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PlantPAX Process Application Development Lab1 PDF
PlantPAX Process Application Development Lab1 PDF
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PlantPAx™ is the process automation system from Rockwell Automation with all the core capabilities expected in
a world-class modern distributed control system (MDCS). The system is built on a standard-based architecture
using Integrated Architecture components that enable multi-disciplined control and Premier Integration with the
Rockwell Automation Intelligent Motor Control portfolio.
A traditional distributed control system (DCS) is built for only one purpose — process control.
But in today’s competitive economy, you need to consider forward-thinking possibilities and utilize technology and
innovation to your advantage. It’s time to rethink what to expect from a DCS. In order to drive productivity,
increase efficiencies and reduce costs you need to integrate all of your automation operations to achieve The
Connected Enterprise. And the only way to do that is through the technology offered by a modern DCS — the
PlantPAx system.
The PlantPAx modern distributed control system offers process control and more:
The RA Library of Process Objects is a predefined library of Application Code, Graphic Objects and
Faceplates that let you quickly assemble large applications with proven strategies, rich functionality, and known
performance. The Application code contains the code which controls the associated device. This code is
embedded in an Add-On Instruction (AOI) which can be instantiated multiple times in a given application. The
Graphic Objects are used to build HMI Displays. There is a selection of Global Objects available for each Process
Library Element. These Global Objects can be imported into displays and provide visual feedback to the user.
Clicking on these devices will launch the associated Faceplate.
Global Objects
For rapid development of information-rich operator displays, the Rockwell Automation Library of Process Objects
provides a collection of display objects that are linked to the Add-On Instructions with a drag and drop wizard.
This allows rapid development of main plant display graphics.
Faceplates
All global objects have an associated faceplate which appears when the global object is clicked. These faceplates
require no additional configuration. When an object has additional support functions linked, such as Run Time
Monitor, Interlock Block, or others, the faceplate for these extended functions will also be accessible from the
faceplate.
Application templates are included in the RA Library of Process Objects for both controller applications (Logix
Controller Templates) and HMI applications (HMI Project Templates) to provide a consistent starting point for
system implementation. As part of the future PlantPAx v4.0 System Release, control strategies will also be
provided with the library as sample code (Control Strategies from the RA Library of Process Objects).
The current release of the library v3.1 supports Studio5000 software version v24 (and later). Templates are also
provided in software v18 so they can be used in any later supported version of RSLogix 5000.
The Studio 5000® environment combines design and engineering elements into one standard framework. It
optimizes productivity, shortens design cycles and reduces time to market. Studio 5000 helps you respond quickly
to changes in market and business needs and reduce total costs of ownership. New design capabilities can
increase automation productivity and reduce costs during a project’s lifecycle. The environment is the one place
for engineers to develop all elements of their control system for operation and maintenance. Studio 5000 extends
beyond one controller to be a system-wide development and design tool.
The Logix Designer 5000® application, within the Studio 5000® environment, is a scalable application solution,
used to program and configure/code any of the Logix5000 family of controller products. It provides ladder logic,
structured text, function block diagram and sequential function chart editors for program development as well as
support for the S88 equipment phase state model for batch and machine control applications.
Logix Application Templates are available with different levels of pre-loaded library content; No library, Basic
library, and All library. In this lab we will begin with the Basic library controller template. Note that for lab
purposes we have pre-modified the controller properties to run on Emulator 5000 and added code for process
simulation and I/O simulation.
Click the Studio 5000 V24 icon on the desktop to open Studio 5000.
To open the existing lab controller template project, Click on Open Existing Project.
Using the Controller Organizer window, note that the Basic Library template includes pre-configured
MainPrograms within each Task to be used as organizational “containers” to speed up engineering time.
Whereas the traditional Controller Organizer is used to view and configure the controller from an execution
time and utilization perspective (Tasks), the new Logical Organizer provides a way to view and create an
organizational model of the system (Programs and Routines). This allows operators and maintenance to
troubleshoot the system more quickly while new features such as Selecting Multiple project components like
AOI's, UDT's, Programs, and then copy/paste, drag/drop, export/ import them as one to reduce engineering
time.
For this lab we will work in the new Logical Organizer window. Click the Logical Organizer.
We will now rename the main program in Task D, from Task_D_MainProgram to Tank1, by double-clicking
on Task_D_MainProgram to open the Program Properties window. Change the Name of the program to
Tank1 and click OK.
Control Strategies from the RA Library of Process Objects support the concept of Re-use engineering to
save time. Starting from pre-configured and tested control strategies that are imported as Routines into a
controller application we save engineering time. By organizing a controller into Programs (for example each
Tank is a Program) and Routines (levels, pumps, valves) we simplify the location of a desired piece of code,
and can Re-use code in line with best practices and standards management.
Later in the lab, because we organized the controller by Tasks, Programs and Routines, we can easily copy
the code for a complete tank (a Program), including all components like AOI's, UDT's, Routines, Tags, and
then paste it, as one, to create more tanks to reduce engineering time.
In this section, we will import a (pre-configured and tested) control strategy routine for a motor (CS_Motor)
into the program named Tank1. A motor can drive a blower, conveyor, mixer, agitator or a pump. We are
configuring a drain pump to empty the tank. Right-click on the program named Tank1. From the menus
select Add and then Import Routine.
Select the control strategy import file for a motor, CS_Motor.L5X, and click Open.
In the Import Content area of the configuration window, click on the Tags folder to view all the tags that will
be imported. We want to modify the tagnames by replacing the generic MT motor designator with PMP during
the routine import. The MT is a default tag designator for any type of motor. A motor can drive a blower,
conveyor, mixer, agitator or a pump. In this case we are designating a pump using PMP in the tagnames.
Click on the Find/Replace button.
Wait for the import to complete. Once the import completes, a new routine named Pump is added to the
Tank1 program. Double-click on the Pump routine to open the function-block editor and view the new code.
Click on the Tags folder in the Import Content area of the window.
Find all instances of XT and replace with LT. Confirm that only Final Name is checked in the Find Within
options. Then click the Replace All button. Now click OK.
Wait for the import to complete. A new routine named Level has been added. Double-click on the Level
routine to view the code.
Next we need to add instructions to execute the new routines. We will do this by adding rungs to the
MainRoutine that include “Jump to Subroutine” (JSR) instructions. The “Jump to Subroutine” (JSR)
instructions will execute the Pump and Level subroutines.
Double-click the MainRoutine for Tank1.
Click on Rung 0 to select the rung (indicated by a blue box) and then right-click and select ADD Rung.
A new rung has been added to the bottom. The e’s in the blue box indicate that Rung 1 has an error. The
error is because the rung is empty. We need to add an instruction to the rung.
After adding the JSR to the rung it is still in error because the JSR instruction needs to have the Routine
Name parameter filled in.
Double-click the question mark, click on the down-arrow, and double-click the routine named Pump.
Now we need to add another rung for the JSR that will execute the Level routine. We will do this by copying
Rung 1. Click on Rung 1 to select the rung (indicated by the blue box) and then right-click and select Copy
Rung from the menu.
Click on the bottom rung (End) to select the rung (indicated by a blue box) and then right-click and select
Paste from the selection window.
The coding for Tank1 is complete and ready to download to the controller. In the upper left of the Logix
Designer window click the Save button. Click on the Controller Status button and select Download.
In this lab we are using RSLogix Emulate 5000 software to emulate a physical Logix controller.
While waiting for the “emulated controller” download to complete, read about RSLogix Emulate 5000.
RSLogix Emulate 5000 software is an engineering tool that is capable of emulating a Logix controller. It can
be used in conjunction with Logix Designer 5000 and FTView Studio SE to write and test application code and
HMI displays without the need to connect to a physical Logix controller. For this lab, RSLogix Emulate 5000
software is already running and the chassis has a controller configured in slot 2.
Section Summary
The new Logical Organizer provides a way to view and create an organizational model of the system.
Application Controller Templates are available with pre-loaded library content to start your Logix project.
Control Strategies where used to quickly add pump control and level indication code to the project supporting
the concept of Re-use engineering to save time.
Three HMI Project templates are available each of which supports a different display resolution:
All of the above HMI templates include the following attributes: Basic display layout, Navigation, and Alarm
displays. However, the HMI templates do not include Library objects; the Library objects must be imported
into the templates. In the following lab section, we will open an HMI Project template that has been pre-
configured for the lab with all logical servers (data, HMI, and alarms) and communication settings, and the
Library objects already imported.
FactoryTalk View Studio is configuration software for developing and testing PlantPAx HMI applications.
With FactoryTalk View Studio, you can:
Configure a single operator station or configure an entire distributed application from one location
Access tags via a tag browser that presents direct PLC tags and HMI tags in a logical hierarchy
Remotely configure FactoryTalk View Site Edition servers
Create displays and faceplates using a full-featured graphics editor
Select the type of the application as a View Site Edition (Local Station) application and click Continue.
This is the blank “P1f Home” display. We will start with this display because navigation to it is already
configured on the template button bars. The next step will be to add a pump and level object for Tank1 to the
display and then link the objects to tags in the controller. The easiest way to do this will be to use Global
Objects.
A global object is an HMI display element that is created once and referenced multiple times on multiple
displays in an application. When changes are made to the original (base) object, the instantiated copies are
automatically updated.
In the Explorer window, expand the Global Objects folder. Scroll down until you find the global object named
“(RA-BAS) P_Motor Graphics Library”. The RA-BAS stands for Rockwell Automation Base library and the
P_Motor means this screen contains motor objects for process control.
Double-click on the Global Object “(RA-BAS) P_Motor Graphics Library” to open the display editor.
For rapid development of information-rich operator displays, the Rockwell Automation Library of Process
Objects provides a collection of Global Objects that are linked to the Add-On Instructions with a drag and
drop wizard. Display elements include motors, valves, analog and digital indicators and even a sequencer.
Together with the HMI Project Templates they allow for rapid development of display graphics.
In the Explorer window, search the Global Objects folder, scrolling until you find the global object named
“(RA-BAS) P_AIn Graphics Library”. The RA-BAS stands for Rockwell Automation Base library and the
P_AIn means this screen contains analog input objects for process control.
Double-click on the Global Object “(RA-BAS) P_AIn Graphics Library)” to open the display editor.
Right-click on the new pump object in the Main graphic window and select Global Object Parameter
Values from the selection menu.
The Global Object Parameters Values window opens. We need to enter the tag Value for the Motor into
parameter 1. This parameter links the tag PMP100 (that we created earlier in the Logix code) to this instance
of the pump object. For parameter 1, click on the Ellipses button in the column named Tag to open a Tag
Browser window.
Scroll-down the list and select the tag PMP100. Verify that the Selected Tag is [Tanks]PMP100. The tag-
prefix “[Tanks]” is the Device Shortcut name for the controller in slot 2. Click OK.
Right-click on the new Analog Input object and select Global Object Parameter Values from the selection
menu.
The Global Object Parameters Values window opens. We need to enter the tag Value for the Level into
parameter 1. Type in {[Tanks]LT100} or click on the Ellipses button and use the Tag Browser to browse to
the tag as we did with the pump.
Click on the Save button to save the updates to the “P1f Home” display.
The display is complete and functional but can be customized with tanks, piping, and more. The following
section introduces and uses the Symbol Factory HMI library to add a tank symbol to the display.
The Symbol Factory is an HMI library of over 5,000 graphics symbols for use in process HMI applications.
Symbols include pumps, pipes, valves, tanks, mixers, motors, ducts, electrical symbols, flow meters, material
handling, sensors, PLCs, transmitters, and ISA symbols. You can use drag-and-drop to transfer symbols from
the Symbol Factory into an HMI display.
Wait for the Symbol Factory window to open. Drag-and-drop a tank symbol from the Symbol Factory to the
P1f_Home display.
Categories include:
pumps
pipes
valves
tanks
mixers
motors
ducts
electrical symbols
flow meters
material handling
sensors
Transmitters
and more
Click on the Save button to save the updates to the “P1f Home” display.
Section Summary:
For rapid development of operator displays, the Rockwell Automation Library of Process Objects provides a
collection of Global Objects that are linked to the Add-On Instructions with a drag and drop wizard. Together
with the HMI Project Templates they allow for rapid development of display graphics.
The local station application (code and HMI) is finished; test it by running the FactoryTalk ViewSE Client.
FactoryTalk View SE Client is software for viewing and interacting with the FactoryTalk View SE application at
run time. The FactoryTalk View SE Client provides a complete and secure run-time environment for a local
station application. For example, operators can use the client to view and interact with multiple graphic
displays, manage alarms, view trends and adjust set points.
Double-click the Client_Template icon on desktop. Wait for the client window to open.
When the Client screen opens, notice the docked Header and Footer displays. They are part of the
Framework displays contained in the HMI template that also includes button bars and alarm, history and help
displays. The template Header graphic is used to display information that will always be visible to the
operator, such as the current date and time, name of the current area, general alarm and system status and
navigation buttons.
Click on the Reset Tank Levels button on the top button bar.
Wait for the tank level to fill to 60%.
We are now ready to test our application. We can now start the pump and empty the tank.
The new Logical Organizer provides a way to view an organizational model of the system. This allows
engineers to modify the system more quickly. New features such as Selecting Multiple project components
like AOI's, UDT's, Programs, and then copy/paste, drag/drop, export/ import them as one to reduce
engineering time. In this section of the lab we will be doing a copy/paste of program Tank1 to a new tank
program Tank2. For this part of the lab we will work in the new Logical Organizer window.
In the Logical Organizer, Right-click the program Tank1 and click Copy.
Right-click on the controller, PAC01. (PAC01 stands for Process Automation Controller 01)
Click on Paste Special and then select With Configuration.
Schedule the new Tank2 program in Task_D_500ms by using the drop-down menu.
Click on the Tags folder in the Import Content area of the window.
Find all instances of 100 and replace with 200. Confirm that only Final Name is checked in the Find Within
options. Then click the Replace All button. Now click OK.
Because the controller is running and we are making edits to the code On-line, we need choose how the edits
will be imported. Check the selection for “Finalize All Edits In Program” during the import and click OK.
On the “P1f Home” display, use the cursor to highlight the Tank1 objects and then click Arrange from the
editing selections on the upper menu bar. Click Group from the drop-down menu. This groups the objects.
In the Tag Substitution window Search for 100 and Replace with 200. Click the Replace button.
Click OK.
Click on the Save button to save the updates to the “P1f Home” display.
To test the code and graphic updates, Maximize the FactoryTalk View Client window.
Click on the Reset Tank Levels button on the top button bar.
Wait for the level in Tank1 to fill to 60% and Tank2 to 50%.
PlantPAx™ is the process automation system from Rockwell Automation with all the core capabilities
expected in a world-class modern distributed control system (MDCS). The RA Library of Process Objects™ is
a collection of Application Code, Graphic Objects, Faceplates and sample Control Strategies that let you
quickly configure a device from I/O to operator interface in just a few mouse clicks. Configure your Integrated
Architecture control system to meet the PlantPAx system guidelines and you can call it PlantPAx. Start with
the RA Library of Process Objects, a collection of Application Code, Graphic Objects, Faceplates and sample
Control Strategies, and you can quickly configure a device from I/O to operator interface in just a few mouse
clicks. Engineering your modern DCS has never been easier.