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YOKOGAWA TRAINING Section 10.

Laboratory Exercises
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TE 33AU1C3-01 Rev 3.4 21 July 2005 10-1


SECTION 10

CS3000
LABORATORY EXCERCISES




CONTENTS


10. LABORATORY EXERCISES _______________________________________2
PART A - REGULATORY CONTROL EXERCISES __________________________ 2
A1. Dual Redundant Input Exercise ________________________________________________2
A2. ID FAN Flow/Pressure Control Switching Exercise ________________________________3
A3. Ratio Control Exercise_______________________________________________________5
A4. Temperature Profile Control Exercise ___________________________________________6
A5. Boiler Level Control ________________________________________________________7
PART B - CALCULATION FUNCTION EXERCISES ________________________ 10
B1. Boiler Control Simulation Exercise ____________________________________________10
B2. Numerical Calculations _____________________________________________________12
B3. Analog Calculation Blocks __________________________________________________13
B4. Setpoint Setting ___________________________________________________________15
B5. Calculation Exercise _______________________________________________________17
B6. Switching Calculation Exercise _______________________________________________21
PART C - SEQUENCE TABLE EXERCISES________________________________ 23
C1. Global Switch Exercise _____________________________________________________23
C2. Mode Setting Exercise ______________________________________________________24
C2. Pump Interlock Exercise ____________________________________________________25
C3. Relational Expression Exercise _______________________________________________27
C4. Sequence Exercise Using Switch Instrument Block _______________________________28
C5. Boiler Fill Sequence Exercise ________________________________________________30
PART D - TUTORIALS __________________________________________________ 31
D1. System Configuration ______________________________________________________31
D2. Creation of Regulatory Control Function _______________________________________45
D3. Creation of Sequential Control Function ________________________________________64
D4. Creation of Logic Chart Function _____________________________________________84
D5. Creation of SFC Control Function____________________________________________100
D6. Creating Graphic Windows _________________________________________________101



YOKOGAWA TRAINING Section 10. Laboratory Exercises
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10. LABORATORY EXERCISES

PART A - REGULATORY CONTROL EXERCISES

A1. Dual Redundant Input Exercise

Objective: The purpose of this exercise is to gain an understanding of how the SS-
DUAL module is used to provide dual redundancy where two field transmitters are
used.

Description: Two flowmeters are input into the DCS and are registered as PVIs.
These connect to a SS-DUAL to select one of the two for output.

Procedure:

1. Hardwire the outputs in channels 3 & 4 to the input in channels 1 & 2, of the
analog nest.

2. In a control drawing, connect the two analog inputs to two PVIs, and then into
and SS-DUAL. The output of the SS-DUAL connects to another PVI.

3. Drive the two outputs with two Manual Loaders.

Tags names are as follows:

Tag name Description Module
%Z011101 Input 1
%Z011102 Input 2
%Z011103 Output 1
%Z011104 Output 2
FI100A Input Indicator 1 PVI
FI100B Input Indicator 2 PVI
FI100DV Input Selector SS-DUAL
FI100 Selector Input Indicator PVI
CV100A Output Loader 1 MLD
CV100B Output Loader 2 MLD



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A2. ID FAN Flow/Pressure Control Switching Exercise


Objective: This exercise in regulatory control provides an example of a common
control application of flow/pressure control switching using different techniques that
can be employed using function blocks and control drawings. It demonstrates how an
inlet draft fan can be controlled according to flow and pressure.


Description: The speed of a draft fan is controlled by the DCS based on either the
flowrate or the pressure of the incoming air. At low fan speeds, the fan speed is
controlled by pressure. At higher speeds, the control switches to flow control.

The DCS reads the pressure and the flowrate as analog inputs, into PVIs. These feed
into two standard PID controllers. The outputs of these controllers are fed to a high
selector switch (AS-H) which selects the higher of the two outputs for control. This
signal goes through an MLD-SW for operator control and then output to the fan drive
speed controller as a 4-20mA signal.

When the MLD-SW is in manual, the controllers are forced into track mode.

Procedure:

The attached control scheme shows how the requirements above can be achieved.
Note that due to the in-built pushback feature of the system, the controllers track the
manual loader when it is in manual. No tracking wiring is required.

Note that the AS-H was used, rather than the SS-H. This is because the input to the
MLD-SW is a SET, and therefore a Cascade input. Because of the way the
pushback feature works, the preceding module must have an MV through the OUT
terminal. The AS-H has this, whereas the SS-H only has a PV, and therefore cannot
be used in a cascade loop.

Module Details:

1. FI3001 Flowrate PVI Range: 0 to 150 M3/M

2. PI3001 Pressure PVI Range: 0 to 350 KPA

3. FIC3001 Flow Controller PID Range: 0 to 150 M3/M

4. PIC3001 Pressure Controller PID Range: 0 to 350 KPA

5. SFD3001 High Output switch AS-H Range: 0 to 100%

6. FD3001 Output Station MLD-SW

7. PIO FI3001 %Z011103
PI3001 %Z011104
FD3001 %Z011110
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Set up a Control Group called IDFAN, with all of the tags in it.

Call up IDFAN on the operator display and set up the function blocks as follows:

FD3001 - set to AUT
SFD3001 - set to AUT
- set SW = 4
PIC3001 - set to AUT
- set SV = 250
FIC3001 - set to AUT
- set SV = 100

Vary the set points such that the MVs of the blocks move up and down. Notice how
the greater of the two MVs is the one selected for output.

Put FD3001 into MAN and change its output. Notice how this value is pushed back
to the preceding blocks, both the SFD3001 and the controllers. All of these blocks are
in IMAN and are tracking this value.


Test Function

If test function is already running, then the wiring between the inputs and outputs will
not have been done. TO set this up, do the following procedure.

1. In the Test Function Panel, click on the Tools menu and select Wiring Editor
2. Select Tools Auto-Wiring (at the bottom of the menu). Select DR0002.
3. Select File Open and select DR0002.
4. Select File Download.

The I/O is now wired together.

FI

PI
PIC
PID
PID
FIC
High Signal
Selector
Hand
Auto
Station
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A3. Ratio Control Exercise

Objective: The purpose of this exercise is to learn how to use the Ratio block to
perform ratio control.

Description: The flow controller controls the additive flowrate. The setpoint to this
controller is from a RATIO control block, and its input is the main flow. The operator
sets the SV of the RATIO block to (say) 0.1, so that the setpoint of the flow controller
is 0.1 of the main flow.

Procedure:

The attached control scheme shows how the requirements above can be achieved.



The MLD FI201 simulates the main line flow, and this can be adjusted by the operator
accordingly.

The LAG block simulates the dosing flow. To set the lag time of the block, set the I
value to around 5 seconds.

Set the setpoint of the ratio block (FR200) to 0.1. Set FIC200 to CAS.

Thus the setpoint to FIC200 will be a tenth of the flow from FI201.

FIC200

PID
FR200

RATIO
FI200

LAG
FT201

MLD
IN OUT
MV
SET
MV
IN CPV
IN
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A4. Temperature Profile Control Exercise

Objective: The purpose of this exercise is to learn how to use the PG-L13 block to
perform temperature profile control.

Description: The flow controller controls the temperature of the process. The
setpoint to this controller is from a PG-L13 block, and the profile created by the PG-
L13 block will drive the setpoint of the controller.

Procedure:

The attached control scheme shows how the requirements above can be achieved.



Set up the TQ200 in the tuning panel as follows:

X01 = 0 Y01 = 0
X02 = 30 Y02 = 50
X03 = 45 Y03 = 50
X04 = 70 Y04 = 85
X05 = 95 Y05 = 85
X06 = 120 Y06 = 0

Set ZONEND = 5

Set TIC200 to CAS
Set TQ200 to AUT

The PG-L13 should now run through its program defined by the X, Y values given
above. The X values are time in seconds, and each value represents the time from the
beginning, not from the previous zone.

Set TQ200 to CAS. In this case, the program loops around continuously.

TIC200

PID
TQ200

PG-L13
TI200

LAG
OUT
SET
MV
IN CPV
IN
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A5. Boiler Level Control


Objective: The purpose of this exercise is to learn how to use standard control
functions to perform complex boiler control.

Description: The boiler level is to be maintained by level/flow cascade control with
feed forward where the steam flow demand adjusts the requirements for the boiler.
The level is a duplicated field transmitter signal, monitored by an SS-DUAL. The
output is split to two feedwater control valves.

Procedure:

The attached control scheme shows how the requirements above can be achieved.



1. LC105 Boiler Level Controller PID 0 to 2,000 MM

2. FC105 Feedwater Flow Ctrl PID 0 to 200 KG/S

3. FI101 Steam Flow Indicator PVI 0 to 200 KG/S
3a. FT101 Steam Flow Simulator MLD 0 to 200 KG/S

4. FI105 FW Flow Indicator PVI 0 to 200 KG/S

5. LI105A Level Indicator A PVI 0 to 2,000 MM
5a. LI105B Level Indicator B PVI 0 to 2,000 MM
5b. LI105 Level Input Selector SS-DUAL 0 to 2,000 MM

6. CV105 Output distributor SPLIT 0 to 100 %
6a. CV105A FW Valve A MLD-SW
6b. CV105B FW Valve B MLD-SW

7. Process Inputs/Outputs (PIO):
LI105A %Z011105
LI105B %Z011106
FI105 %Z011107
CV105A %Z011111
CV105B %Z011112




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Setting the output scale in FT101:

1. In FT101, go into Edit Detail and select VIEW Detail Setting Items.
2. Click on the Output tab, and under MV Display Setting, select SELF.
3. The scale will appear, and change the 100.0 to 200.0

Setting up the feedforward function:

1. In FI101, go into Edit Detail and select VIEW Detail Setting Items.
2. Click on the Output tab, and under Auxiliary Output Output Data, select
DPV.

3. In LC105, go into Edit Detail and select VIEW Detail Setting Items.
4. Click on the Control Calculation tab, and for I/O Compensation, select Output
Compensation.


LC105

FC105

FI101

LI105
CV105

FI105
PV
IN
SET
OUT
SUB
VN
FT101
MLD
IN
MV
%Z011105
%Z011106
%Z011107
%Z011111 %Z011112
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Setting up Test Function:

If test function is already running, then the wiring between the inputs and outputs will
not have been done. Also, the connection to the level inputs will not be defined. To
set this up, do the following procedure.

1. In the Test Function Panel, click on the Tools menu and select Wiring
Editor
2. Select Tools Auto-Wiring. Select your drawing.
3. Select File Open and select your drawing. Set the following:

TO FROM WIRING TYPE GAIN BIAS DELAY LAG
FI105.IN CV105A.OUT AnDrAn 1.0 0.0 3 5
LI105A.IN CV105B.OUT AnDrAn 1.0 0.0 10 10
LI105B.IN CV105B.OUT AnDrAn 1.0 0.0 10 10
(note, the first line may already be there.)

4. Select File Download and select your drawing.

The I/O is now wired together.


Operating the Boiler Controls:

1. Put the blocks LI105, LC105, FC105, FT101, CV105, CV105A, CV105B,
into a Control Group called BOILER and display this on the HIS operator
display.
2. Put CV105A and CV105B into AUT
3. Put CV105 into CAS, and set SW = 3
4. Put FC105 into CAS
5. Put LC105 into AUT, and set its SV to 1200 mm
6. Set FT101 to 100 Kg/s this can be modified to see the affects of feed
forward control.

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PART B - CALCULATION FUNCTION EXERCISES

B1. Boiler Control Simulation Exercise


Objective: This exercise uses calculation blocks to provide simulation of the
boiler level, based on the above exercise.

Description: The difference between the feedwater flow into the boiler and the
steam flow out of the boiler is calculated in an ADD module. The result of this is
input to a INTEG module to sum the deviation. This is the simulated level and the
output is input to the two level input blocks.

Procedure:

1. To set up a simulated flow loop, add the following blocks:

ADD (FQ105) - Input 1 (IN) = MV of CV105A
- Input 2 (Q01) = MV of CV105B

LAG (FT105) - Input (IN) = CPV of the ADD module
- Output (CPV) = IN of FI105

Setup the LAG block with I = 5.


2. To create a simulated level, add the following blocks:

ADD (LA105) - Input 1 (IN) = the PV of FI105
- Input 2 (Q01) = the PV of FI101

INTEG (LQ105) - IN = the CPV of the ADD module
- CPV = IN of the two level PVIs (LI105A/B)

3. Setup the ADD block with the GN1 = -1, so that it subtracts the inputs.

4. Set the I of the INTEG block to 30 so that the level changes slowly.



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LC105

FC105

FI101

LI105
CV105

FI105
PV
IN

LI105A

LI105B
LQ105
INTEG
LA105
ADD PV
IN
Q01
CPV IN
IN
IN
CPV
GN1=-1 I=30
MV
MV
I=5
FT105
LAG
FQ105
ADD
IN
Q01
IN
CPV
FT101
MLD
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B2. Numerical Calculations

Numerical blocks are ADD, MULTIPLY, DIVIDE and AVERAGE. They all
have similar functions, and this exercise investigates the ADD block in detail as
an example of each of numerical blocks.

Connect two MLDs to an ADD block. Connect the output of the ADD block
to another PVI.

Set the following parameters in the tuning panel:

GAIN = 1
BIAS = 0
GN1 = 1
BS1 = 0

Note that the result of the ADD is the sum of the two inputs. Try varying the
GAIN and BIAS and look at the effect on the final value.

The GN1 and BS1 are a gain and bias on the second input. Set the values as
follows:

GN1 = -1
BS1 = 0

Note that the result of the ADD is the difference between the two inputs. This
is how this module is used as a subtractor.

A common application is for the second input to be a +/- trim on the first
input. So, if the first input is 0-100%, and the second input is also 0-100%,
but it is required that the second input trim the first by -50 to +50%, set the
parameters as follows:

GN1 = 1
BS1 = -50

What would you set these values to, to trim the first input by +/-20%, when
the second input is 0-100%?

GN1 = 0.4
BS1 = -20


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B3. Analog Calculation Blocks

Analog calculations are single input blocks that provide a calculation function on this
input. Most are self explanatory, but some of the more used blocks will be discussed
here.

LAG

Connect an MLD block to the input of a LAG block. Connect the output
of the LAG block to a PVI.

On the operator display, move the value in the MLD block and observe
the corresponding value on the PVI.

In the tuning panel of the LAG block, note that there is a data item called
I. This is the time constant of the LAG block. The greater this value, the
more lag there is between output and input. Try increasing this and
changing the MLD, monitoring the corresponding change on the PVI.

Note that as well as the I item, there is also a GAIN item. This is a
multiplier on the output. Set this value to 2 and see what happens to the
output.

INTEG - Integration Block

This block is a totaliser, that is, it sums the input over time. The
integration can be started and stopped with the SW item.

Connect an MLD to an INTEG block and monitor the integration on
the operator display. Note the following data items:

I
GAIN

The I is used to set the time base of the integration. For example, if the
input being totalised is in:

L/sec, then I = 1 sec/sec
L/min, then I = 60 sec/min
L/hr, then I = 3600 sec/hour

Try setting the I to different values and monitor the change in speed of
integration.

The GAIN is used as a multiplier on the output. Try setting the GAIN
to different values and monitor the change in output.

Set the SW to 2 and then 1. The totaliser will stop and then continue
without resetting. Set SW to 0. The totaliser will reset and then
continue, with the SW automatically returning to 1.
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AVE-M

The moving average can be used as a more sophisticated form of
smoothing of an input.

Connect an MLD to the input of an AVE-M. In the tuning panel, set the
following data items:

SMPL = 1 (the sampling rate in seconds)
NUM = 10 (the number of samples that are being averaged)

Change the input value by adjusting the MLD output, and monitor the
change in the AVE-M calculated value (CPV).

Change the SMPL to 2 and monitor the changes again.

The number of sampling points and the sampling interval can be
changed to dampen the input signal in different ways.



FUNC-VAR

The Function block provides a free-form function to be applied to an input.

Connect an MLD block to the input of a FUNC block. Set the X,Y
parameters in the FUNC block tuning panel to different values and
monitor the result.

X1 = 0 Y1 = 0
X2 = 10 Y2 = 20
X3 = 20 Y3 = 35
X4 = 30 Y4 = 70
X5 = 40 Y5 = 80
X6 = 50 Y6 = 85
X7 = 60 Y7 = 75
X8 = 70 Y8 = 50
X9 = 80 Y9 = 20
X10 = 100 Y10 = 0

SECT = 9


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B4. Setpoint Setting

This exercise uses some of the Calculation modules to set the setpoint of a controller.

Create the following function blocks:

Tagname Block Type

DATA01 DSW-16
RAMP01 RAMP
SWITCH2 SW-33
SET01 DSET
TIC500 PID
LG01 LAG01

These are to be connected as follows:



When this is compiled and loaded, set the following tuning parameters:

DATA01 RAMP01

SD01 = 0 STEP = 100
SD02 = 10
SD03 = 20
SD04 = 30
SD05 = 40
SW = 1

DATA01

DSW-16
RAMP01

RAMP
SET01

DSET
SWITCH2

SW-33
TIC500

PID
LG01

LAG
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Operation:

Set TIC500 to CAS
Set SWITCH2, SW = 1
In DATA01, set SW = 2

Its output will increase from 0 to 10, and the output of the ramp block will ramp
up from 0 to 10. The should be transferred to the PID block for it to control to.

Set the SW in DATA01 to different switch values and notice how the set point in
the controller changes accordingly.

In SWITCH2, set SW to 2. The set point is now set by changing the SV in the
DSET.



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B5. Calculation Exercise

Objective: To learn how to build a CALCU to perform arithmetic functions.

Description: This exercise is in four parts:

The first part reads 3 inputs, performs a calculation on it and writes
the result to the first output (CPV).
CPV = (RV + RV1 * P01 ) / (RV2 + P02)
The second part selects the maximum of the 3 inputs and writes the
result to the second output (CPV1).
The third part loads RV into CPV2 if RV1 > RV2.
The fourth part averages all or some of the inputs depending on the
status of three selection switches (%SW).
If one switch is on, the related input is loaded to CPV3.
If two switches are on, the two related inputs are averaged
and the result is loaded into CPV3.
If three switches are on, all inputs are averaged and the
result is loaded into CPV3.

Procedure:

1. Create the following blocks on a control drawing:

Tag Type
FI201 MLD
FI202 MLD
FI203 MLD
FQ201 PVI
FQ202 PVI
FQ203 PVI
FQ204 PVI
CL201 CALCU


FI201

MLD
FI202

MLD
FI203

MLD
CL201

CALCU
FQ201

PVI
FQ202

PVI
FQ203

PVI
FQ204

PVI
MV
MV
MV
IN
Q01
Q02
CPV
CPV1
CPV2
CPV3
IN
IN
IN
IN
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2. Create the following Common Switches:

TX1SEL
TX2SEL
TX3SEL

3. Select the CALCU, right click Edit Detail, to enter the editing mode for the
program.

4. Write the equation in for the first part of the exercise. Select File Update
and then Exit. Save the control drawing and run test function.

5. Create a Control Group in the HIS:

Right click on Window and select Create New Window.
Window Type = Control (8-loop), Window Name = CALCEX
Double-click on CALCEX in the right hand window.
Type in all of the tag names of the blocks in the control drawing.

6. Run test function and set different values for the manual loaders. In the
Tuning Panel for CL201, set P01 = 5 and P02 = 10. Notice the resultant value
in FQ201.

7. Go back into the CALCU and add to the program for the second part of the
exercise. Update and Load and monitor the result in FQ202.

8. Return to the CALCU and add to the program for the third part of the exercise.
Update and Load and adjust FI202 so that it is less than, then greater than
FI203. Note the result in FQ203.

9. Return to the CALCU and add to the program for the fourth part of the
exercise. Update and Load. On the operator display call up the three switches
and monitor the result in FQ204, by switching 1, 2 or all 3 switches on.

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The solution is on the next page

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TE 33AU1C3-01 Rev 3.4 21 July 2005 10-20

Solution:

Part 1

CPV = (RV + RV1 * P01 ) / (RV2 + P02)

Part 2

CPV1 = dmax(RV,RV1,RV2)

Part 3

CPV2 = RV * (RV1 > RV2)
or
If (RV1 > RV2) CPV2 = RV

Part 4

P05 = RV * TX1SEL.PV
P06 = RV1 * TX2SEL.PV
P07 = RV2 * TX3SEL.PV
P08 = TX1SEL.PV + TX2SEL.PV + TX3SEL.PV
CPV3 = (P05 + P06 + P07)/P08

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B6. Switching Calculation Exercise


Objective: To learn how to use a CALCU to switch digital outputs, based on an
analog input.

Description: The CALCU reads an analog input.
- If the input < P01, then switch OFF the first digital output
- If the input > P01 and < P02, then switch ON the first digital output
- If the input > P02 and < P03, then switch ON the second dig output
- If the input >P03, then switch ON the third digital output

Only one output is to be on at any one time.

Procedure:

1. Create an MLD (Tag = IN101) and a CALCU (SWITCH1) and connect MV of
MLD to IN of CALCU.
2. Create three digital outputs in the IOM configuration, with tags DO1, DO2, DO3.
3. Connect these to OUT, J01 and J02 on the CALCU.
4. Write a program in the edit detail of the CALCU to perform the above function.




IN101

MLD
SWITCH1

CALCU
DO1
DO2
DO3
MV IN
OUT
J01
J02
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TE 33AU1C3-01 Rev 3.4 21 July 2005 10-22
Solution:

Solution 1 Solution 1a

if (RV < P01) then if (RV < P01) then
CPV = 0 CPV = 0
CPV1 = 0 CPV1 = 0
CPV2 = 0 CPV2 = 0
end if else if (RV < P02) then
if (RV > P01) and (RV < P02) then CPV = 1
CPV = 1 CPV1 = 0
CPV1 = 0 CPV2 = 0
CPV2 = 0 else if (RV < P03) then
end if CPV = 0
if (RV > P02) and (RV < P03) then CPV1 = 1
CPV = 0 CPV2 = 0
CPV1 = 1 else
CPV2 = 0 CPV = 0
end if CPV1 = 0
if (RV > P03) then CPV2 = 1
CPV = 0 end if
CPV1 = 0
CPV2 = 1
end if


Solution 2

CPV = 0
CPV1 = 0
CPV2 = 0
If (RV > P01) and (RV < P02) CPV = 1
If (RV > P02) and (RV < P03) CPV1 = 1
If (RV > P03) CPV2 = 1


Solution 3

CPV = (RV > P01) and (RV < P02)
CPV1 = (RV > P02) and (RV < P03)
CPV2 = (RV > P03)

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PART C - SEQUENCE TABLE EXERCISES

C1. Global Switch Exercise

Objective: The purpose of this exercise is to provide an understanding of how
Global Switches work across a network.

Description: The sequence in FCS01 waits for Global Switch 1 in FCS02 to turn
on. When it is on, it turns the local Global Switch 1 off. When the sequence in
FCS02 sees that Global Switch 1 in FCS01 is off, it turns the local Global Switch 1
off. When the sequence in FCS01 see that Global Switch 1 in FCS02 is off, it turns
the local Global Switch 1 on. Thus the Global Switches toggle each other.

Procedure: Create 2 sequence tables, 1 in each of FCS01 and FCS02 as follows:


ST16 - FCS01, Tag= GLOBAL1 ST16 - FCS02, Tag=GLOBAL2

%GS00102.PV 1 Y N %GS00101.PV 1 Y N
%GS001.PV H N Y

%GS001.PV H Y N


Register each switch in the Switch Definition, giving each a tagname:

FCS01 - GSW0101
FCS02 - GSW0102


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C2. Mode Setting Exercise

Objective: The purpose of this exercise is to explore the uses of mode setting in a
controller from a sequence table.

Description: This exercise makes use of the cascade controller exercise (Tutorial
D2). If there is a problem with the input to the flow controller, then
force it into PRD so that the primary controller is controlling through
it. If the temperature controller (TIC100) goes into HI alarm, then
force it into manual and set the output to zero.

Procedure:

1. Create a common switch, tagname: IOPALRM
2. Open DR0001 where the cascade control loop is.
3. Add a sequence table (ST16), tagname: SEQ100
4. Enter the following logic into it:

C01
C02
C03
C04
C05
C06
IOPALRM.PV
TIC100.ALRM
ON
HI
Y N


Y

N

A01
A02
A03
A04
A05
A06
FIC100.MODE
FIC100.MODE
TIC100.PSW
TIC100.MODE
PRD
CAS
1
AUT
Y
Y



Y



Y


Note: Because we cannot simulate a BAD input, the tripping of FIC100 to
PRD is done by creating a switch call IOPALRM and turning this on
manually.

Operation:

5. Call up FIC100, TIC100 and IOPALRM.
6. Make sure that FIC100 is in CAS and TIC100 is in AUT.
7. Turn on IOPALRM. Note that FIC100 goes to PRD, and the output is set by
the output of TIC100.
8. Set the PH of TIC100 to 70, and set its setpoint to 80. Every time it goes into
HI alarm, it is forced to manual and the output is set to zero, causing it to go
back into AUT.



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C2. Pump Interlock Exercise

Objective: This is a practical exercise that uses a timer and counter to limit the
number of pump starts in a given period. The objective is to learn how to use timers
and counters.

Description: The sequence counts the number of starts made by a pump. If the
maximum number of starts are exceeded within a time period, the start command is
interlocked so that no more starts can be made and an alarm is sounded. When the
timer expires, the counter is reset.

Procedure:

1. Create 2 Common Switches to simulate the pump:

P1START Operator Request
P1CMD Start Command from Sequence

2. Create Annunciator Message

Tag = P1INT
Message = Pump1 Interlock

3. Create an Operator Guide

%OG0001
Message = The Pump interlock is cleared

4. On a new Control Drawing:

Comment = Pump1 Control
Create: Timer (TM) - P1TM
Counter (CTS) - P1CT
Sequence (ST16) - P1CTL

5. Sequence Table Logic:

C01
C02
C03
C04
C05
C06
P1START.PV
P1CMD.PV
P1CT.BSTS
P1TM.BSTS
P1TM.BSTS
P1INT.PV
1
1
CTUP
CTUP
RUN
ON
Y
N
N
N
Y



Y




N



Y


N


Y
A01
A02
A03
A04
A05
A06
P1CMD.PV
P1CT.ACT
P1CT.ACT
P1TM.OP
P1INT.PV
%OG0001.PV
H
ON
OFF
START
H
NON
Y
Y

N

Y
Y



Y




Y




N
Y

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Sequence Operation:

1. Create a Control Group with the following tags on it:

P1START
P1CMD
P1INT
P1TM
P1CT
P1CTL

2. Put the sequence table into AUT
3. Set the PH of P1TIM (the timer) to 60
4. Set the PH of P1CT (the counter) to 5
5. Turn on P1START. P1CMD will come on and the counter will increment.
6. Turn off P1START. P1CMD will turn off.
7. Repeat this 5 times. The alarm will sound (P1INT will go on).
8. When you try to turn it on again, P1CMD will stay off.
9. When the timer reaches 60, the counter will be reset and the Operator Guide
will come on to indicate that the interlock is cleared.




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C3. Relational Expression Exercise

Objective: This exercise shows how to compare analogue values in a sequence.

Description: A Manual Loader is used to generate an analog value. If the value goes
above 75.0 or below 25.0, then an alarm is generated using Annunciators:

If MLD > 75.0, Set Alarm 1
If MLD < 25.0, Set Alarm 2

The set points are stored in a BDSET and are set through the operator display.

Procedure:

1. Create the following function blocks in a control drawing:

MLD - VSET
RL - VCMP
ST16 - VSQ
BDSET-1L - VDATA

And register the following annunciators:

VALRM1 - comment = High Alarm
VALRM2 - comment = Low Alarm

2. In the RL Block, go to EDIT DETAIL, and enter the following:

VSET.MV CMP VDATA.DT01
VSET.MV CMP VDATA.DT02

3. Sequence Table logic:

C01
C02


VCMP.X01
VCMP.X02

GT
LT

Y


N


Y

N
A01
A02


VALRM1.PV
VALRM2.PV

H
H

Y


N
Y

N

4. When in operation, go to the tuning panel of VDATA and set:

DT01 = 75.0
DT02 = 25.0
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C4. Sequence Exercise Using Switch Instrument Block

Part 1

Objective: The purpose of this exercise is to learn how a switch instrument block
works, and how to control it from a sequence table.

Description: A pump with isolation valve is used to fill a tank using the following
logic:

If tank level is low:
Put valve and pump into Auto
Open Valve
When valve is open:
Start pump

If Level is high:
Put valve and pump into Auto
Stop Pump
When pump is stopped:
Close Valve

Procedure:

1. On a Control Drawing, create the following modules:

Tagname Description Module
BFP1 Pump Control Block MC-2
BFV1 Valve Control Block SIO-11
BLI1 Level Indicator PVI
BLI1-M Level Simulation MLD
LVLCTL Pump Sequence Control ST16

2. To set up the pushbutton labels on BFP1, select the block, and right-click, select
EDIT DETAIL. In the BASIC tab, set the Switch Position Label to
RUN,,STOP,RUN. In the INPUT tab, set the Answerback Check to BOTH
SIDES. This can also be done for the valve (BFV1).

3. Register four consecutive Common Switches to act as contact I/O for the Pump
Control Block, with the following tag names:

%SW1001 BFP1-RUN Run Feedback
%SW1002 BFP1-STP Stop Feedback
%SW1003 BFP1-START Start Command
%SW1004 BFP1-STOP Stop Command

4. Link the BFP1-RUN switch into the IN terminal of BFP1, and connect the OUT
terminal to BFP1-START. Note that BFP1-STP and BFP1-STOP are
automatically linked when the software is downloaded.


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5. Connect the MV of BLI1-M to the IN terminal of BLI1.

6. Configure the sequence table according to the sequence described above.

7. Setup: Put the tags into a control group. In the Operators panel, go to the
tuning panel for the Pump control faceplate (BFP1) and set the SIMM = 1. Do the
same for BFV1. Set the high and low alarm levels in BLI1 to 75% and 25%.

8. Put the sequence into AUT and raise the MLD value to above 75% and observe
what happens to the pump. Lower it to below 25% and observe the pump starting.



Part 2 - I/O Simulation

Objective: Provide simulation for the Pump I/O. This provides learning in how to
drive and monitor switches from a logic chart.

Description: If the BFP1-START switch is on, switch on BFP1-RUN. If BFP1-
STOP switch is on, switch on BFP1-STP. Use On Delay timers (OND) to simulate
lags in the process.

Procedure:

1. Create a new Logic Chart on the control drawing, with tag name: BFP1IO.
Put in the logic as described above.
2. In BFP1, set SIMM = 0.
3. Confirm its operations by running it in Manual.


Part 3 - Using the Motor Control Module (MC-2)

Objective: To learn how the MC-2/3 works and the differences between it and the
SIO module.

Description: Add an analog feedback for pump speed, and TRIP and INT contacts.

Procedure:

1. Create a Manual Loader (MLD) with tagname BFP1-SPEED, and wire it into the
FB terminal of the MC-2
2. Create two Common Switches with tagnames: BFP1-INT and BFP1-TRIP and
connect to terminals IL and TT of the MC-2
3. Add these extra modules to the control group for display.




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C5. Boiler Fill Sequence Exercise

Objective: To learn how to use the step feature of the sequence table.

Description: This is a boiler fill sequence which contains a monitoring step, and a
sequence of steps. The step sequence is as follows:

Step 1 - Conditions: Burner Off (*1)
Deaerator Level >= NWL (normal water level)
Deaerator Temp < 70 Deg C
Boiler Level <= NWL
Operator Start Request

- Actions: Open Feedwater Regulating Valve full open
Start BFP Lube Oil Pump
Goto Step 2

Step 2 - Conditions: If Lube Oil Pump running for 1 minute

- Actions: Start BFP
Goto Step 3

Step 3a - Conditions: If boiler level >= NWL

- Actions: Set Boiler Ready switch and operator guide
Start Burner (*1)
Set Feedwater Control to CAS

Step 3b- Conditions: If Deaerator Level Low

- Actions: Trip BFP
Stop Lube Pump
Goto Step 1


Step 00 (continuous monitoring step)

- If Boiler Level High - Trip BFP
- If DA Level Low - Trip BFP
- If Boiler Level Low and Burner is on - Stop Burner
- If Lube Oil Pump Stopped - Trip BFP

in all these cases, force the step to A1.


Use the boiler level control drawing and the boiler feed pump drawing for the existing
tags. Create a manual loader and PVI loop to simulate the Deaerator level and
temperature.

(*1) For burner, use a Common Switch which should be off at the beginning of the
sequence and is turned on in step 3.
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PART D - TUTORIALS

D1. System Configuration



In this tutorial, we will learn how to set up a project, and create & edit control stations
within the project. This will involved the following steps:

1. Create a new project
2. Define hardware devices
3. Define field I/O
4. Define PLC communications

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1. Create a New Project

To create a new project:

Click on SYSTEM VIEW within the System View window

Either: Click on FILE CREATE NEW PROJECT
Or: Click on SYSTEM VIEW with the right might button and select
CREATE NEW PROJECT




Click OK



















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A new window appears. Enter the information as follows:

Project: TRAINING (or any name, uppercase, 8 characters or less)
Position: C:\CS3000\ENG\BKPROJECT

Click on the Constant tab and enter the number of domains. In this case,
enter 1.



Click OK.





















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This creates a new project, and a dialog box appears to create a new FCS.



Enter the Station Type (AFG30D) and the Station number and click OK. A new FCS
is created.

The Create New HIS dialog box appears next:



Enter the above information and click OK. A new HIS is created.

The project creation procedure is now complete. Notice that an FCS and a HIS are
created automatically when the project is created.
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2. Define Hardware Devices

The properties of the existing hardware devices can be edited, and new hardware can
be created.

2.1 Creating and Editing the FCS

To edit the properties of an existing FCS, click on it with the right mouse
button and select PROPERTIES. The same dialog box appears as when a new
FCS is created, except that certain options are grayed out. Note which items
cannot be changed once the FCS is created.

The are two ways of creating a new FCS:

1. Select CREATE NEW FCS from the FILE menu.

This creates a new FCS for the project. Note that the station address is
incremented by 1.


2. Click on an existing FCS and drag it upto the project name. This
copies the FCS and all it's properties and contents to a new FCS.

Note that the properties of this FCS are the same as the FCS it was
copied from and cannot be changed.


2.2 Creating and Editing the HIS

To edit the properties of an existing HIS, click on it with the right mouse
button and select PROPERTIES. The same dialog box appears as when a new
HIS is created, except that certain options are grayed out. Note which items
cannot be changed once the HIS is created.

The are two ways of creating a new HIS:

1. Select CREATE NEW HIS from the FILE menu.

This creates a new HIS for the project. Note that the station address is
decreased by 1.


2. Click on an existing HIS and drag it upto the project name. This
copies the HIS and all it's properties and contents to a new HIS.

Note that the properties of this HIS are the same as the HIS it was
copied from and cannot be changed.



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2.3 Creating and Editing the BCV (Vnet Vnet)

There is only one way of creating a new BCV:

1 Select CREATE NEW BCV from the FILE menu.



This creates a new BCV for the project. Select the CONSTANT tab
and select a Domain number of 2 (or any number up to 16), and a
station number (1-64) for the lower address. The BCV is connected to
two networks (domains), and so the address must be set up for both
networks on which it resides.

Note that the station address is increased by 1 from the previous FCS
or BCV. A BCV cannot be copied.



To edit the properties of an existing BCV, click on it with the right mouse
button and select PROPERTIES. The same dialog box appears as when a new
BCV is created, except that certain options are grayed out. Note which items
cannot be changed once the BCV is created.




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2.4 Creating and Editing the BCV (Vnet RL Bus)

Before a Bus Converter for uXL can be created, the stations in the uXL domain must
be specified in the project so that a tag-list can be generated for the bus converter.

To create a uXL station in the project:

1. Select CREATE NEW STATION from the FILE menu.
2. Select the uXL station type (eg MFCD-EXT).
3. Set the domain (17 or above) and the station address.
4. Click OK. A folder is created with the name STNddss

where: dd = domain number for the uXL system
ss = station number for the MFCD on the RL bus.

5. Open the STN folder (click on the +) and click on the TAGLIST folder. Three
files will appear on the right hand side. These are:

TFDATA - List of function blocks, etc in the MFCD
OGDATA - Operator Guides in the MFCD
SMDATA - Sequence Message Requests in the MFCD


Double click on the TFDATA file to open the following page:



Enter a Tagname, Function Block Type, and Tag Comment as shown above.
Select File Save

note: If the TFDATA file does not contain any tag information then the Vnet
RL Bus Bus converter will not compile.
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The tag information can be manually entered or imported as a CSV file. To import a
CSV file, select: FILE EXTERNAL FILE CSV FILES IMPORT. The
following box appears:




Select those items to be imported, and the name of the CSV file. Note: at this stage
you will have nothing to import, so CLOSE this dialog.

Double click on files OGDATA and SMDATA and Save and Exit these. This is
necessary to create the files, even though there is nothing in them.

Once the Stations have been defined, the Bus Converter can be created.

To create a new RL Bus Converter:

1. Select FILE CREATE NEW BCV.
2. Select Bus Converter for RL Bus.
3. Set Domain and Station number for the Vnet side.
4. Click on the Constant tab and set the domain and station number for the RL
bus side. Domain will be 17 or greater.
5. Click on the Lower Station tab and there should be a list of all the uXL
STATIONS defined in that domain in the project. Check those ones that are to
be included in the Taglist (usually all of them).
6. Click OK (there is nothing to set in the Lower Gateway Definition tab).

The Bus Converter is now created. When it is downloaded, the taglists from the
associated uXL stations are included in the download.

Note that an offline load is required every time a new tag is added. This stops the Bus
Converter. If a tag is modified, rather than added, then an online load can be carried
out.


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3. Define I/O - FIO

I/O resides in each of the FCSs and is located in the IOM folder. Within the IOM
folder are up to 10 NODE folders, and within each of these reside the files for each
I/O card.

1. Expand an FCS folder by clicking on the + next to it.

2. Click on the IOM Folder. Currently there are no NODE folders in it.

3. Right Click on the IOM folder and select CREATE NEW NODE.




4. Select a local node, with an address of 1. It does not matter whether Dual-
Redundant Power Supply is selected or not.
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5. Click on the NODE folder with the right mouse button and select CREATE NEW
IOM. The following window appears:




6. Creating Analog I/O

- Select Analog Input/Output under Category
- Select AAI841-S under Type
- Select Slot =1
- Click OK

This creates an analog I/O module file in slot 1 on the node. The file name is
1AAI841-S (ie, Slot 1, Type AAI841-S). To configure I/O points within it:

- Double click on the file. The I/O definition window appears.
- The I/O is in fixed positions (Inputs are 1 8 and Outputs are 9 16).
- Click Save and then FILE EXIT

This can be edited later at any time by double clicking on this file.

7. Creating Digital Inputs

- Repeat step 5 to create another IOM
- Select Category = Status Input. Pushbutton input can also be selected.
- Select Type = 32-Channel Status Input (ADV157-S).
- Select Slot 2
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- Click OK
- Double click on the new file (2ADV157-S)
- Details for all 32 points point are available here
- The most important field is TAGNAME. If a tag name is configured here,
then the system recognises the digital input by that name.
- Select FILE EXIT


- Repeat step 5 to create another IOM
- Select Category = Status Output
- Select Type = 32-Channel Status Output(ADV557-S).
- Select Slot 3
- Click OK
- Double click on the new file (3ADV557-S)
- Details for all 32 points point are available here, including Tag name
setting.
- Select FILE EXIT


8. Creating a Remote Node

A remote node cannot be created until an ER Bus Interface module (EB401) is
configured in a local node. Once this is created, up to 9 remote nodes can be
connected to this one module. Note that this maximum of 9 is limited by the
overall maximum of 10 nodes for the FCS.

Create a Bus Interface module in the Local Node:

- Right click on a local node (in this example, Node1)
- Select Create New IOM.
- Category = Remote Node Communication
- Type = EB401 (ER Bus Interface Module)
- Slot = 5
- Click on Duplicate Next Card as it is normal (but not mandatory) to have
dual redundant communications to the remote nodes.
- Click OK, and the two cards (EB401 and EB401Dup) will appear.

Create a Remote Node connected to this Bus Interface card:

- Right click on IOM and select Create New Node
- Select Remote Node and choose the EB401 module you have created from
the drop down list. Unless you have created more in other nodes, this
module will be the only one on the list.
- It is recommended that the IP address is left on default and not changed.
- Click OK.

This new node is a remote node connected to the EB401 module created above.

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4. Define PLC Communications

PLC Communications are defined in the same way as process I/O is defined.

- Right click on NODE 1 and select CREATE NEW IOM
- Select Category = Serial Communication
- Select Type = RS232C Serial Communication Interface (ALR111)
- Select Slot = 4
- Click on the CARD COMMON tab
- Select Connection Device = MODBUS
- Click on the Port 1 tab
- These are the communications settings for the first port. These can be left on
default, or set as needed.
- Repeat for Port 2
- Click OK

A new file called 4ALR111 is created, where the number at the beginning is the slot
number.

To define the I/O points to be transferred between the card and the PLC, double click
on the file. For this exercise, we are going to set up a Modbus communications link to
a PLC, reading and writing the following I/O:

10 Analogue Inputs
64 Digital Inputs
5 Analogue Outputs
32 Digital Outputs

The entry fields are configured as follows:

- Buffer Size - Enter a value (say 100) to define the overall size of the data to be
transferred with this ALR111 card.

Note that this is in number of Words (= 16 bits).
- The number of analogs to a word varies on the size of the analog.
A 32 bit analog is 2 words in size.
- There are 16 digitals to one Word.
For Modbus, there is a maximum of 500 words for one communications
card.

- Program Name - select the device driver selected when defining the module
properties (K1-1-4MODBUS i.e., the Modbus communications card in slot 4
of Node1).

This actually specifies the card being used in this part of the I/O
definition. The same definition table is used for the whole FCS.

- Data Size - Specify the data size in words for this block of data. Enter 10
words for the analogue inputs.

- Port Number an ALR card has two ports on it. Specify which port you are
communicating through. In this case, set Port = 1.
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- Station Number and IP address for an ALR card, only the station number is
relevant, and this is usually a number between 1 and 128 that is an address set
within the PLC. The IP address is used if this is an ALE card. For now, set
the Station Number = 1 and leave the IP Address blank.

- Device & Address depend on the PLC in use. In this case it is Modbus (see
section 5.7.4), so for analogue inputs, enter A30001. That is, we are reading
10 analogue inputs starting from input 1 in the PLC.

- Data Type Select Input (16 bit signed). This tells the FCS that this block of
data is an input to the DCS, i.e., it is being read by the ALR111. It is also
telling the FCS to convert the word to a 16 bit analogue value. Input
processing in PVIs and PIDs can convert this to a real number. If the
analogues being read are 32 bit, then 1 analogue value would use 2 words.

Repeat this procedure for the other inputs and outputs as follows:

Size Port Address Device & Address Data Type
10 1 1 A30001 Input (16 bit signed)
4 1 1 A10001 Input (Discrete)
5 1 1 A40001 Output (16 bit signed)
2 1 1 A00001 Output (Discrete)





Select File Save


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Points to note:

1. For the Discrete I/O, the Data Size (being in 16 bit words) is the number of
digitals divided by 16. So, in the above example, 4 words of Digital Inputs
represented 64 DI, and 2 words of Digital Outputs are 32 DOs.

2. The system uses an even number of packets for Data Size, so when 5
analogue outputs are selected, 6 are configured.




Configuring Tagnames for Digital I/O:

It is possible to give the digital I/O tagnames so that they can be referenced in the
system by recognisable names, rather than system numbers (E.g. %WB000107).
Up to 1000 tagnames can be assigned. Any that are not assigned a tagname can
still be addressed by its system name.

To understand how this works, it is necessary to understand how digitals are
extracted from words. In the above example, words 11 14 contains 4 words of
Digital Inputs, i.e., %WW0011 to %WW0014. Within %WW0011 are 16 bits
and these are addressed as follows:

%WB001101 to %WB001116

In other words, bits 01 to 16 from Word 11.

In the communication I/O builder, click on

TOOLS Call %WB Tag Number Definition.

There are two fields that need to be configured:

Element enter the system number of the bit being assigned a number, e.g.

%WB001107

Tagname enter the required tagname for this system number.

All the other parameters are optional and are the same as configuring Digital I/O
and common switches.

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D2. Creation of Regulatory Control Function

In this tutorial we will learn how to create a control application using a cascade loop
as an example.

This exercise assumes that the previous tutorial has been completed, and the following
I/O card has been configured:

Node1, Slot1 Create an analogue input/output module, e.g. AAI841-S


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1. Starting the Control Drawing Builder

Start System View and open the required FCS.
Left Click on FUNCTION_BLOCK
Double Click on DR0001 in the right-hand pane.




The Control Drawing Builder appears:



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2. Drawing the Function Blocks

We are going to place two PIC function blocks on the control drawing: TIC100
and FIC100, and three PIO Link blocks to connect the Process I/O to the inputs
and outputs of these blocks.

To call up the Function Block selection menu either:
Insert Function Block
or click on the function block button



The Select Function Block menu appears as shown below.
Open Regulatory Control Block by clicking on the + sign.
Open the Controller menu and select PID.
Click OK.



OR
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Click somewhere on the Control Drawing to place the PID block.
Type in the Tagname (TIC100)
Click on the Control Drawing again to place another PID block.
Type in the Tagname (FIC100)


TIP: The cursor will have a Function Block icon on it as follows:



This means that when you click on the Control Drawing, a Function Block will
appear. When you no longer wish to place a function block on the control drawing,
click on the cursor button:



The Control Drawing will now have two PID controllers on it as follows:







TIP: Function Block Execution order the order in which the function blocks are
executed is the order in which the blocks are placed on the control drawing. This
order is displayed in the Tag Name column on the left hand side of the drawing.

The order can be changed by clicking on the number next to the tag and dragging it
up or down to the place you want it to execute.
Note the dashed line. This means that the
destination block (FIC100) is executed
before the source block (TIC100). In the
case of analog functions, this does not
really matter, but the order can be changed
by moving the tag in the tag column.
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3. Create the Process I/O Link Blocks

Click on the Function Block menu
button.
Select Link Block PIO
Click on the Control Drawing so that
the Link block appears.
Type in the I/O element number as
shown below.
Repeat to create three blocks.

The element names are as follows:

%Z011101 (analogue input)
%Z011102 (analogue input)
%Z011109 (analogue output)








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4. Wiring the Blocks

To wire the blocks together, select the Wiring function from the Insert
menu, or click on the Wiring button:


To wire the first analogue input (%Z011101) to TIC100:

Click on a handle on the link block (%Z011101). You can click on any
handle, but a top one would be the most convenient. The handle will
turn to a green colour.

Double-click on a handle on the TIC100 block. Again, you can select
any handle, but one on the left hand side would be most convenient. If
the cursor is not directly on the handle, the connection will not be
made. It may be necessary to start again. In this case, click on the
cursor button and then on the wiring button again.



OR
TIP: By clicking on the source and double-clicking on the destination, the builder
automatically determines the path of the wiring. This is fine for simple drawings
such as this. But there are cases when you may want to control the path of the
wiring. In this case, you can click on the control drawing wherever you want to
change the direction of the wiring, and then double clicking on the final
destination. You can also split off from a wire by clicking on it so that a dot
appears and then going from there.
1
2
1
2
1
2
1
2
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5. Assigning Terminals

When wiring the blocks together, the builder assigns default terminals to the
connections, usually IN and OUT. This may need to be changed. In this case, the
connection from TIC100 to FIC100 should be OUT SET (rather than IN).

To change a terminal assignment:

Click on the cursor key.
Click on the terminal to be changed.
either:
click again and manually type in the terminal name
or
right-click on the terminal name and select
Terminal Name IO1 SET






TIP: One of the great difficulties of connecting blocks is knowing when to use
terminals and when to use data items. In addition, the difference between a
terminal and an item is not always clear. In the context menu, IO1 gives a list of
terminals for the block, and DATA1 gives a list of the most used data items for
the block.

Except for CASCADE connections (as in this exercise), you should always connect
terminals to data items or visa versa. You never connect data items to data items,
and rarely do you connect terminals to terminals.
2. right click
1. click
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6. Editing the Properties of the Function Blocks

Call up the Properties of the function blocks either by double-clicking on
them, or selecting Properties from the context menu, as described below:

To double-click on the Function Block, make sure that you double click
on a handle (the X on the border of the block) or the border of the block
itself.

To select the Properties from the context menu, click on a handle on the
function block so that it goes green (that means it is selected). Then right-
click on the function block and select Properties from the context menu.

For each of the function blocks, set the properties as follows:






TIP: To change the tag name of a function block, click on a handle on the block to
select it, then click once on the tag name. You will then be able to edit the tag
name as required.
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7. Editing Function Block Details

There are certain function block settings that are not set through the properties
of the block. These are known as Detail Items.

To access the detail items of a function block:

select the required function block (in this case, TIC100).
either:
click on the WINDOW menu and select Edit Function Block Detail
or
right click on the function block and select Edit Detail

Function Block Configuration for TIC100

In the BASIC tab, scroll down to Measurement Tracking
Set MAN mode = YES for measurement tracking

There are no more items to be set
To save the configuration changes, select FILE UPDATE

There are other items that can be set (but will not be for this exercise).

To access them. select VIEW Detailed Setting Items, or click on the
Detailed Setting Items button:




When finished, select FILE Exit Function Block Detail
Builder.

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8. Compiling and Saving the Control Drawing

The drawing is now ready for compiling and saving.

In the Control Drawing builder, select FILE SAVE

In the message window, the progress of the compile will be displayed. If
there are no errors, the message display will show ERROR = 0. It will
then create a Status Display file for operator viewing.




If there are errors, they will be reported in the message area. The error
message includes the tag name where the error occurs and what the error is.


TIP: Note that if there are errors the control drawing is not saved. If you need to
exit the control drawing before you have fixed all of the errors, save it as a
Working File (FILE Create Working File). When you exit, say NO when it
asks if you want to save.

If you have several control drawings saved as Working Files, you may not be able
to compile if they use tags from each other, because these tag references are not set
until the drawing is compiled and saved. To solve this situation, close the control
drawing builder, and in System Builder, select FCS All Generation. This will
resolve all these links and compile the drawings (provided there are no errors on
them).
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9. Setting up Operator Displays in the HIS

9.1 Control Group Creation

We will now set up a control group to display the controllers on the operator
screen.

Open the HIS folder and right-click on the WINDOW folder.
Select Create New Window



For Window Type select Control (8-loop)
Window Name = CASCADE
Window Comment = Cascade Control Exercise (this is optional)



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Double-click on the CASCADE file in the right-hand window and the
graphic editor appears:




Click on the first faceplate to select it.
Right-click and select Properties. The
following dialog appears
Click in the Tag Name field and type in
TIC100.

Click Apply (so that the dialog box stays
open) and click on the second faceplate.
Type FIC100 into the Tag Name field.
Click OK to close the dialog box.

Save and exit the graphic builder (through
the FILE menu).




TIP: The faceplates that you can see in the graphic editor are not necessarily what you
will see on the operator display. When the control group is called up on the HIS, only
those faceplates that have a tag name assigned to them will be displayed. And how they
look will depend on the nature of the tag. If the faceplate that you typed a tag name into
does not appear, it is because you have typed in the tag name incorrectly.
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9.2 Trend Configuration

To set up the trend display, we must first set up the trend collection specification.
Then the display group can be configured.

In the HIS folder, click on the CONFIGURATION folder.
Right-click on TR0001 (trend block 1) and select properties.










Set the following for the trend block:

Trend Format = Continuous and Rotary Type
Sampling Period = 1 Second

Click OK.

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Double-click on TR0001 and the trend group configuration page will
appear:



Type in the following tags:

TIC100.SV
TIC100.PV
TIC100.MV
FIC100.MV

Select File Save
Select File Exit




TIP: Usually, you do not set the High and Low Limit for the tag. This will be
automatically picked up from the function block. Use this only if you want to
display a trend of a tag with a span that is different to the span of the function
block.
TIP: You can also put tags into the other groups. There are 16 of them and they
are accessed by clicking on the Group tabs. To call these up as windows in the
HIS operator displays, their names are TGxxyy (e.g. TG0102), where xx is the
block number and yy is the group number.
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10. Test Function

Test Function is a package that simulates the FCS and HIS functions within a PC.
It runs an image of the FCS within the PC. It also runs the HIS function and
creates a virtual Vnet so that the two can communicate to each other. In addition,
it soft wires the inputs and outputs of the FCS so that process simulation is
possible. This soft wiring can be modified to suit the application.

To run test function:
Click on the FCS you want to run.
Click on the FCS menu and select Test Function.



A generation message appears which can be closed when finished.
A dialog box then appears where the HIS is selected. Make sure that you
select the HIS that you created the graphic in. If you select the wrong HIS
you will not be able to access you control groups and graphics.




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The Test Function Panel appears:




The HIS function starts up and the FCS simulation function runs.
The start up is complete when the words Completed Downloading
Wiring appears.


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11. Operator Functions

This HIS Toolbar appears at the top of the screen and all windows have a
red border to indicate that you are in Test Function.
Click on the NAME button and type in CASCADE. Press Enter, or click
OK.





The control group window appears.
Put FIC100 into cascade (CAS) and TIC100 into auto (AUT).
Move the setpoint of TIC100 to approximately 50%.



To change setpoint of TIC100:
1. Click on the red SV arrow
2. Click and hold on the Up
arrow in the SV dialog.
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The trend is called up in the same way by clicking on NAME and typing in
TG0101:



The tuning panel of a faceplate contains all the tuning parameters of the function
block, as well as a short term trend.

To select FIC100, click on the tag name so that a green arrow appears (a
single faceplate may also pop-up on the screen).
Click on the menu button and select TUNING, or right click on the
tagname and select TUNING from the context menu.



The data items in the tuning panel can be
changed by clicking on them and entering a
new value. Some of the main ones are:

HH high-high process alarm
PH high process alarm
PL low process alarm
LL low-low process alarm

P Proportional Band (%)
I Integral time (seconds)
D Derivative time (seconds)

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12. Modifying Test Function Wiring

The wiring of test function can be modified by calling up the wiring editing
window in the test function panel.

In the Test Function Panel, select TOOLS Wiring Editor
Click on FILE OPEN and select DR0001.wrs
The following appears:



Scroll to the right and for each of the two lines set:

Delay = 3
Lag = 7

This provides a delay and lag into the system.

Save the changes (File Save)
Download be selecting FILE DOWNLOAD
A dialog appears with a list of drawings. Make sure that the drawing you
want loaded is ticked, then click OK.



TIP: The test function wires IN and OUT terminals together that already have PIO
link blocks attached to them (i.e., they are connected to process I/O). The wiring
happens when the Test Function is started up. If Test Function is already running
when the control drawing is loaded, you will have to create the wiring yourself. This
is made easier using the Auto-wiring tool in the TOOLS menu.
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D3. Creation of Sequential Control Function

In this tutorial we will learn how to create a sequence application using the Sequence
Table.

Reference: Engineering Manual (33S4H10-01E), Section 3.3



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1. Sequence Table Creation

In this exercise, master the creation procedures of a sequence table by creating a
simple sequence table.

Exercise:

When the start switch SS445-11 turns ON, the timer TM222-11 starts and
the start switch SW445-11 turns OFF.
After 3 seconds, the timer TM222-11 times up and the switch SW446-11
turns ON.
After another 3 seconds, the switch SW446-11 turns OFF and the switch
SW447-11 turns ON.
After another 3 seconds, the switch SW447-11 turns OFF




Operation of Sequence Exercise



Start Switch
SW445-11


Switch
SW446-11
3s 3s

Switch
SW447-11

3s
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PROCEDURE:

Common Switch Definition

1. Select the SWITCH folder in the FCS0101 folder in System View. Double-click the
SwitchDef file. The Common Switch Definition Builder appears as shown below.



















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2. Scroll the display until %SW0445 appears.

Enter Tag names for %SW0445, 0446 and 0447 as shown below:

Element Number Tag Name
%SW0445 SW445-11
%SW0446 SW446-11
%SW0447 SW447-11

3. Enter common data in other items as shown below:

Tag Comment : Enter arbitrarily
Switch Position Label : ON,,OFF,ON
Display Format : Direct Format
Label Colour 1 : Red
Label Colour 2 : Green






4. Select File Save to save the SwitchDef file.

5. File Exit Common Switch Definition Builder to exit the switch builder.







Three switches SW445-11, SW446-11 and SW447-11 have now been created in
FCS0101.
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Starting the Control Drawing Builder

1. Expand the required FCS from System View.
2. Left Click on FUNCTION_BLOCK folder.
3. Double Click on DR0031 in the right-hand pane.




The Control Drawing Builder appears:







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4. We are now going to place a sequence table function block (ST-16), and a
timer function block TM onto the control drawing.

To call up the Function Block selection menu either:
Insert Function Block
Or click on the function block button

The Select Function Block menu appears as shown below
Open Sequence by clicking on the + sign
Select Sequence Tables
Click OK



Click somewhere on the Control Drawing to place the ST16 block
Type in the Tagname ST222-11


TIP: The cursor will have a Function Block icon on it as follows:



This means that when you click on the Control Drawing, a Function Block will
appear. When you no longer wish to place a function block on the control drawing,
click on the cursor button:
OR
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Follow the same process as above and place a TM block (TM222-11) onto
the Control Drawing.


Hint: The Timer block is found in the Sequence Elements 1 Sub-Folder.


You should now have two blocks contained on your control drawing as shown below:





Defining the Timer

1. Click on the TM222-11 Timer block in the control drawing window.
Select Window Edit Function Block Detail.
2. In this exercise, leave all data in default. Select File Exit Function
Block Detail Definition Builder.













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Defining the Sequence Table

1. Click on the ST222-11 Sequence Table block in the control drawing window.
Select Window Edit Function Block Detail. The Edit Sequence Table
window can also be opened by left clicking and then right clicking on the
ST222-11 block. Then select Edit Detail.
2. The Edit sequence table window as shown below is now activated.



3. Select Edit Change Processing Timing.
4. The Set Start Timing dialog appears as shown below.



5. In this exercise, leave all items in default and click OK.



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6. Click on the field of C01 in the [Tag Name.Data Item] column in the
condition signal setting area and enter the data as follows:

(C01) SW445-11.PV
(C02) TM222-11.BSTS


7. Click on the field of A01 in the [Tag Name.Data Item] column in the action
signal setting area and enter the data as follows:

(A01) TM222-11.OP
(A02) SW446-11.PV
(A03) SW447-11.PV
(A05) SW445-11.PV






















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8. Click on field C01 in the [Data] column in the condition signal setting area
and enter the data as follows:

(C01) ON
(C02) CTUP

9. Click on the field of A01 in the [Data] column in the action signal setting
area and enter the data as follows:

(A01) START
(A02) H
(A03) H
(A04) H

10. Click on the field of C01 in the [Comment] column in the condition signal
setting area and enter the data as follows:

(C01) Start Switch
(C02) Timer

11. Click on the field of A01 in the [Comment] column in the action signal
setting area and enter the data as follows:

(A01) Timer
(A02) Switch 1
(A03) Switch 2
(A04) Start Switch





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10. Rule columns are defined with the combination of Y (Yes) and N (No). Move
the mouse cursor to the position to define and then click the mouse button to
specify the position.

On the specified position:

One click of the mouse button : Y
Two clicks of the mouse button : N
Three clicks of the mouse button : Deletion of Y or N

Note: Ys and Ns and also be added by entering the letter at the specified position.

11. Complete the sequence table rule columns referring to the figure below:



12. Move the cursor to the step label setting area of the Rule 01 and click the left
mouse button. Enter A1, then A2, A3 and A4 in order as shown below:




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13. Move the cursor to the next step label setting area of the rule 01 and click the
left mouse button. Enter A2, then A3, A4 and A1 in order as shown below:



14. Select File Update to save the sequence table.

15. Then select File Exit Function Block Detail Definition Builder

16. Select File Save and then File Exit to exit from the control drawing.

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Defining the Control Group

We will now set up a control group to display the faceplates on the operator
screen.

Open the HIS folder and right-click on the WINDOW folder.
Select Create New Window



For Window Type select Control (8-loop)
Window Name = SEQTABLE
Window Comment = Cascade Control Exercise (this is optional)



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Double-click on the SEQTABLE file in the right-hand window and the
graphic editor appears:




Click on the first faceplate to select it.
Right-click and select Properties. The
following dialog appears
Click in the Tag Name field and type in
SW445-11.

Click Apply (so that the dialog box stays
open) and click on the second faceplate.
Type TM222-11 into the Tag Name field.
Follow the above step and enter the
following Tagnames in the next three
faceplates: SW446-11, SW447-11, ST222-11
Click OK to close the dialog box.
Save and exit the graphic builder (through
the FILE menu).




TIP: The faceplates that you can see in the graphic editor are not necessarily what you
will see on the operator display. When the control group is called up on the HIS, only
those faceplates that have a tag name assigned to them will be displayed. And how they
look will depend on the nature of the tag. If the faceplate that you typed a tag name into
does not appear, it is because you have typed in the tag name incorrectly.
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Test Function

If Test function is still running from the last tutorial skip this section
and turn to page 10-79.

If test function is not running on your machine follow the steps below:


To run test function:
Click on the FCS you want to run.
Click on the FCS menu and select Test Function.



A generation message appears which can be closed when finished.
A dialog box then appears where the HIS is selected. Make sure that you
select the HIS that you created the graphic in. If you select the wrong HIS
you will not be able to access you control groups and graphics.




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The Test Function Panel appears:




The HIS function starts up and the FCS simulation function runs.
The start up is complete when the words Completed Downloading
Wiring appears.

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Operator Functions

This HIS Toolbar appears at the top of the screen and all windows have a
red border to indicate that you are in Test Function.
Click on the NAME button and type in SEQTABLE. Press Enter, or click
OK.







The control group window appears.














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Set the Mode of the sequence table ST222-11 to AUT, and confirm that
PV is A1. If not set to A1.



Enter 3 into the PH value of the Timer TM222-11.



Setting the switch SW445-11 to ON activates the sequence table.







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Confirm that the switches SW446-11 and SW447-11 change.

The rule condition display column is provided between the condition
rule column and the action rule column in the sequence table window.

Confirm that when the rule is satisfied, the colour of the satisfied rule
in the rule condition column changes from;
Green (not satisfied) to Red (satisfied)




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Extra Exercise:
For those of you who like a challenge


Building from the above example, try and get the operation of your sequence exercise
to follow the diagram below:



Operation of Sequence Exercise Extra Exercise



Start Switch
SW445-11


Switch
SW446-11
3s 3s

Switch
SW447-11
7s


























Hint: You might want to think about another timer block
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Confirming Operation with Operation and Monitoring Function

D4. Creation of Logic Chart Function

In this tutorial we will learn how to create a logic control application using a Logic
Chart.

Reference: Engineering Manual (33S4H10-01E), Section 4.3


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1. Logic Chart Creation

In this exercise, master the creation procedures of a logic chart by creating a simple
logic chart.

Exercise:

When the switch SW545-11 turns ON OR the switch SW546-11 turns ON,
a 20s timer starts.
After the timer times out the switch SW547-11 turns ON.
5 Seconds after SW547-11 turns on switch SW548-11 is pulsed ON for 2
seconds.




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PROCEDURE:

Common Switch Definition

1. Select the SWITCH folder in the FCS0101 folder in System View. Double-click the
SwitchDef file. The Common Switch Definition Builder appears as shown below.



















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2. Scroll the display until %SW0545 appears.

Enter Tag names for %SW0545, 0546, 0547 and 0548 as shown below:

Element Number Tag Name
%SW0445 SW445-11
%SW0446 SW446-11
%SW0447 SW447-11
%SW0448 SW448-11

6. Enter common data in other items as shown below:

Tag Comment : Enter arbitrarily
Switch Position Label : ON,,OFF,ON
Display Format : Direct Format
Label Colour 1 : Red
Label Colour 2 : Green






7. Select File Save to save the SwitchDef file.

8. File Exit Common Switch Definition Builder to exit the switch builder.







Three switches SW545-11, SW546-11, SW547-11 and SW548-11 have now been
created in FCS0101.
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Starting the Control Drawing Builder

3. Expand the required FCS from System View.
4. Left Click on FUNCTION_BLOCK folder.
5. Double Click on DR0031 in the right-hand pane.
Note: If you have already completed the sequence table exercise you will have
an ST16 and TM block existing in DR0031. You can either use DR0031 for this
exercise also or choose another blank drawing.




The Control Drawing Builder appears:




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5. We are now going to place a logic chart function block (LC64) onto the
control drawing.

To call up the Function Block selection menu either:
Insert Function Block
Or click on the function block button

The Select Function Block menu appears as shown below
Open Sequence by clicking on the + sign
Select Logic Chart
Click OK



Click somewhere on the Control Drawing to place the LC64 block
Type in the Tagname LC222-11


TIP: The cursor will have a Function Block icon on it as follows:



This means that when you click on the Control Drawing, a Function Block will
appear. When you no longer wish to place a function block on the control drawing,
click on the cursor button:
OR
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You should now have you logic chart function block contained on the control drawing
as shown below:


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Defining the Logic Chart

6. Click on the LC222-11 Logic Chart block in the control drawing window.
Select Window Edit Function Block Detail. The Edit Logic Chart window
can also be opened by left clicking and then right clicking on the LC222-11
block. Then select Edit Detail.
7. The Edit logic chart window as shown below is now activated. The edit logic
chart window is used to draw logic of logic chart blocks.





8. The grid pattern can be set for ease of drawing. Select the [GRID] tool button
on the toolbar. A grid pattern is now displayed.



The area where logic is configured in a logic chart is called a client area. A client
area is a matrix with 26 rows (A-Z) and 32 columns (1-32). The co-ordinates of
the matrix range from (A, 1) to (Z, 32).




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Input Element Setting Procedure

9. Select the [Element] tool button on the toolbar.



10. The Select Element dialog box is displayed. Select [Input1] below [Input
Element].





11. Click OK, the shape of the mouse pointer changes to indicate that the input
element is ready to be placed onto the logic chart matrix.














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12. Click the co-ordinates (B, 2) in the logic chart matrix. An input element
symbol waiting for condition signal entry is displayed.



13. Enter SW545-11.PV.ON as a condition signal.

14. Click the co-ordinates (B, 4) and enter SW546-11.PV.ON, finally click the co-
ordinates (B, 7) and enter SW547-11.PV.ON.

The following window represents the operation up until now:











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Logic Operation Setting Procedure

15. Select the [Element] tool on the toolbar.

16. The Select Element dialog box is displayed. Select the [OR] from the [Logic
Operation Element].


17. Click OK, the shape of the mouse pointer changes to indicate that the logic
element is ready to be placed onto the logic chart matrix.

18. Click the co-ordinates (F, 3) in the logic chart matrix. An OR gate element
symbol is displayed.

19. Select the [OND] from the [Logic Operation Element], and place the OnDelay
Timer at the co-ordinates (I, 3). Place another OnDelay Timer at the co-
ordinates (F, 7).

20. Select the [TON] from the [Logic Operation Element] and place the TON at
the co-ordinates (I, 7).

21. Select the [OFFD] from the [Logic Operation Element] and place the
OffDelay Timer at the co-ordinates (L, 7).











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The following window represents the operation up until now:




Output Element Setting Procedure

22. Select the [Element] button on the toolbar.

23. The Select Element dialog box is displayed. Select the [Output1] from the
[Output Element].



24. Click OK, the shape of the mouse pointer changes to indicate that the output
element is ready to be placed onto the logic chart matrix.
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25. Click on the co-ordinates (P, 3) to display an output element symbol.

26. Enter SW547-11.PV.L

27. Click on the co-ordinates (P, 7) to display another output element symbol and
enter SW548-11.PV.L.


The following window represents the operation up until now:


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Drawing Wiring

28. Select the [Wiring] tool button on the toolbar. The shape of the mouse pointer
changes.



29. Click the co-ordinates (C, 2) and double click the co-ordinates (F, 3) to draw
wiring from the input element symbol [SW545-11.PV.ON] to the logic
operation element symbol [OR].

The following window represents the operation up until now:




















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30. Complete the wiring as shown in the window below using the same method as
described in step 29.


31. Select File Update to save the logic chart.

32. Then select File Exit Function Block Detail Definition Builder

33. Select File Save and then File Exit, to exit from the control drawing.
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Testing the Logic

After saving and exiting the control drawing it is now time to go to the online HIS and
test the logic for functionality.

34. The HIS Toolbar appears at the top of the screen and all windows have a red
border to indicate that you are in Test Function.

35. Click on the NAME button and type in LC222-11 DRAW. Press Enter, or
click OK. This will take you to the online control drawing that contains your
newly configured logic chart.




36. Left click on the logic chart function block and the online version of your
logic chart is now displayed.

37. By Default the logic chart will be in MAN after being created and
downloaded. The logic chart must be put into AUT before it will start
executing any logic. Click the tagname LC222-11 in the top left hand corner to
call up the faceplate and place the logic chart to AUT as shown below.



38. Timer parameters must now be entered into the timers on the logic chart. To
do this left click the timer and enter a value as shown below.



39. The logic can now be tested. Turn switch SW545-11 to ON and watch the
result in the logic chart

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D5. Creation of SFC Control Function

In this tutorial we will learn how to create a sequence application using a Sequence
Function Chart.

Reference: Engineering Manual (33S4H10-01E), Section 5.3



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D6. Creating Graphic Windows

In this tutorial we will learn how to create a graphic using the standard graphics
functions.

Reference: Engineering Manual (33S4H10-01E), Section 6.3