Batch-PhaseManager Hands On Lab

RSBizWare Batch Integration with
RSLogix 5000 PhaseManager

WELCOME TO: COMPLETE AUTOMATION ON THE MOVE _________________________________5
RSBIZWARE BATCH INTEGRATION WITH RSLOGIX 5000 PHASEMANAGER HANDS-ON LAB ______5
ABOUT THIS HANDS-ON LAB __________________________________________________5
BEFORE YOU BEGIN ________________________________________________________5
LAB MATERIALS ___________________________________________________________6
PART 1: UNDERSTANDING S88, BATCH, LOGIX WITH PHASEMANAGER ______________________8
ABOUT THIS LAB ___________________________________________________________8
AREA 1 - LOGIX 5000 CONTROLLERS (HOW IS IT AFFECTED?) _________________________9
AREA 4 - BATCH SERVER (HOW IS IT AFFECTED?) _________________________________11
PART 2 REVIEW CLASSIC S88 BATCH EQUIPMENT PHASE DESIGN ______________________12
ABOUT THIS LAB __________________________________________________________12
PART 3 - WORKING WITH EQUIPMENT EDITOR TO BUILD PHASEMANAGER EQUIPMENT PHASES ___14
START THE EQUIPMENT EDITOR SOFTWARE AND OPEN A PROJECT ____________________15
EDIT DATA SERVER FOR LOGIX CIP AND A SPECIFIC CONTROLLER _____________________17
CREATE NEW PHASE MANAGER EQUIPMENT PHASES WITHIN THE EQUIPMENT EDITOR ______21
REVIEW EXISTING LOGIX 5000 EQUIPMENT PHASES WITHIN IN11.ACD ___________________29
USING BATCH EQUIPMENT EDITOR TO SYNCHRONIZE LOGIX 5000 DATA SERVERS _________31
REVIEW EQUIPMENT PHASE TAGS IN LOGIX 5000__________________________________36
REVIEW SIMILAR PHASE TAGS IN RSBIZWARE BATCH EQUIPMENT EDITOR _______________37
PART 4 USE RSLOGIX 5000 TO BUILD LOGIC AND PHASE STATE ROUTINES ________________38
BUILD ALL PHASE STATE ROUTINES FOR T300_TIMER_PHASE WITH THE EXCLUSION OF HOLDING
AND RESETTING STATE ROUTINES _____________________________________________45
Welcome to: RSBizWare Batch Integration with RSLogix 5000 PhaseManager Hands-On Lab
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TEST EQUIPMENT PHASE LOGIC USING RSLOGIX EQUIPMENT PHASE MONITOR ____________ 48
PLACE THE CONTROLLER INTO RUN MODE AND TEST PHASE CODE _____________________ 51
PART 5 BUILD PHASE MANAGER EQUIPMENT PHASES (SYNCHRONIZE TO UPDATE YOUR RSBIZWARE
BATCH AREA MODEL) _________________________________________________________ 55
CREATE A NEW PHASE _____________________________________________________ 56
ADDING PARAMETERS AND REPORTS __________________________________________ 61
PHASE TAGS AND DATA ____________________________________________________ 63
CREATE PHASE STATE ROUTINES _____________________________________________ 66
ADDING THE LOGIC TO THE STATE ROUTINES _____________________________________ 69
SYNCHRONIZE TO UPDATE AREA MODEL ________________________________________ 71
PART 6 RUNNING A RECIPE IN RSBIZWARE BATCH __________________________________ 75
SAVING EQUIPMENT AREA MODEL AND SYNCHRONIZING RECIPES _____________________ 75
EXTRA CREDIT ___________________________________________________________ 82
WRAP UP ______________________________________________________________ 84
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Welcome to: Complete Automation on the Move
RSBizWare Batch Integration with RSLogix 5000
PhaseManager Hands-On Lab
About This Hands-On Lab
In this lab you will explore the new PhaseManager capability for creating, implementing, and
monitoring the new batch equipment phases within ControlLogix. Part 1 of the lab will provide a
overview of S88, RSBizWare Batch and Phase Manager. Part 2 of the lab you will review a classic
Batch equipment phase design.
In part 3 of this lab, you build two new equipment phases in an existing area model using the
RSBizWare Batch Equipment Editor. Next, you use synchronization to automatically create these
equipment phases in RSLogix 5000 from the modified area model within the Equipment Editor.
In part 4 of this lab, you will build equipment phase logic, and state routines for each of the two
phases created from part 3. For the simple timer phase, there will be no Holding abnormal
condition handlers (i.e. HOLDING state routine). For the other phase, an agitator, there will be a full
set of phase state routines to coincide with abnormal condition handling capabilities. Most state
routines will be programmed in ladder logic, except Aborting, Stopping, and Holding, which use
structured text programming. Note that although functions blocks and SFC programming can be
used, they are not covered in this lab. You will test the phase in RSLogix 5000 using the monitor
phase window tool.
In part 5 of this lab, the purpose will be the creation of a new Phase Manager equipment phase, a
heat phase, from within RSLogix 5000. Rather than building new logic code for this phase, you will
convert the logic code from a classic S88-compliant equipment phase for this phase functionality.
Once you have finished the state routines and the PreState routine for this phase, you will
synchronize with the Equipment Editor to build the new phase in the S88 area model.
In Part 6, you will verify existing recipes and run a recipe against this newly built Phase Manager
Equipment phase that was converted from a S88 classic equipment phase.
This lab takes approximately 90 minutes to complete.
Before You Begin
Before you begin this Hands-On Lab, please be sure to close any applications that are currently
running.
PhaseManager is an extension to the RSLogix 5000 and ControlLogix capability. Rockwell

Automation is incorporating equipment model awareness into the Logix products. In this first
release, the S88 and PackML state capability are brought to the Logix processor. This document
will only focus upon the equipment phase object and S88 (it does not discuss PackML features).
The designer can now build an equipment phase object more easily and faster than ever before. A
seamless S88 state capability is fully integrated, as is automatic phase tags creation, new
instruction sets, and abnormal condition handling routines. The Phase Logic Interface (PLI) is
embedded in the Logix processor to provide effortless functionality and equipment phase support
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for the user. Programmers can take advantage of a new instruction set to allow embedded and
consistent programming of equipment phase objects. Now, each Phase Manager equipment phase
object, with all its supporting S88 functionality, can be quickly built using one of two methods
whichever the user prefers.
One method uses the RSBizWare Batch Equipment Editor tool to allow definition of the equipment
phase in a unit within the process cell. From within the Equipment Editor tool, the user may quickly
synchronize with an RSLogix 5000 project by creating Phase Manager equipment phases
automatically. This method is recommended if using the RSBizWare Batch product because
parameter and report tags will be automatically created.
The other method is to quickly build the Phase Manager equipment phases in the RSLogix 5000
editor, creating parameter and report tags one at a time. If using RSBizWare Batch, you can utilize
the Equipment Editor, the user has the option to automatically create the equipment phases in the
area model through synchronization with RSLogix 5000. Users may now choose their own
preference.
The coupling of the RSBizWare Batch product with the RSLogix 5000 editor for equipment phase
functionality will greatly improve development, testing, and implementation lifecycles. Other benefits
will be quickly realized by customers who want a consistent method for phase design with
integrated PLI and monitoring capabilities. In addition, it will add simplicity of maintenance and
support for the batch control system. Other savings could be quickly realized for batch-time critical
processes; the speed and performance improvements these equipment phases provide are
significant. CIP is a more reliable and faster protocol than OPC communications.
It should be understood that for most batch systems, Phase Manager equipment phases do not
eliminate the need for the RSBizWare Batch product; they are complimentary to the RSBizWare
Batch product to build and manage equipment phase logic and associated tags and instructions
much easier. Together they can provide the end user a significant benefit.
Windows Login Username/Password
If Log On To Windows dialog is active Type administrator for Username and Type rockwell
for password.
Lab Materials
For this Hands-On lab, we have provided you with the following materials that will allow you to
complete the labs in this workbook.
Hardware
This hands-on lab uses the following hardware:
Computer running Windows Server 2003, Standard Edition
Software
This hands-on lab uses the following software:
RSBizWare Batch 8.00
RSLogix 5000 with the Phase Manager option, Version 15
SoftLogix 5800, Version 15
RSLinx Version 2.50
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Files
This hands-on lab uses the following files:
IN11.ACD
IN11.CFG
INI11_OP.UOP
File Locations
RSLogix 5000 .ACD file
RSBizWare Batch area model and recipe files.
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Part 1: Understanding S88, Batch, Logix with
PhaseManager
About This Lab
This lab makes references to the S88 standard. Primarily this scope is limited to the equipment
model, equipment phase state model, parameters, reports, phase tags, PLI and phase logic. The
S88 state model for batch is located in the next section. The state model for Phase Manager is
located in this section. Please use these as references for this lab when working with the Recipe
Editor, Equipment Editor, RSLogix 5000, and Phase Manager.
The following is an overview of the Batch Server product with ControlLogix:
The following is an overview of the 4 areas affected by new Phase Manager Functionality:
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Four Areas affected by Phase Manager
1. Logix5000 Controllers
2. RSLogix 5000 & Project File (.acd)
3. Equipment Editor & Area Model (.cfg)
4. Batch Server
The main purpose of this lab to provide a basic understanding of these four areas. Specific lab
exercises under part 3, 4 and 5 of this lab will be provided to cover areas 2 and 3 in great detail.
Areas 1 and 4 will be addressed here in brief and understood more as the labs are performed.
Area 1 - Logix 5000 controllers (How is it affected?)

Equipment phase object added to Logix core
ControlLogix (for example, L63, L55) (Currently disabled for Safety Controllers)
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CompactLogix (for example, L35E)
FlexLogix and SoftLogix
Encapsulated a state machine within equipment phase object
Equipment phase has concept of ownership
RSLogix 5000 user is the highest priority, up to 15 concurrent users
HMI middle priority (future), up to 15 concurrent users
Batch Server /Internal Sequencer lowest priority. Only 1 user; first one to attach wins
Added new instructions
PSC, PFL, PCLF, PPD, PRNP, PXRQ, PCMD, POVR, PATT, PDET
Allows the phase to function in a similar manner to OPC phases
Allows the equipment phase to be controlled by the Batch Server, or by one of the other owners
Allows the user to write simple hard-coded SFC operations in the controller (not covered in this
lab)
Note: Many of the new instructions are outside the scope of this lab, and they will not be covered.
The state model for Phase Managers equipment phase object is located below. Please use this as
a reference for this lab. Take time to note the states and the paths between the states. Also notice
the Running, Holding, Restarting, Stopping, Aborting and Resetting states. These states can be
code routines that act upon devices, and/or tags. The equipment phase object is a superset of a
program that allows the creation of such routines.
done Restart
Holding Held Restarting
Hold done
done Start
Resetting Held
Idle Running
Abort
Stop
Abort
done Stopping Aborting
done done
Complete Stopped Aborted
Reset
Final States
Quiescent States
Transient States
Phase Commands
Phase Logic Initiated
Phase Manager Equipment Phase State Model
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Area 4 - Batch Server (How is it affected?)
Added new data server (CIP) and communication protocol
New dsdf file: Logix5000_CIP.dsdf
Batch Server communicates directly to the controller through RSLinx, providing tighter integration
with RSBizWare Batch
Using CIP: Faster and more reliable communications
Enhanced robustness related to controller mode (program vs. run) and faults
Enhanced robustness related to unscheduling or inhibiting equipment phases
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Part 2 Review Classic S88 Batch Equipment
Phase Design
About This Lab
We will briefly discuss classic S88 equipment phase design. You will convert a classic S88
equipment phase into a ControlLogix Phase Manager equipment phase. A similar type of
methodology could be applied to other classic S88 equipment phases in PLC5, SLC 500, or
competitor controllers that may be replaced by the ControlLogix controller. A similar methodology
may be applied to convert equipment phases designed to sequence under a competitor batch
product such as Wonderware, or Intellution and replace those batch products with RSBizWare
Batch and ControlLogix.
1. State Diagram for S88 Batch is listed below:
S88 Batch State Model

Note: The Batch State Model differs from PhaseManager State Diagram by excluding the Resetting
state. In addition, Stop and Abort commands are not valid when a S88 phase is IDLE.
Since the Batch Server ignores a RESETTING state, it is recommended that this routine in any
PhaseManager equipment phases execute quickly for those sequencing with the batch engine.
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1. Review the classic layout.
The standard way of implementing a state model in a ControlLogix Processor was to build a
routine that would contain all the states, as shown below in the Unit_Tank200 program.
Phase Logic
Interface (PLI)
routine
Phase routine
2. In the above routines, the T200_Agitator_Phase_Main would call the Phase Logic Interface
(PLI) routine and then call the phase routine, T200_Agitator_Phase routine (if phase is active).
The PLI exchanges OPC / DDE data with the external Batch server. The phase is made up of a
series of segregated logic sets for each of the states (using the MCR instruction). All setup and
layout of the code and data models was done manually.
T200_Agitator_Phase
Failure Logic
Aborting Logic
Stopping Logic
Holding Logic
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Part 3 - Working with Equipment Editor to build
PhaseManager Equipment phases
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Start the equipment Editor Software and Open a Project
If you are prompted for a username/password enter Administrator for a user and rockwell for
a password.
1. Start the program.
From the Start menu,

select Programs > Rockwell Software > RSBizWare > Batch > Equipment Editor or click on
the equipment editor icon on the right side of the desktop.
2. Open the Area Model named IN11.cfg. Select File > Open.
You can find the project area model, IN11.cfg, in the directory: C:\autofair_lab_7\Recipes\
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Note: The other area model file, IN11_LabFinal.cfg, is a completed version of this lab.
3. Select the file name IN11.cfg and click Open.
The Equipment Editor software will load an existing area model that descibes previously defined
S88 Equipment Model objects such as Process Cells, Units, and Equipment Phases
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Edit Data Server for Logix CIP and a specific controller
You will simply edit an existing data server within the area model to use the proper IN11.acd
project file and the controller of reference for the Phase Manager equipment phase connections
1. Select the Edit Data Server icon, , in the toolbar,
or, select the menu option Edit > Data Server as seen next:
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1. The Data Servers window appears. This window allows you to create, delete, or edit data
server definitions for the equipment phases and Unit tags in the area model. For our
purpose, you will only edit the existing data server definition which acts as a connection
reference to Phase Manager equipment phases for a particular controller. If this were a new
area model, you would add a new data server definition rather than edit an existing one.
Also, if you needed to add new controllers using Phase Manager equipment phases, you
would add new data server definitions.
Select the CLX_CIP data server defined for this area model, then select the Edit button.
2. The Edit Data Server window appears. This window allows you to rename, select type and
define attributes specific to the type. For Logix 5000 CIP type, the attributes are a specific
acd file, and a specific controller. First, you will change the ACD file reference. Please
select the Browse button for the PATH attribute as follows:
Data Server Types:

PC Phase OPC
RSLinx Classic OPC
RSLinx Gateway OPC
RSOPC Gateway
Logix5000 CIP
Simulator
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3. Navigate to the path C:\ autofair_lab_7\RSLogix 5000. Select the IN11.ACD file in this
directory, then select OPEN.
4. The Edit Data Server window appears again. Now, you will change the Controller Network
Path reference. Please choose the Select Path button to reference the appropriate
controller for Phase Manager equipment phases.
Select the Soft Logix controller, 1756 module that will be used as the Logix controller for this
lab.
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Select OK to each open window in order for changes to be applied.
5. Save the area model, named IN11.cfg, with your changes. Select File> Save
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Create new Phase Manager Equipment phases within the Equipment Editor
1. Review the S88 equipment model defined within the area model file named IN11.cfg. It
represents the area named AREA1 and contains a single process cell named IN11_CELL that
was built from the cell-class object named IN11.
2. Starting at the highest level of the S88 equipment model (the process cell), double-click
IN11_CELL to drill down to the unit level, which represents all defined S88 units for the process
cell.
Below is the display at the unit level within the selected process cell. There are only 3
unit-defined for this area models process cell. Each unit object was created from the unit class
named MIX_CLASS.
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3. To get a better idea of where you are currently working within the editor, select View >
Location Bar to toggle it on.
A location indicator is displayed. In this case, it shows that you are editing within the Unit level
inside the process cell named IN11_CELL.
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4. Double-click to drill into the unit named Tank300 to display the next level of the S88 equipment
model that represents the equipment phases for the unit selected.
Note: The Phases column on the left represents phase class objects. A phase class object will
represent the phase name in a recipe for a particular unit and equipment phase. This
establishes the one-to-one relationship between the S88-Procedure-Model phase and the S88-
Equipment-Model equipment phase. Therefore, the phase class object only allows one
equipment phase instance to be created from it within a single unit. Material enable phases are
an exception to this rule, but are outside the scope of this lab.
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You will create two new equipment phases within the unit named TANK300.
5. Create one phase from the phase class named TIMER_CL located in the Phases column left
of the phase design area. Select the TIMER_CL object, then move your cursor to the right,
placing it slightly below the phase named T110_ADD_PHASE as shown circled below.
6. Click the left mouse button to position and create the new equipment phase instance.
The Edit Equipment Module dialog box is displayed. Here you will name the equipment phase
T300_TIMER_PHASE and verify that the Data Server selection is CLX_CIP.
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7. Type T300_TIMER_PHASE over the default name of TIMER_CL1. Verify the data server is
CLX_CIP. This defines the equipment module as a PhaseManager type phase.
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8. Click OK. The unit design area reflects the new phase addition as shown next.
9. Repeat this equipment phase building process by selecting the AGITATOR_CL phase class,
moving your cursor to the middle of the unit design area, and clicking. Change the equipment
phase name to T300_AGITATOR_PHASE.
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10. Verify the Data Server is CLX_CIP.
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11. Click OK to create the equipment phase in the area model as shown here.
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Review existing Logix 5000 equipment phases within IN11.acd
1. RSLogix 5000 may be easily launched directly from inside the Equipment Editor by double-
clicking on any CIP enabled equipment phase within a unit of the area model. In the Tank300
unit, move your cursor over the T300_XOUT_PHASE located at the bottom of the design area.
Notice that the mouse cursor appears different when placed over any CIP enabled equipment
phases as indicated by the following symbol,
Traditionally, you would start RSLogix 5000 from the Start menu, then select Programs >
Rockwell Software > RSLogix 5000 Enterprise Series > RSLogix 5000. From the File menu,
you would open IN11.ACD, our prebuilt RSLogix 5000 project file for this phase that is located
in the directory C:\ autofair_lab_7\Logix 5000.
Today, tradition will be changed. Simply double click on the equipment phase,
T300_XOUT_PHASE, and watch RSLogix conveniently open to the phase logic for the phase
selected.
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2. Take a moment to look at the structure of scheduled tasks and equipment phase objects in this
ACD file.
In the task folder, UNIT_TANK300, there are only two existing equipment phase objects. In the
newly modified area model, you created two additional equipment phase objects called
T300_TIMER_PHASE and T300_AGITATOR_PHASE for the unit TANK300. Next, you will be
using this new area model to synchronize and automatically create these new phase objects
into the RSLogix 5000 ACD file.
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Using Batch Equipment Editor to Synchronize Logix 5000 Data Servers
From the open area model in the Batch Equipment Editor, you will initiate the Synchronization
feature to automatically build two phases, T300_TIMER_PHASE and T300_AGITATOR_PHASE, in
the RSLogix 5000 project.
1. To synchronize, click the toolbar button or select Edit > Synchronize Logix5000 Data
Servers.
This Warning dialog box is displayed.
2. Click Continue Without Saving. The Synchronize Logix5000 Data Servers dialog box is
displayed.
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3. Select the CLX_CIP controller if not selected.
4. Click Continue.
5. For both phases, T300_TIMER_PHASE and T300_AGITATOR_PHASE, set the Resolution

option from Skip this Time to Create in Project as shown here.
6. Click Synchronize.
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7. Look under the Result column for the two phases, T300_TIMER_PHASE and
300_AGITATOR_PHASE. The status should be Successful for those two phases
8. Click Yes to save the IN11.ACD RSLogix 5000 project file.
9. Click Close to the synchronization window.
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10. In RSLogix 5000, review the two new Phase Manager equipment phases.
Note that the two phases, T300_TIMER_PHASE and T300_AGITATOR_PHASE, are

automatically created under the Unscheduled Programs/Phases task.
11. Notice that within each new equipment phases that the Phase Tags that were automatically
built for you. You will examine this more closely in the next section.
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12. Move new equipment phases into a scheduled task, Unit_Tank300 from the unscheduled
programs/phases
Drag and drop both new equipment phases into the scheduled task Unit_Tank300.
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Review Equipment Phase Tags in Logix 5000
1. Double-click Phase Tags within T300_AGITATOR_PHASE . Make sure the SPEED and the RUN_TIME
tags exist.
Note that phase parameters are labeled input usage tags in RSLogix, while phase reports are
characterized as output. If the Usage column is not being displayed in RSLogix, right-click the header
column to toggle it on.
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Review similar phase tags in RSBizWare Batch Equipment Editor
1. In the Equipment Editor, double-click the phase class AGITATOR_CL.
2. Select the Parameters tab.
3. Confirm that the SPEED phase parameter is displayed.
4. Select the Reports tab.
5. Confirm that the RUN_TIME report is displayed.
6. You may also perform a similar cross reference with T300_Timer Phase and Timer_CL, then minimize the
Batch equipment editor.
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Part 4 Use RSLogix 5000 to build logic and phase
state routines
In this section, you will create the Phase Manager equipment phase routines in RSLogix 5000. For
the phase named T300_AGITATOR_PHASE, create the new Phase State routines Aborting,
Holding, Running, Restarting, and Stopping within RSLogix 5000.
1. To create each routine, right-click the T300_AGITATOR_PHASE and select New Phase State
Routine.
2. For the first state routine, select Aborting.
3. In the Description box, type Phase Aborting Routine.
4. For the Type, select Structured Text.
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The routine should look like this:
5. Click OK.
6. Repeat these steps to build the following additional Phase State routines(skip Resetting):
Holding (Structured Text Type)
Restarting (Ladder Logic Type)
Running (Ladder Logic Type)
Stopping (Structured Text Type)
Now within RSLogix 5000, the T300_Agitator_Phase should look like the following.
Note: You could also create a Resetting State routine, PreState routine, and FaultState
Routine. These routines will not be created for this phase, but examined later.
7. Next, you will build logic for each Phase State routine in T300_AGITATOR_PHASE
You will be using the code written in the next set of tables for your routine coding within the
T300_AGITATOR_PHASE. Some tables are structured text, and others are ladder logic.
Note: you can use some tricks to speed your logic building time. You may cut and paste code
directly from this lab to build your phase state routines. Open the Word document for this lab
called, Lab 7 logic code.doc to cut code directly from the phase state logic tables in the
following pages. You can paste the code from these tables into the following area of RSLogix
5000:
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Insert copy here!
For Ladder code you need to paste one rung of instruction at a time. This can be done for both, the Restarting
and Running phase state routines for this lab example.
For Structured Text code you can cut and paste the entire phase state routine logic in one instance as seen
below:
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Do not include the step index column when you cut and paste
Aborting logic
Note: ABORTING valid Step Index ranges from 7100 to 7777.
StepIndex Description (Aborting Logic Structured Text)
0 // Aborting Step 0
// Initialize Timer and set for 5 second setpoint
If T300_AGITATOR_PHASE.StepIndex = 0 Then
T300_Agitator_Ab_Timer.pre := 5000;
T300_Agitator_Ab_Timer.reset := 1;
T300_AGITATOR_PHASE.StepIndex := 7100;
End_If;
// Stop Agitator and wait for x second
CM_Motor_Array[0].Command := 0;
T300_Agitator_Ab_Timer.timerenable := 1;
RTOR(T300_Agitator_Ab_Timer);
If T300_Agitator_Ab_Timer.DN Then
End_if;
End_If;
// Calculate Agitate Time (in Second) for reporting through output tag
RUN_TIME := T300_Agitator_Timer.ACC / 1000;

End_If;
7777 // Complete Aborting
PSC();
End_If;
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Holding logic
Note: HOLDING valid Step Index ranges from 8100 to 8888.
StepIndex Description (Holding Logic Structured Text)
0 // Holding Step 0
End_If;
8100 // Holding Step 8100
End_if;
End_If;
8200 //Holding Step 8200
// Calculate Agitate Time (in Second) for reporting through output tag

End_If;
8888 // Complete Holding
PSC();
End_If;
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Restarting logic
Note: RESTARTING valid Step Index ranges from 6100 to 6666.
StepIndex Description (Restarting Logic - Ladder)
0 EQU T300_AGITATOR_PHASE.StepIndex 0 MOV 6666
T300_AGITATOR_PHASE.StepIndex
6666 EQU T300_AGITATOR_PHASE.StepIndex 6666 MOV
T300_Agitator_Hold_Index T300_AGITATOR_PHASE.StepIndex
EQU T300_AGITATOR_PHASE.StepIndex T300_Agitator_Hold_Index
PSC
Running logic
Note: RUNNING valid Step Index ranges from 100 to 4444.
StepIndex Description (Running Logic - Ladder)
0 EQU T300_AGITATOR_PHASE.StepIndex 0 MOV 100
T300_AGITATOR_PHASE.StepIndex
100 EQU T300_AGITATOR_PHASE.StepIndex 100 BST MOV
T300_AGITATOR_PHASE.StepIndex T300_Agitator_Hold_Index NXB
RES T300_Agitator_Timer NXB MOV 36000000
T300_Agitator_Timer.PRE NXB PPD GEQ WI300 50 MOV 210
T300_AGITATOR_PHASE.StepIndex BND
210 EQU T300_AGITATOR_PHASE.StepIndex 210 BST MOV
T300_AGITATOR_PHASE.StepIndex T300_Agitator_Hold_Index NXB
PPD BST MOV SPEED M300_Speed NXB OTL M300.Command NXB
XIC M300.Running MOV 400 T300_AGITATOR_PHASE.StepIndex
BND BND
400 EQU T300_AGITATOR_PHASE.StepIndex 400 BST RTO
T300_Agitator_Timer ? ? NXB PPD LES WI300 50 BST OTU
M300.Command NXB XIC M300.Stopped MOV 200
T300_AGITATOR_PHASE.StepIndex BND BND
4444 EQU T300_AGITATOR_PHASE.StepIndex 4444 PSC
Stopping logic
Note: STOPPING valid Step Index ranges from 5100 to 5555.(continued on next page)
StepIndex Description (Stopping Logic Structured Text)
0 // Stopping Step 0
End_If;
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StepIndex Description (Stopping Logic Structured Text)
End_if;
End_If;
// Calculate Agitate Time (in Second) for reporting

End_If;
5555 // Complete Stopping
PSC();
End_If;
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Build all phase state routines for T300_TIMER_PHASE with the exclusion of
Holding and Resetting state routines
You will create new phase state routines for the equipment phase called, T300_TIMER_PHASE, in
the Unit_Tank300.
1. From within the Unscheduled Programs/Phases, you may copy the phase state routines from
the phase named T300_TIMER_PHASE_SAVE, shown below.
2. From the T300_TIMER_PHASE_SAVE phase object, use CTL-C to copy each complete phase
state routine and CTL-V to paste each into the T300_TIMER_PHASE object. You will copy the
state routines Aborting, Restarting, Running, and Stopping.
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3. Within the new T300_TIMER_PHASE object, make use of the Search and Replace function
within the editor to make changes for tag references from T300_TIMER_PHASE_SAVE to
T300_TIMER_PHASE : Click on the T300_TIMER_PHASE equipment phase and from the
Logix 5000 menu select Search > replace and fill out as seen below:
4. Click on Replace All to update the equipment phase reference
Note: The Find Where selection allows replacement for all routines in the current equipment
phase. Make sure this is selected to optimize your time.
In the T300_TIMER_PHASE, you will learn that in the absence of a state phase routine,(i.e.
Holding) the behavior can be set to immediately complete for that state. For this simple timer
phase, it will not be necessary to have a Holding or Resetting state routine. Therefore, if a Hold
command is issued to this equipment phase, it would immediately complete that state as HELD.
We will now show you how to set the option to complete an unconfigured state command.
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5. Right-click the equipment phase and select Properties.
6. In the Configuration tab, make sure the Complete State Immediately If not Implemented
is selected.
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Test equipment phase logic using RSLogix Equipment Phase Monitor
1. Verify SoftLogix is running and will be the Logix controller for this lab. If not running, you may
launch from the Start menu, select, Programs>Rockwell
Automation>SoftLogix5800>SoftLogix Chassis Monitor. Or click on the shortcut on the right
side of the desktop.
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2. From the Logix 5000 editor, Select Offline > Download. This downloads the ACD Project to the
controller from RSLogix 5000.
3. Click Download.
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Place the controller into Run mode and test phase code
1. In RSLogix 5000, select Rem Prog > Run Mode.
2. Click Yes on the confirmation message.
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3. Expand Tasks > Unit_Tank300. Right-click the T300_AGITATOR_PHASE. Select Monitor
Equipment Phase.
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4. Take ownership (control) of the equipment phase. From the Monitor Equipment Phase screen,
select the Take Ownership button to acquire the T300_AGITATOR_PHASE.
5. Click Yes to confirm your action to take ownership.
Valid values for Ownership could be <none>, Internal (another program in the same Logix
controller), RSLogix 5000, or External (for example, the Batch Server).
Once you have taken ownership of a phase, you will be able to issue commands to the phase
based upon conformity to the equipment phase state machine. Such conformity to the state
machine does not allow the Hold command to be a valid option whenever the phase state is
IDLE. For a phase in IDLE, a valid command could be a Start command. Active (valid)
commands are identified by underlined blue text.
Note: STOP or ABORT are not valid commands for a S88 phase in idle, but is valid within the
execution of PhaseManager.
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6. Click the Start target (blue text) for the T300_AGITATOR_PHASE to initiate the start command
to the phase. Once this occurs, the Running routine will process.
List of all PhaseManager

equipment phase in the
project
7. Try other commands when appropriate, such as Hold, Stop, Abort, or Reset.
Note: T300_AGITATOR_PHASE will remain in the Running Routine for a long time if a
command to Stop, Abort, or Hold is not issued.
8. Double click on any phase state routine to bring up its logic in the window.
9. Finish up by setting the phase into the IDLE state with a reset command. Also, release
ownership of the phase.
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Part 5 Build Phase Manager Equipment Phases
(Synchronize to Update your RSBizWare Batch
Area Model)
AREA 2 - RSLogix 5000 & Project File (.acd)
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Create a New Phase
With RSLogix 5000 and the IN11.ACD file, please take the program Offline.
1. Create the equipment phase object named, T400_HEAT_PHASE, under Unit Unit_Tank400,
expand Tasks and then expand Unit_Tank400 scheduled sub-task.
2. Right-click Unit_Tank400 and select New Equipment Phase.
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3. Name the phase T400_HEAT_PHASE, and fill in the Description section as below:
8. Select OK.
You have just created a new phase called T400_HEAT_PHASE.
9. Right-click on the new phase and select Properties.
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The Properties window is displayed with the General tab displayed. This tab allows you to
rename the phase and edit the description.
6. Select the Configuration tab.
The options in this Configuration tab are as follows:

Assigned Routines Prestate: You can configure a Prestate routine to run when the phase
runs. This routine would contain failure conditions or semi-continuous logic required by the
phase. During pre-scan, the Prestate routine is executed once. After pre-scan, it is executed
along with each state routine.
Assigned Routines Fault: You can configure a fault routine. This works as the classic fault
routines work today. This routine would run whenever a major fault occurs in the Equipment
Phase as a result of instruction execution (for example, divide by zero).
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Inhibit Equipment Phase: When selected, the phase is never scanned.
Initial State: Used to configure the initial state of the phase. Valid options are Idle, Stopped,
Aborted, and Complete. The S88 standard would expect Idle state.
Complete State if Not Implemented: If selected and a phase state is not implemented, a call
to that state will cause the state will go to its final state (such as Held for Holding; Aborted
for Aborting; and Stopped for Stopping). This allows you to only implement those states that
you need.
Initial Step Index: Defines the value of the step index (SI) that the phase state will initialize to
at the start.
External Sequencer Loss of Communication Command: Define the action of the phase if it
loses communication with an external system, such as the Batch Server. The classic
implementation will only take you to hold. This option gives you None, Abort, Hold, and
Stop.
External Request Hold Action: Specify action to take when a request to an external
sequencer is in progress and the phase receives a HOLD command.
Clear phase aborts request that is currently in progress (recommended for Batch)
7. Select the Parameters tab.
This displays the configured Parameters and Report Tags. Since you did not push them down
from the Batch area model at the creation of this phase, they must be created by you in
RSLogix. This will be done later.
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8. Select the Monitor tab.
This displays information about the execution, state, and ownership of the Equipment Phase.
Phase Scan Times just like Program
State Current Phase State and Substate
Owners Current Phase Owner (covered in detail later in the lab)
9. Select OK.
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Adding Parameters and Reports
S88 defines parameter and report tags as part of the inputs and outputs to transfer process
information to a phase. Parameter tags tell an agitator phase what speed to run at. Report tags
provide actual process data, such as the actual agitator run time, for archiving purposes.
Parameter and Reports within the RSLogix 5000 editor are called:
Input Parameter (S88 Parameter tags)
Output Parameter (S88 Report tags)
They are used to transfer information into and out of the phase.
Parameters are Phase Scoped.
1. To set up an Input Parameter, right-click the Phase T400_Heat_Phase and select New
Parameter.
2. In the Name box, type SETPOINT. T
3. Enter description: Heat control setpoint, For usage, select Input Parameter.
4. Leave Type set to Base.
5. Set Data Type to REAL.
6. Leave Scope set to T400_HEAT_PHASE.
7. Leave Style set to Float.
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You should have the following.
8. Select OK.
Here you have created an Input Parameter that is scoped within the Phase. To create Input
Parameters (Parameters) and Output Parameters (Reports) that can be referenced throughout
the controller, create a variable in the Controller Scoped data space and then alias the Phase
parameter to it.
For report parameters, follow this step, but set the Usage as Output parameter.
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Phase Tags and Data
In this section, we will have a look at where the data is stored and what the scope of the data is,
controller or program scoped.
Phase data:
When a phase is created, a controller scoped tag is automatically created
The Data Type of the tag is PHASE
The Tag cannot be deleted or renamed by the user
Internal Sequencing logic, state routine logic, or any other logic can read the tag
All tag updates (except one) are done by the phase object. These are essentially read only tag
elements.
Step Index is the only tag element that can be written by the user logic.
1. Open the controller tags by right-clicking Controller Tags and selecting Monitor Tags. You can
also double-click Controller Tags.
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2. In the window that appears, find the tag T400_HEAT_PHASE phase and expand it by clicking the
+ as seen:
Phase Data
Type
Current State of
the Phase
Step Index (written by

logic)
Phase Failure Code
Unit ID of the unit this

phase is running in
Current Phase Owner
Phase data is stored at the controller scope as it is referenced throughout the controller.
3. Examine the data structure for the phase. (You may need to resize the columns).
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4. Expand the T400_HEAT_PHASE under Unit_Tank400. Open the T400_HEAT_PHASE Phase
Tags by right-clicking Phase Tags and selecting Edit Tags.
5. Examine the tags that are present in the Phase scope. The only tags present are the Input and
Output parameters that were created earlier. The Phase scope tag space is a great area to
store variables that are specific to the phase, be it parameters or local variables for the phase to
store information.
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Create Phase State Routines
We are now going to create some of the available state routines within the phase
T400_HEAT_PHASE.
1. Right-click the phase T400_HEAT_PHASE and select New Phase State Routine.
2. Note the attribute window for adding a new state routine.
State Routines are just like normal

routines except they:
Have a fixed name
Are executed according to the state
machine rules
Have state names that reflect only valid
states:
o Aborting
o Holding
o Resetting
o Restarting
o Running
o Stopping
Just like Normal routines, State

routines can be implemented in any
Select whether to available language
immediately open the Ladder Diagram
routine and begin Sequential Function Chart
Function Block Diagram
editing it Structured Text
3. Select Running as the phase state routine.
4. Select Type of Ladder Diagram.
5. Make sure Open Routine is cleared.
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6. Click OK.
7. Conversion of the remaining phase state routines, Aborting, Stopping, Holding, and
Restarting will be covered in the Appendix material. For this current exercise you will take
advantage of an attribute of the Phase Manager equipment phase oject. This will be mentioned
in step 12.
8. Right-click T400_HEAT_PHASE and select New Routine.
Note: Not New Phase State Routine!
9. Create a New Routine called PreState, of Type Ladder Diagram, as shown below.
You should now have the routines shown below.
Note that the phase state routines

have a different symbol than the
standard routine, PreState.
Right-click T400_HEAT_PHASE and select Properties
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10. Select the Configuration tab.
11. Set the Assigned Routine PreState to the routine we just created, PreState.
12. Click OK.
Checking this
attribute allows
any phase state
routine that is not
implemented to
act as if it exists
for the phase
object. Then, upon
its command, it
will automatically
be set to a
complete state for
execution.
We just assigned the routine PreState as the prestate logic for the T400_HEAT_PHASE. This
routine will execute once during the Pre-Scan and then execute along with each state routine.
This routine would contain failure condition monitoring or any semi-continuous logic required by
the phase.
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Adding the Logic to the State Routines
We created the state routine of Running, and a routine called PreState. In the next sections we will
be copying and pasting code from the Un-scheduled > T400_HEAT_PHASE_CLASSIC routine to
the T400_HEAT_PHASE state routine. This will give an brief glimpse into the conversion of classic
phase code to a PhaseManager framework. This will be covered in more detail in the supplemental
material in the appendix.
1. For the T400_HEAT_PHASE Running routine, copy and paste rungs 24 to 30 from
T400_HEAT_PHASE_CLASSIC T400_Heat_Phase_Logic in the unscheduled
Programs/phases folder.
2. Search and replace T400_HEAT_PHASE_CLASSIC.SI with T400_HEAT_PHASE.StepIndex

for the running routine.
3. Add a rung at the end of file EQU T400_HEAT_PHASE.StepIndex 4444 PSC
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4. For the T400_HEAT_PHASE PreState routine, enter the two rungs below.
StepIndex Description
XIC XV410.Alarm PFL 1210
XIC XV420.Alarm PFL 1220
5. Save your IN11.ACD file.
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Synchronize to Update Area Model
1. With the Batch equipment editor, Open the Area Model IN11. It is in the directory C:\
autofair_lab_7\Recipe.
2. Make sure the RSLogix 5000 project is offline.
3. Drill down to Unit Tank400 and click the Synchronize Logix 5000 Data Server button.
4. Click Continue Without Saving.
5. Click Continue.
6. For Equipment Module T400_HEAT_PHASE, set resolution to Create in Area Model.
7. Click Synchronize.
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8. Select the HEAT_CL phase class and TANK400 unit.
9. Click Continue.
Note: You may create a new Phase Class by entering the New Phase Class Name in the Enter
new name for new phase text box.
You have just created the T400_HEAT_PHASE successfully.
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10. Click Yes.
11. Click Close.
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Notice that the T400_HEAT_PHASE is present in the Area Model, under Unit TANK400.
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Part 6 Running a recipe in RSBizWare Batch
Saving Equipment Area Model and Synchronizing Recipes
1. Save your IN11.cfg file in the batch equipment editor
2. Start the Recipe Editor by selecting Start > Programs > Rockwell Software > RSBizWare
> Batch > Recipe Editor, or click on the shortcut on the desktop
Result: The Recipe Editor application opens with a recipe requiring variation
3. Click yes to verify all the recipes in the recipe directory
4. Result - a preconfigured Operation level recipe that was pre-created has been verified
against your area model.
5. Click OK then close to close the verification dialog
6. Close both the batch recipe and equipment editors.
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7. Next Maximize the Logix 5000 screen and Select Offline > Download. This downloads the
ACD Project to the controller from RSLogix 5000.
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8. Click Download.
Place the controller into Run mode
9. In RSLogix 5000, select Rem Prog > Run Mode.
10. Click Yes on the confirmation message and Minimize RSLogx 5000.
Start the Batch Service Manager application: Start > Programs > Rockwell Software >
RSBizWare > Batch > Batch Service Manager, or click on the desktop icon.
Result: The Batch Service Manager application opens.
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Selects the computer where the service will be
located.
Selects the Batch Server or the

Batch Archiver services
Demo Mode allows the

Batch Server to run with full
functionality for two hours
without an activation license.
Cold Boot: The Batch Server restarts but

batches that where running when the Batch
Server stopped are not restored.
Warm Boot: The Batch Server restarts and

attempts to restore any batches that were
running when the Batch Server stopped.
Batches may or not be restored.
Warm All Boot: The Batch Server restarts

11. Select Batch Server in the Service box. only if it can restore all batches. The user
can fix any problems and attempt to restart
12. Select Cold Boot in the Server area. the Batch Server as many times as
needed.
13. Click Start/Continue.
Note: Activations are installed on your machine so it is not necessary to select Demo mode.
Result: The Service State indicates Running. When the light turns green.
14. Minimize the Batch Service application.
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Start the Batch View and Run a Recipe The Batch View application is the operating
window for the creation and execution of batches. In Batch View, you will create a Control recipe
from a Master recipe.
A Master recipe is the recipe that was created in the Recipe Editor
A Control recipe is an instance of a Master recipe
The Batch Server creates an Event Journal containing information about the creation and execution
of every Control recipe.
1. Start the Batch View application: Start > Programs > Rockwell Software > RSBizWare >
Batch > View, or click on the icon on the desktop.
Result: The Batch View application opens.
2. Select the Add Batch button (to the right) to add a new batch.
Result: The Recipe List dialog box opens. It lists all of the possible Master recipes. In our case,
the only Master recipe we have built is a simple single recipe.
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3. Select the INI11_OP recipe and click OK.
Result: The Batch Creation dialog box is displayed.
4. In the Batch Creation dialog box, enter a Batch ID of TEST_ONE.
5. In the Unit Binding area select Tank300 as the bound unit.
6. Click Create.
Result: The TEST_ONE control recipe appears on the Batch List.
7. Select the Recipe and click the Start button .
Result: The following dialog box is displayed.
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8. Click Yes.
9. Result: The recipe begins execution.
10. Click the Procedure as SFC button (on the top).
Result: The Procedure as SFC window is displayed. Note that the color of the phase indicates
its status. For example, green indicates RUNNING.
The SFC is organized into three sections:
Hierarchy View
SFC View
Auxiliary Information
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SFC View
Hierarchy View
Auxiliary Information
Note: the Phases in the SFC view correspond with the phases that you built earlier in the lab.
Recipe will be completed when the final phase in the SFC turns from Green to clear
Extra Credit
1. Rerun a second recipe in T300 and in Logix 5000, observe the Phase Monitor window in one of the
T300 Phases. You will notice the Batch server taking ownership of the phase when it executes.
2/1/2006 Page 82 of 84
2. Get out your watch to use as a timer and run a recipe against Unit T200 which uses classic phase
design and OPC communication. Run a second recipe against either T300 or T400. Do you notice
a faster execution time? This is the result of using CIP Messaging as the communication interface
between the Batch server and the Logix controller
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Wrap up
We have had a chance to look at the features of the Phase Manager functionality in RSLogix 5000
and how it integrates into RSBizWare Batch. The IN11_Lab_final.ACD is a completed project for
this lab. Supplemental materials for this lab will be handed out to give more detail on phase design.
2/1/2006 Page 84 of 84

Batch-PhaseManager Hands On Lab

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Format Tersedia

Batch-PhaseManager Hands On Lab

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Hak Cipta:

Format Tersedia

RSBizWare Batch Integration with

RSLogix 5000 PhaseManager

ABOUT THIS HANDS-ON LAB __________________________________________________5

BEFORE YOU BEGIN ________________________________________________________5

LAB MATERIALS ___________________________________________________________6

PART 1: UNDERSTANDING S88, BATCH, LOGIX WITH PHASEMANAGER ______________________8

ABOUT THIS LAB ___________________________________________________________8

AREA 1 - LOGIX 5000 CONTROLLERS (HOW IS IT AFFECTED?) _________________________9

AREA 4 - BATCH SERVER (HOW IS IT AFFECTED?) _________________________________11

PART 2 REVIEW CLASSIC S88 BATCH EQUIPMENT PHASE DESIGN ______________________12

ABOUT THIS LAB __________________________________________________________12

START THE EQUIPMENT EDITOR SOFTWARE AND OPEN A PROJECT ____________________15

REVIEW EXISTING LOGIX 5000 EQUIPMENT PHASES WITHIN IN11.ACD ___________________29

REVIEW EQUIPMENT PHASE TAGS IN LOGIX 5000__________________________________36

REVIEW SIMILAR PHASE TAGS IN RSBIZWARE BATCH EQUIPMENT EDITOR _______________37

CREATE A NEW PHASE _____________________________________________________ 56

ADDING PARAMETERS AND REPORTS __________________________________________ 61

PHASE TAGS AND DATA ____________________________________________________ 63

CREATE PHASE STATE ROUTINES _____________________________________________ 66

ADDING THE LOGIC TO THE STATE ROUTINES _____________________________________ 69

SYNCHRONIZE TO UPDATE AREA MODEL ________________________________________ 71

PART 6 RUNNING A RECIPE IN RSBIZWARE BATCH __________________________________ 75

SAVING EQUIPMENT AREA MODEL AND SYNCHRONIZING RECIPES _____________________ 75

EXTRA CREDIT ___________________________________________________________ 82

This lab takes approximately 90 minutes to complete.

Before You Begin

PhaseManager is an extension to the RSLogix 5000 and ControlLogix capability. Rockwell

Windows Login Username/Password

RSLogix 5000 .ACD file

RSBizWare Batch area model and recipe files.

About This Lab

The following is an overview of the Batch Server product with ControlLogix:

2. RSLogix 5000 & Project File (.acd)

3. Equipment Editor & Area Model (.cfg)

Area 1 - Logix 5000 controllers (How is it affected?)

Complete Stopped Aborted

Phase Manager Equipment Phase State Model

1. State Diagram for S88 Batch is listed below:

S88 Batch State Model

1. Start the program.

From the Start menu,

3. Select the file name IN11.cfg and click Open.

1. Select the Edit Data Server icon, , in the toolbar,

Data Server Types:

This Warning dialog box is displayed.

5. For both phases, T300_TIMER_PHASE and T300_AGITATOR_PHASE, set the Resolution

8. Click Yes to save the IN11.ACD RSLogix 5000 project file.

9. Click Close to the synchronization window.

Note that the two phases, T300_TIMER_PHASE and T300_AGITATOR_PHASE, are

1. In the Equipment Editor, double-click the phase class AGITATOR_CL.

2. Select the Parameters tab.

3. Confirm that the SPEED phase parameter is displayed.

4. Select the Reports tab.

5. Confirm that the RUN_TIME report is displayed.

2. For the first state routine, select Aborting.

3. In the Description box, type Phase Aborting Routine.

4. For the Type, select Structured Text.

RUN_TIME := T300_Agitator_Timer.ACC / 1000;

RUN_TIME := T300_Agitator_Timer.ACC / 1000;

RUN_TIME := T300_Agitator_Timer.ACC / 1000;

4. Click on Replace All to update the equipment phase reference

1. In RSLogix 5000, select Rem Prog > Run Mode.

2. Click Yes on the confirmation message.