean Extension Position bits read only UP PND PSN PSS DOWN PND PSN PSS TRVL PSN PSS Fail bits read only FTR PSS FTL PSS FAILD PND Operation bits read write DSBLD PSN PSS LOCKD PSN PSS NRDY PSN PSS MRAISE PND PSN PSS Override bits read write OVRD PSS OVRDU OVRDD OVRDL OVRDH PSD PSD PSD PSD PSD PSD PSD PSD PSD PSD PSD PS
199. terface 7 1 Using APT to Configure an OSx Database 7 2 Marking Tags for Translation 0 0e eee e eee eee eee eee eens Recommendations for Marking Objects 7 3 Compiling the Program oococcccccnccnr Recommendations for Compiling a Program Report by Exception 0 00 cece ene tee tee teen eens Reserving Memory for RBE Series 505 7 4 Translating TAGS cian a ai SIMATIC APT Applications Manual APT and the OSx Operator Interface 7 1 7 1 Using APT to Configure an OSx Database In a process control system a controller and an operator interface interact to control and monitor the process The controller has the actual physical control over the process while the operator interface monitors the process You can use APT to program the controller and to configure the objects and variables that are sent to the operator interface The controller addresses for objects that are monitored by the operator interface must remain unchanged in the controller program if the operator interface is to access data during run time The APT Mark Tags utility enables you to fix the locations of variables in memory After objects are marked for an OSx operator interface the APT Compile Translate File Build places the variable name descriptor controller address and other information into a file called install tag The data in this file can be used to automatically update the OSx database For a non OSx operator interface you must enter
200. ters from your controller by selecting the Clear P C before download option Generating an APT In order to set up a redundant system that is compatible with APT you Address Report need to obtain certain data from an APT address report first Furthermore and Configuring when you perform your operating system configuration using COM 155H COM 155H you need to provide certain parameters as specified in this chapter that make your system compatible with APT The APT address report lists all of the controller memory that you are using however you only need to know which DB DXs are used in the APT program Once you have generated an APT address report by the process that is described in Section 6 2 you are ready to invoke COM 155H The COM 155H utility allows you to configure the four types of data listed below e Operating system parameters SYSTEM See Section 6 3 Data block transfer lists TRAFDAT See Section 6 4 Expansion units I O 314 See Section 6 5 e I O point configuration IOCONF See Section 6 6 SIMATIC APT Applications Manual Redundant Configuration for 5 6 3 6 2 Generating an APT Address Report Before you invoke COM 155H you must generate an address report from APT in order to see which DBs and DXs APT is using This section explains how to generate an APT address report If you want more information about object files or the P C address to APT symbol name option see the section entitled
201. th APT Extensions Seman o worm moren amas E sme See e amon ania ania iron mon amici CO A A fover fover fov SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 13 Translating APT Objects to OSx PCS and TISTAR continued Table C 11 shows the APT extension correlation with OSx MTR2 attributes Table C 11 APT Tag Correlation with OSx MTR2 Attributes OSx Status Bit Data Read APT Extension 2 from Controller 1 OSx Command Form Data OSx Attribute Written to Controller Override P C Memory Location 32768 High TSx OVRDH 1 C of Length 2 16384 Low TSx OVRDL 1 16384 Both TSx OVRDH 1 TSx OVRDL 1 Neither TSx OVRDH 0 TSx OVRDL 0 Mode_Cmd P C Memory Location Disable TSx DSBLD 1 C of Length 2 Lock TSx LOCKD 1 Unlock TSx LOCKD 0 Setpoint PC Memory Location TSx MSTRT 1 C of Length 2 TSx MHIGH 1 TSx MSTRT 0 TSx MHIGH 0 Timeout_1 P C Memory Location Integer X 0 1 sec TCP Not implemented in TSx RTCP OSx status word Timeout_2 3 P C Memory Location Integer X 0 1 sec TCP 1 Refer to Figure C 3 2 TSx represents TS1 or TS2 For the valve the setpoint extensions are Vx MOPEN and Vx MHIGH and the timeout extensions are Vx OTCP and Vx CTCP For the press the setpoint extensions are Px MRAISE and Px MHIGH and the timeout extensions are Px UTCP and Px DTCP Not implemented in TSx STCP OSx status word 3 For OSx the Timeout_1 and Timeou
202. this information into its database manually This procedure is designed for an OSx system but you can use it for any operator interface Currently there are four releases of PCS OSx available TISTAR 1 x TISTAR 2 x and PCS 3 x and OSx 4 x TISTAR 1 x and TISTAR 2 x can read similar install tag files although TISTAR 1 x cannot translate APT units The format for the install tag file Figure 7 1 used with PCS 3 x and OSx 4 x is different it is a comma delimited file that can be imported and exported to and from spreadsheet programs for editing The install tag file is located in the apt program program_name prr subdirectory where program_name is the name of your APT program Appendix A of this manual describes the install tag files APT supports all types of memory on the various Series 505 and S5 controllers However VMM and VMS memory used in the 575 controller cannot be translated to OSx and FW FD 8 SW SD and RSW memory used in an S5 controller cannot be translated to OSx For an S5 controller D memory cannot be read from OSx directly however APT does translate D memory by packing bits into a word DW that can be translated and read by OSx TISTAR 1 x and 2 x are limited to translating only 64K bytes of V memory and K memory for Series 505 controllers APT displays a warning when more than 64K bytes have been allocated for these memory types for translation 7 2 APT and the OSx Operator Interface SIMATIC APT Applications
203. tion Xx 0 1 sec Not implemented in VSx OTCP TCP OSx status word Timeout_2 3 P C Memory Location Integer X 0 1 sec Not implemented in VSx CTCP TCP OSx status word 1 Refer to Figure C 4 2 VSx represents VSN VSS PSN or PSS 3 For OSx the Timeout_1 and Timeout_2 attributes are reflected in the status word via the combination of the opened and closed bits as shown below VLV1 Opened Closed State 0 Opened 1 Closed 0 Travel C 16 OSx PCS and TISTAR Tag Translation SIMATIC APT Applications Manual Translating Tags The OSx VLV2 corresponds to the APT VSD VDD VMD and VUD valve for OSx PCS VLV2 types CYL and CUD cylinder types and PSD PDD and PMD press types Figure C 5 shows the VLV2 status word OSx Status Set in OSx Close Not closed Mode Setpoint Ovrd close Manual set Alrm UnAck Not open In use Travel Active Attribute Failed Open Interlocked Ovrd open Bit Positions 10 APT Extensions LOCKD OVRDC FAILD FTC DSBLD OVRDO TRVL CLSD NRDY MOPEN OPND Not implemented in OSx Figure C 5 APT Tag Correlation with OSx VLV2 SIMATIC APT Applications Manual OSx PCS and TISTAR Tag Translation C 17 Translating APT Objects to OSx PCS and TISTAR continued Table C 13 shows the APT extension correlation with OSx VLV2 attributes Table C 13 APT Tag Correlation with OSx VLV2 Attributes OSx Status Bit Data Read APT Extension 2 from Contr
204. tions You may discover better ways to handle exception conditions that occur in your plant You can add safe state SFCs that provide a smoother transition to a holding condition or that waste less product You may decide that it is preferable to salvage your product or recycle it for example instead of dumping the product when an emergency such as a power failure occurs You may be interested in pointing out additional data to the operator during runtime operation For an OSx system you can consider writing code that reads SFC status attributes such as SPIN FILL AGITATE etc for each SFC Then when the attribute is true you can have an icon that is specific to the unit or device change color to reflect the status change You may want to write code that enables the operator to advance the process to the next step before the current procedural SFC has finished Although the solution to this requirement may appear to be complex it is easily coded if you have designed the SFCs with care When your program design is modular and well structured the key to the solution rests in the fact that most procedures spend a lot of time waiting for the termination condition to become true You can design a CFB to stop steps by programming it to monitor a stop command and to turn on a stop command when the operator requests that the step be terminated You can add the terminate flag to the appropriate transitions within an SFC and to the device inte
205. top the drain pump and spin motors Level 2 A process at Level 2 has operational goals imposed on a Level 1 process with a simple operator interface structure Your prerequisites for the development of a process to Level 2 include a sequence list of defined procedures an execution order for the procedure and a formula recipe list As control development proceeds the process advances through three states Procedural Structural and Objective Control Procedural Control Basic control procedures are defined You concentrate on developing the set of operational procedures that perform specific functions when activated by a higher level of control Procedures include tasks such as Fill Tank Agitate Drain Tank etc You have two priorities for procedural control the procedure does the assigned tasks correctly and the procedure operates independently and potentially in parallel with all other procedures In the laundry example your goal is to design a procedure which responds to a discrete signal such as a pushbutton to begin operation When this procedure has finished it turns on another discrete signal For example the Fill procedure begins when a pushbutton is pressed and illuminates a lamp when filling is finished SIMATIC APT Applications Manual fill Vo wool agitate knits drai cottons Good morning Ralph Please insert your laundry and will be happy to
206. ty is to make sure that each SFC does the intended task and does it correctly Be sure to test your code thoroughly In the laundry example consider an SFC called Fill which helps coordinate the fill task for the washing machine The steps and transitions are shown in Figure 1 15 and described below e Step S1 waits for a signal from the procedure activator called Phases in the laundry example that the fill procedure is to begin e Transition T1 Strt_fill becomes true when the start command Strt_fill is true An SFC at a higher management level which you program for Objective Control page 1 40 latches on the start command e Step S2 Increment fill_s Fill_level wr fill_sp Temp_setpt wr tempt_setpt loads setpoints for level and temperature based on values in the working recipe S2 also increments a counter to keep track of the number of times that the Fill SFC is executed Transition T2 is always true e Step S3 contains no code and waits for the level to reach the selected level Water level is controlled in part by a CFB that opens the hot and cold water valves when a new setpoint is loaded An interlock CFB is programmed to shut off the valves by setting the cold_water NRDY and hot_water NRDY bits when the level reaches the setpoint e Transition T3 Fill_at_sp becomes true when the level reaches the level specified by the setpoint Step S4 On fill_done Clear stop_fill turns on a flag to indicate that the fi
207. ued Limiter Blocks Output Limiter Extensions Read only Boolean Read only Integer Read only Real IOUT OUT Read Write Boolean Read Write Integer Read Write Real ENABL JIN IN NRDY HLIM LLIM Rate Limiter Extensions Read only Boolean Read only Integer Read only Real IOUT OUT Read Write Boolean Read Write Integer Read Write Real ENABL JIN IN NRDY RLIM Unit Extensions ENABL ABORT B 6 Extensions Fixed by the Compile SIMATIC APT Applications Manual C 1 C 2 Appendix C OSx PCS and TISTAR Tag Translation Translating APT Objects to OSx PCS and TISTAR 0 cece cece ee eee ee eeee OVEIVIOW siii rita a hee hie ete a dot o a aoe ha oie ade UNITS ri weaved ei occa tobe aed a Ravel a A BR mance vba al mace bets Batch Unit Tags siii tone cate ee bin chon A echo codon coke ae DOVICCS aaa a pias ae ana ae aie eee ae ee eee Pees Correlating APT Device Types with OSx PCS Attributes Translating Tags for OSxX PCS MTR1 ooocccccccccc eet eee Translating Tags for OSx PCS RMTR 2 ccc eee eee eee tenet eee Translating Tags for OSxX PCS MTR2 20 ccc eee eee ene eee Translating Tags for OSx PCS VLV1 1 eet ene ene Translating Tags for OSx PCS VLV2 cece eee eee VO ois a sath dM hehe A ae ae eee wa Oe ee ad A E cee a Declarations ccoo A eps eae eae Made wea boats Cae ER RECIDOS asic ccs bee A A Wiad a Roe doe EESE pa CFB EXTensiONS ocio oi rio
208. use the literal values true and false a WARNING Many tools including Debug MAITT TISOFT and STEP 5 allow you to change the values of APT constants in the controller after the program has been downloaded to the controller Changing the value of APT constants could cause unpredictable operations that could result in death or injury to personnel and or damage to equipment Never change the value of an APT constant by any other method than editing re compiling and downloading the APT program Variables change value during the course of program execution You can use the APT Debug Utility to change variables but any changes should be made only by qualified people who understand the APT program Initial values of variables are set during download These variables can be changed at any time by the program or with TISOFT or the APT Debug Modify Option APT does not reset the initial values of variables unless the program is downloaded again Forced elements in Series 505 controllers cannot be changed until they are unforced or forced to a different value Forced elements remain forced when you download a new program to the controller unless you clear the controller first in the Download Menu 4 6 APT and Controller Memory SIMATIC APT Applications Manual Reserving I O If you want to configure a Series 505 or Series 500 I O module in a base it Locations in Series must be configured in the Module Definition Table This must be
209. utables directory For example if APT is installed at D APT enter the following command PATH If D APT is not included in the list output by PATH add it by entering the following command PATH PATH D APT If you are loading the example program from the CD enter the following command substituting your diskette drive for E and your disk drive containing the APT database for D E DISK8 LOADDEMO E DISK8 WASH_DEM D If you are loading from diskette enter the following command substituting your diskette drive for A and your disk drive containing the APT database for D A LOADDEMO A WASH_DEM D The APT database is typically on the drive where you installed the APT software unless you selected the Configure Directories option during installation or reconfigured your system at a later time SIMATIC APT Applications Manual If you have configured APT so that the APT software is installed on multiple drives and or in non standard directories then you must ensure that the environment variables APT_DB and APT_ COMMON exist and are assigned appropriate values APT_DB specifies the path to the APT database and APT COMMON specifies the path to the directories FORMS LIB505 LIBMC5 and TEXT If these environment variables are not set and you know the correct values you can set them For instance consider that the APT executables are in D APT the database is in C DATABASE and the TEXT directory is
210. washer will also be determined by the fill phase A common washer design includes a simple solenoid valve for hot water and one for cold water In this system the fill phase will manipulate the hot and cold water valve to provide both level and temperature control The essence of the fill phase is to open the correct combination of water valves and wait for the level to reach the specified setpoint When the level has been achieved the water valves shut down automatically You should analyze each of the other phases similarly Add soap Agitate vas LD ore Waa en oo Figure 1 2 Determine the Process Tasks SIMATIC APT Applications Manual Approach to APT Program Design 1 9 Do a Top Down Analysis continued Determine Control Needs Example Mental Exercise for Top Down Analysis Identify the kinds of continuous control needed and which safety interlocks are required Examples of continuous control include temperature control or a mass totalizer in a batch reactor An example of an interlock is a provision for shutting down the water valves if the tank is full Another interlock could stop the spin motor if the washer lid is open Define what sequential procedures need to be used in conjunction with the continuous control For example the mass totalizer would be used in the fill phase of a chemical reacto
211. y the process temperature curve The order of execution for the phases of the process is flexible and changeable The product recipe determines which phases operate and when they are active 2 16 Program Descriptions SIMATIC APT Applications Manual P amp ID for the Heat Figure 2 3 shows the P amp ID for the Heat Exchanger program Exchanger SUPPLY_PUMP SUPPLY_SV c TC_CTRL IC A FLO_CTRL FLOW TEMPERATURE Heat Exchanger Figure 2 3 Heat Exchanger Example P amp ID SIMATIC APT Applications Manual Program Descriptions 2 17 Examining the Heat Exchanger Example continued Process I O for the Table 2 3 lists the Series 505 I O for the Heat Exchanger Example program Heat Exchanger Table 2 3 Heat Exchanger Example I O High AE C po pe IS IS O EL ow a eo 00 fa TN Temperate AT wes Z 00 E NS Senin ao oos P LN Ea E A AS am pump start 2 18 Program Descriptions SIMATIC APT Applications Manual 3 1 Organization of APT Logic ooocoooncccnccnn eee eee 3 2 Math HIMS 2 2062s cede fete eee deb ete eee bee wedi bene 3 3 SF Program Loop Analog Alarm Hints for Series 505 Controllers 3 4 Recipe HINTS occ a a ede c ease peewee 3 5 Hints for Using Debug 2 2 cece cette eee eee eee 3 6 Miscellaneous Hints oooooocconoco eee eens 3 7 Configuring Devices 0 ccee eee eee eee eee 3 8 Table and I O Hints 0 0 0 e eee eee eee eee 3

Display - Service, Support

Contents

Download Pdf Manuals

Related Search

Related Contents