Structured Ladder/FBD 6/12/2020

Data Name : POU_01

1 Task Handling This controls the task i.e. Start, Hold, Hold if alarm, Resume or abort. it checks that the Task
sequence is idle (0) and if HMI Start Button pressed puts 1 into the Task sequence word.
EQ AND MOV Status
Task_Seq EN ENO
Runnin
0 HMI_Start 1 s d Task_Seq

MOV
EN ENO
0 s d Actual_Mix_Time

2 This segment checks that the Task sequence is Running (1) and if HMI Halt Button pressed puts 2 into the
Task sequence
Status
EQ AND MOV Held
Task_Seq EN ENO
1 HMI_Halt 2 s d Task_Seq

3 This segment checks that the Task sequence is Running (1) and if in alarm puts 3 into the Task sequence

Status
EQ AND MOV Held_
Task_Seq EN ENO
1 Alarm_Hold 3 s d Task_Seq

4 This segment checks that the Task sequence is in hold (2) or Held_E and if HMI Resume Button pressed puts
1 into the Task sequence
Status
EQ OR AND MOV Resum
Task_Seq EN ENO
2 HMI_Resume 1 s d Task_Seq

EQ
Task_Seq
3

5 This segment checks that the Task sequence is in hold (2) or Held_E and if HMI Abort Button pressed puts 0
into the Task sequence
Status
EQ OR AND MOV Abort
Task_Seq EN ENO
2 HMI_Abort 0 s d Task_Seq

EQ MOV
Task_Seq EN ENO
3 0 s d Sequence

6 If the Task is told to Hold or is held on alarm then enable hold motors bit and after time hold valves bit, this
allows motors to stop before closing valves i.e. gracefull shut down. Allow the Resume & Abort Buttons
Hold_Valves_Delay
EQ OR TON Hold_Valves
Task_Seq IN Q
2 T#2s PT ET
Hold_Motors
EQ
Task_Seq
3 HMI_Resume_Enable

HMI_Abort_Enable

7 If the Task is Idle, then enable The start button visibility on the HMI

EQ HMI_Start_Enable
Task_Seq
0

8 If the Task is Running, then enable The Hold button visibility on the HMI

EQ HMI_Halt_Enable
Task_Seq
1

9 If Task is started, then move process to start sequence.

GE MOVP
Task_Seq EN ENO
1 10 s d Sequence

1
Structured Ladder/FBD 6/12/2020
Data Name : POU_01
10 Check Tank is below min level for starting. if so step on to main control sequence
EQ AND MOV
Sequence EN ENO
10 100 s d Sequence

LT
Tank1_Level
5

11 Check Tank is above min level for starting. if so step on to inform operator
EQ AND MOV
Sequence EN ENO
10 15 s d Sequence

GE
Tank1_Level
5

12 Enable Ack Key if level below min and Operator confirm, step on
EQ AND MOV
Sequence EN ENO
15 100 s d Sequence

LT
Tank1_Level
5

HMI_ACK_Button

13 Open Water Valves Main & Trickle V1 V2 until recipe sp - 10 , move on to trickle

EQ AND MOV
Sequence EN ENO
100 110 s d Sequence

GE
Tank1_Level

SUB
HMI_Recipe_Water
10

14 Trickle valve open until SP reached, step on

EQ AND MOV
Sequence EN ENO
110 120 s d Sequence

GE
Tank1_Level
HMI_Recipe_Water

15 Heating Sequence to SP1 Run Heaters 1 & 2, When complete step on, store level
into temp for milk addition

EQ AND MOV
Sequence EN ENO
120 130 s d Sequence

GT MOV
Tank1_Temperature EN ENO
HMI_Recipe_HeatSP_1 Tank1_Level s d Temp_Store

2
Structured Ladder/FBD 6/12/2020
Data Name : POU_01
16 Add milk Sequence add the total tank level stored to recipe milk level Operator Ack

EQ AND MOV
Sequence EN ENO
130 140 s d Sequence

ADD GE
Temp_Store MOV
HMI_Recipe_Milk EN ENO
Tank1_Level s d Temp_Store
Tank1_Level

HMI_ACK_Button

17 Add Starch Sequence Operator Ack Added timer to stop operator pressing it again
PB_Delay
EQ TON AND MOV
Sequence IN Q EN ENO
140 T#2s PT ET HMI_ACK_Button 150 s d Sequence

18 Heating Sequence to SP2 Run Heaters 1 & 2, When complete step on, To mix seq.

EQ AND MOV
Sequence EN ENO
150 160 s d Sequence

GT
Tank1_Temperature
HMI_Recipe_Heat_SP2

19 Mix & Heat Maintain time, when complete move on

EQ AND MOV
Sequence EN ENO
160 170 s d Sequence

GT
Actual_Mix_Time
HMI_Recipe_Mix_Time

20 Mix time accumulator

EQ AND INCP
Sequence EN ENO
160 Sec_1 d Actual_Mix_Time

21 Mix Complete Request Take Sample & confirm

EQ AND MOV
Sequence EN ENO
170 180 s d Sequence

HMI_ACK_Button

22 Discharge When tank < 5 % plus Time delay, step on to stop motors

Empty_Delay
EQ AND TON MOV
Sequence IN Q EN ENO
180 T#10s PT ET 190 s d Sequence

LE
Tank1_Level
5

23 Stop Motor, delay step on to close valve, reset process to idle

Close_Valve_Delay
EQ TON MOV
Sequence IN Q EN ENO
190 T#4s PT ET 0 s d Sequence

MOV
EN ENO
0 s d Task_Seq

3
Structured Ladder/FBD 6/12/2020
Data Name : POU_01
24 Enable Ack Button visible

EQ OR HMI_Ack_Enable
Sequence
15

EQ
Sequence
130

EQ
Sequence
140

EQ
Sequence
170
25 Add Water Control Main Valve

EQ Hold_Valves Main_Water_Valve
Sequence
100

26 Add Water Control Trickle Valve

GE AND Hold_Valves Trickle_Water_Valve

Sequence
100

LE
Sequence
110

27 Mixer Control

GE AND Hold_Motors Mixer_Motor

Sequence
120

LE
Sequence
160

28 Main Heater Control

EQ AND OR Hold_MotorsMain_Heater
Sequence
120

LE
Tank1_Temperature

SUB
HMI_Recipe_HeatSP_1
10

GE AND
Sequence
150

LE
Sequence
160

LE
Tank1_Temperature

SUB
HMI_Recipe_Heat_SP2
10

4
Structured Ladder/FBD 6/12/2020
Data Name : POU_01
29 Trickle Heater Control

EQ AND OR Hold_Motors Trickle_Heater

Sequence S
120

LE
Tank1_Temperature
HMI_Recipe_HeatSP_1

GE AND
Sequence
150

LE
Sequence
160

LE
Tank1_Temperature
HMI_Recipe_Heat_SP2

30 Trickle Heater Control

EQ AND OR Hold_Motors Trickle_Heater

Sequence R
120

GE
Tank1_Temperature

ADD
HMI_Recipe_HeatSP_1
2
GE AND
Sequence
150

LE
Sequence
160

GE
Tank1_Temperature
EQ
Sequence
ADD 130
HMI_Recipe_Heat_SP2
2 EQ
Sequence
170

31 Discharge Valve control

GE AND Hold_Valves Discharge_Valve

Sequence
180

LE
Sequence
190

32 Discharge Motor control

EQ Hold_Motors Discharge_Motor
Sequence
180

5
Structured Ladder/FBD 6/12/2020
Data Name : Simulation
1 Simulatation Tank Filling with Water Fast

Main_Water_Valve Sec_1 INCP

EN ENO
d Tank1_Level

2 Tank filling Water slow

Trickle_Water_Valve Sec_1 INCP

EN ENO
d Tank1_Level

3 Simulatation Tank Discharging

Discharge_Valve Sec_100ms AND> DECP

EN ENO EN ENO
Tank1_Level s1 d Tank1_Level
0 s2

4 Simulatation Tank Heating Fast

Main_Heater Sec_1 INCP

EN ENO
d Tank1_Temperature

5 TankHeating slow

Trickle_Heater Sec_1 INCP

EN ENO
d Tank1_Temperature

6 TON_1
Sec_5_Pulse TON Sec_5_Pulse
IN Q
T#5000ms PT ET
7
GE Sec_5_Pulse DECP
Tank1_Temperature EN ENO
16 d Tank1_Temperature

8 Simulate operator adding milk

GE ADDP
Sequence EN ENO
130 HMI_Recipe_Milk s1 d Tank1_Level
Tank1_Level s2
9 Simulate operator adding starch
GE ADDP
Sequence EN ENO
140 HMI_Recipe_Starch s1 d Tank1_Level
Tank1_Level s2