Controller-based Batching Using

SequenceManager™
 Important User Information
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Controller-based Batching Using SequenceManager™

Contents
Before you begin ........................................................................................................................................... 5
About this lab (an estimated time to complete is about 100 minutes) ............................................................................................... 5
Software and versions used; project files required ........................................................................................................................... 5

Start the software and open a project ........................................................................................................... 6

What level batch user are you? .................................................................................................................. 19

What is Batch? ............................................................................................................................................ 20

Overview ANSI/ISA-88.01 concepts, terms and models................................................................................................................. 20
Design concepts to keep in mind for a better modular design ........................................................................................................ 20
Two S88 models to help facilitate more modular design ................................................................................................................ 21
Where does SequenceManager™ fit into the Two Primary S88 Models ........................................................................................ 21
The S88 Physical Model and the Modular Components in the Unit ................................................................................................ 23
Rockwell’s Preferred S88 Integration starting with PhaseManager™ Equipment Phases ............................................................. 24
Rockwell’s Latest Preferred Integration with SequenceManager™ Equipment Sequences ........................................................... 28
FactoryTalk Batch®, SequenceManager™, and PhaseManager™ all follow the S88 state transition rules .................................. 30

Overview of Rockwell’s preferred integration batch products - FactoryTalk Batch®, SequenceManager™

and PhaseManager™ ................................................................................................................................. 31
How Rockwell’s preferred integration products fit across all magnitudes of S88 batch processing? ............................................. 32

SequenceManager™ - the Operator Perspective ....................................................................................... 34

Let’s get Started - Running a Sequence in FactoryTalk View SE ................................................................................................... 34

SequenceManager™ the Engineer’s Perspective ...................................................................................... 58

SequenceManager™ – an equipment sequence in firmware ......................................................................................................... 58
Logix Designer SequenceManager™ Environment for Equipment Sequences ............................................................................. 60
Understanding more about Equipment Sequence .......................................................................................................................... 66
Create a New Sequence ................................................................................................................................................................. 72

SequenceManager™ a Manager’s Perspective (an extra-time section) .................................................... 83

Appendix A - Sequence Tag Overview .......................................................................................................................................... 91

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Appendix B – Engineering: Making Online updates for new Equipment Sequences...................................................................... 92
Appendix C - Engineering: Creating a new Sequence using copying ............................................................................................. 96
Appendix D - Engineering: Adding and Configuring the SequenceManager™ ActiveX Controls for FT View SE ........................ 110
Appendix E - Operations: Advanced Interactions with SequenceManager™ ............................................................................... 115
Appendix F - More Details on SequenceManager™ Archiving ..................................................................................................... 119
Appendix G - Setting the Event Client Service Controller Path .................................................................................................... 124
Appendix H - SequenceManager™Help ....................................................................................................................................... 132

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Before you begin

The following steps should be completed before starting the lab exercise:
▪ The VMware image (computer name = PASS-C01-FTB01) is a running snapshot with the logon credentials:
Username: labuser Password: rockwell

About this lab (an estimated time to complete is about 100 minutes)
This lab introduces Rockwell Automation’s SequenceManager™ product which provides single-unit batch sequencing in the
Logix 1756-L7 family of controllers supporting v28 firmware and above. SequenceManager™ is a controller-based batch
solution targeted for OEM skids, or recipes operations requiring fast cycle times. It’s an integral part to Rockwell’s scalable batch
solution story that brings the ANSI/ISA-88.00.01-2010 batch standard closer to the process and plant floor. In addition, it
provides premier integration with FactoryTalk Batch® helping customers with more advanced batch requirements and/or multi-
unit recipes.
In this lab, an operator’s perspective will be taken to showcase how SequenceManager™ works while describing what it is. For
a more technical understanding, a brief engineer’s perspective will be taken to help understand the mechanics behind the
SequenceManager™ product using Logix Designer. Finally, an optional section provides a manager’s perspective on how batch
data from a SequenceManager™ is captured and logged into an electronic batch records (EBRs). This data can be moved into
SQL server. Rockwell currently provides 11 pre-designed SQL batch reports and a database for efficiency in use and
deployment through the FactoryTalk Batch v13.02 installation. Here, we explore a prior reporting package of 9 reports that can
be downloaded from Rockwell.

Software and versions used; project files required

▪ Microsoft Windows Server 2016 Standard R2 (64 bit) and Microsoft SQL Server 2016 R2 Express Edition
▪ FactoryTalk Services Platform v3.00.00 (CPR 9 SR10)
▪ RSLinx Classic v4.00.00 (CPR9 SR10)
▪ FactoryTalk Linx v6.00.00 (CPR9 SR10)
▪ FactoryTalk Alarms and Events v3.00.00 (CPR 9 SR 10)
▪ FactoryTalk View Site Edition v10.00.00 (CPR9 SR10)
▪ FactoryTalk Batch® v13.00.02 Event Archiver Database, Reports and Data Management Tool
▪ Studio 5000 Logix Designer v30.01.00 (CPR9 SR9) with Phase Manager™ and SequenceManager™ option
▪ Studio 5000 Logix Emulate v30.01.00 (CPR9 SR9)
Files required:
• Logix Designer:
o C:\Users\labuser\Documents\Studio 5000\Projects\SMgr_PlantPAxDemo_v3_5_2019.ACD
o C:\ Users\labuser\Documents\Studio 5000\Projects\SeqMgr_Soup_2019.ACD
• FactoryTalk View SE Project(Network Distributed SE View project, and ):
o C:\Users\Public\Public Documents\RSView Enterprise\SE\HMI Projects\PlantPAx Demo HMI Server\
o C:\Users\Public\Public Documents\RSView Enterprise\SE\HMI Projects\SoupLine\

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Start the software and open a project

You will need to start applications and load project software files. This may takes some time, so please plan ahead and be
patient.

1. The desktop will have application shortcuts on the left side. The first application to start will be the Studio 5000
Logix Emulate controller. This application will emulate a Logix hard controller. Please verify your screen looks
like this, and double-click on the Studio 5000 Logix Emulate icon pointed to by the arrow below:

Please take note that “Additional Lab Files” folder that exist on the desktop. It contains completed, or partially
completed project files. These files can help avoid tedious keyboard work. In addition, should you experience any errors,
these files may help you move on quicker than troubleshooting the issue. These files are located within the following
desktop folder:

If the PC hardware running this lab is not a higher performance CPU, it may take up to 10 minutes to download to the
controller. Under these circumstances, the pre-configured files may help you to save much needed time, and prevent
wasting time troubleshooting potential keyboard errors and repeated downloads.

Note: To avoid long delays in downloading the acd files for this lab, the PC’s CPU should be high-end. It can
be rated through a website like www.cpubenchmark.net for high-end CPUs where the performance for this
lab machine should be rated above 9,000 from this website. A SSD hard drive should be used with a
minimum of 8 GB internal memory for best performance.

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2. As the Studio 5000 Logix Emulate is starting up, the BAT light indicator should be blinking on-and-off yellow for
a minute or two before a project file can be download to either slot 5 or 6. Please wait for the BAT light in the
controller slots to stop blinking yellow as shown below:

=>

Once the blinking has stopped, Logix Emulate is ready to accept a project download.

On the upper right side of the desktop, launch the Studio 5000 shortcut,

There will be a most recent controller file in the list for slot 5, select “SMgr_PlantPAx_v3_5_2019” file to open
in Logix Designer,

Note: This release of SequenceManager™ only runs on the 1756-L7x and L3y family of controllers. A future
release of firmware will support SequenceManager™ in the 1756-L8x controller family - likely in 2020.

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Upon opening and loading the project file, Logix Designer will show offline with the controller. Select the Offline
pull-down tab:

Choose the option to Download from the menu:

Confirm the download on the next pop-up display:

A small progress pop-up display will help provide some feedback on the progress for the download:

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Upon completing, verify zero errors and the connected state with the controller is “Rem Prog” mode:

Select the “Rem Prog” pull-down tab, and select “Run Mode” as seen below:

Confirm “Yes” to change to “Remote Run” mode:

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The Logix Designer connection with the controller should indicate Rem Run:

Finally, you may visually verify that the Logix Emulate controller in slot 5 is set to ‘Run’ and ‘OK’ state (e.g.
Run green, OK green,) as shown below:

Update the time and date of the controller through Logix Designer controller properties by right-mouse clicking on the
controller, select Properties,

Select the “Date/Time” tab, then select the “Set Date, Time and Zone from Workstation” as shown below:

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Select the OK button to accept any changes…

Now, open the project file for the slot 6 controller so it can be loaded. In Logix Designer, select File -> Open:

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Select the project file “SeqMgr_Soup_2019.acd,” and select Open.
Upon opening the project file, Logix Designer will show offline with the controller. Select the “Offline” pull-down tab to
change it:

Choose the “Download” option from the menu list:

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In the “Download” pop-up display, select the “Download” button:

A small progress pop-up display will help provide some feedback on the progress for the download:

Upon completing, verify zero errors and the connected state with the controller is “Rem Prog” mode:

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Select the “Rem Prog” pull-down tab, and select “Run Mode” as seen below:

Confirm “Yes” to change to run mode:

The Logix Designer connection with the controller should indicate Rem Run:

Visually verify that the Logix Emulate controller in slot 6 is set to ‘Run’ and ‘OK’ state (e.g. Run green, OK
green,) as shown below:

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Update the time and date of the controller through Logix Designer controller properties by right-mouse clicking on the
controller, select Properties,

Select the “Date/Time” tab, then select the “Set Date, Time and Zone from Workstation” button as shown below:

Select the OK button to accept any changes for the controller properties,

Before finalizing the controller setup, please power cycle the controllers from Run back to Program and back to Run again.
To do this, right-mouse click each controller in slot 5 and 6 for the menu options to change state…

and

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3. Now that the controllers are launched, loaded, and running, please start the archiving application for capturing
batch events that will be generated by SequenceManager™ sequences running in the controller.

On the desktop, right click on the shortcut, for the option to “Run as administrator.”

Select it for the “Sequence Manager Event Services Console” to launch with proper privileges to command the
two services.

4. For the first service, select the Start button in the “Sequence Manager Event Client Service” area:

Wait for the service to go running with 2 good controller connections as seen below:

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In the lower half there is another service to command. Please select the Start button under the “Sequence Manager Event
Archiving Service” area shown by the red arrow below,

Once the service is running, select the Close button as shown:

This application provides the interface to two services that help manage the electronic-batch-record (EBR) for data retrieval
from the controller when using Sequencing Manager™. The first service is used to transfer EBR data within the controller to
a data file storage location in the PC with proprietary RAW format. The service in the lower half of the display is used to
transfer the RAW formatted data to ASCII data in a SQL Server database for use with the Rockwell’s standard batch
reports.

Appendix G provides instructions on how to check and set the path to the controller for the Sequence
Manager Event Client Service, and how to configure the controller to capture EBR data for each sequence.
Appendix F provides more details on how these services function to get data from the controller into a SQL
Server database.

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5. Close Logix Designer by selecting the Close X box,

6. The desktop has a FactoryTalk View SE application shortcut, for the PlantPAx demo client interface. All
the simulated process control for this demo was loaded into slot 5 of the controller (Logix Emulate). The device
control and graphics use in this demo are from the PlantPAx process library of objects (version 3.5). Double
click on this shortcut to launch the HMI client which should open full screen,

7. This finishes the setup for the lab.

Note: ANSI/ISA-88.00.01 batch standard was first approved in 1995, updated in 2010. Its standardized
terminology and models for batch processing which prior to 1995 were very different across all areas.

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What level batch user are you?

Are you familiar with modern batch processing, and existing batch standards? Are you familiar with Rockwell’s batch products?

This lab reflects the batch standard defined within the ANSI/ISA-88.00.01-2010 Batch Control Part 1: Models and Terminology
standard. This ISA standard provides models for batch and related procedure-oriented manufacturing as used in batch
processing industries, as well as a common terminology set for batch.

Note: “S88” is a common acronym for the ANSI/ISA-88 batch standard. “S88” will be used in place of the
ANSI/ISA-88.00.01 Batch Control Part 1 standard reference throughout this lab. “S88” reads, writes, and
speaks a little easier for most people.

For students constrained by a 2-hour lab session, please follow any markers placed throughout this lab instructing you to skip
content such as the following:
Skip ahead to next step…

For students very familiar with the S88 batch standard, and PhaseManager™ - you may skip ahead to page 34 for the section
labeled, “SequenceManager™ - the Operator Perspective” to begin this lab. This applies to anyone under a 2 hour time limit.
Anything skipped is for enhanced learning which may be reviewed later outside the lab environment; it is not essential to finishing
the lab.

If neither reason to skip ahead happens to apply, then please continue reading to gain a better understanding of existing
Rockwell batch products and pertinent S88 concepts, terminology, relationships and models used throughout this lab. The next
14 pages present a brief overview of some essential batch concepts, models and definitions from the ANSI/ISA-88.00.01 Batch
Control Part 1: Models and Terminology (S88) standard. This information will provide limited exposure to the S88 batch standard
that will enhance your understanding throughout the remainder of the lab and beyond. These added pages also describe how
Rockwell products fit to the S88 standards while extending benefits beyond those gained from S88. Rockwell’s extends benefits
through a preferred product integration which leads to less engineering effort, testing, management, and support for the batch
control system. Please expect to spend at least an additional 1 hour reading these pages to fully comprehend and remember the
S88 concepts, terminology and the multitude of Rockwell’s scalable batch product solutions.

For more information about S88 batch standards, please visit the ISA website to reference their available materials.

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What is Batch?

WARNING: if you are working in a time-constrained lab session, please skip ahead to page 34 to begin the
section labeled, “SequenceManager™ - the Operator Perspective.” Do not skim, or read through this
section, or you will not complete the lab in time. This information can always be reviewed later.

Batch operations produce finite quantities of material by processing input materials in a defined order using one or
more pieces of equipment including automated and/or manual process interactions. Batch control provides a means to automate
the activities and functions associated with the batch production. Modular batch design and scalable product solutions will
provide end users with the most flexible, powerful, and adaptive batch environments for their current and future needs.

The most common products that are produce in batch manufacturing are typically processed foods, beverages, pharmaceuticals,
cosmetics, toothpaste, paints, specialty chemicals, and many of the daily consumer goods people use throughout their lifetime.

Overview ANSI/ISA-88.01 concepts, terms and models

What provides for a flexible and modern batch control system is one that was designed with a modularity in mind. A batch
standard in 1995 was released to help facilitate these efforts and provide a common language for batch to all end users and
vendors. Both, a ‘Procedure Control’ model and a ‘Physical’ model were defined in the standard to naturally help facilitate a more
modular design. Unfortunately, these models do not always guarantee it. It’s important to understand the ‘Procedure Control’
model and the ‘Physical’ model as defined by the standard when designing your batch system. However, optimal modularity is
best assured while keeping a mindset towards two fundamental question surrounding each model during the design process.

Design concepts to keep in mind for a better modular design

Always be aware that there are two very important questions to ponder during the design phase for the physical model, and for
the procedure model. Each question is shown below,
PROCEDURAL CONTROL MODEL PHYSICAL MODEL

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In the design phase for the ‘Physical’ model, always be aware that asking yourself this question, “What is the equipment capable
of?” will lead the design towards better modularity. The same goes for recipe design when addressing the ‘Procedural Control’
model by always considering the question, “What to do with the equipment.”

Two S88 models to help facilitate more modular design

There are four structural components that comprise each of the S88 models as shown in the diagrams below:
PROCEDURAL CONTROL MODEL PHYSICAL MODEL

Where does SequenceManager™ fit into the Two Primary S88 Models
Rockwell’s SequenceManager™ product is limited to a subset of components within each of these S88 models. However, when
SequenceManager™ is used in conjunction with the FactoryTalk Batch®, the combination scales up to cover all components
contained by these models. By itself, the SequenceManager™ product targets single-unit control which comprises a smaller
subset of the model components as identified by the red circles above.

The S88 definition for each of these circled components is provided below to help you understand their meaning for proper
context when working with SequenceManager™ and PhaseManager™ this lab today:
Physical model components
Control module: The lowest level grouping of equipment in the physical model that can carry out a basic control
Equipment phase: A phase that is part of equipment control.
Equipment module: A functional group of equipment that can carry out a finite number of specific minor processing
activities such as heating, agitating, dosing and weighing.
Equipment unit: A collection of associated equipment modules and/or control modules that can carry out one or
more major processing activities
Process Cell: A logical grouping of equipment that includes the equipment required for production of one, or
more batches. It defines the span of logical control of one set of process equipment within an
area.

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Procedural Control model components:
Phase: The lowest level of procedural element in the procedural control model.
Operation: A procedural element defining an independent processing activity consisting of the algorithm
necessary for the initiation, organization and control of phases.
Unit Procedure: A strategy for carrying out a contiguous process within a unit. It consist of contiguous operations
and the algorithm necessary for the initiation, organization, and control of those operations.
Procedure: The strategy for carrying out a process. Note – in general, it refers to the strategy for making a
batch within a process cell. It may also refer to a process that does not result in the production of
product such as a clean-in-place procedure.

In the design phase of a batch project, the very first model to focus upon is the “Physical” model. Using P&ID diagrams for the
process, a majority of the equipment comprising each component of the physical model can be identified and grouped. The units
can often be identified from these P&ID diagrams alone. At times, a clearer understanding might be aided through the help of
others such as, process engineers, and operators.

For a unit there may be dedicated or shared control modules, equipment modules, and equipment phases that should be
identified during the design phase for each. Permissive and abnormal condition handling should to be considered as well. It is
likely that the majority of the batch system design time will be spent on the S88 ‘Physical’ model, and equipment control.
Fortunately, Rockwell provides customers with some help in both these areas to reduce overall efforts in programming, code
design, testing, debugging, and long-term management and support.

For the control module component of the ‘Physical’ model, a no-cost option for customers is Rockwell’s library of process
objects. This library provides pre-designed, tested, documented and supported equipment control and UI displays with known
performance characteristics within the recommended guidelines. This library can be downloaded from Rockwell’s website.

For the equipment phase component of the process model, Rockwell’s preferred option is the firmware PhaseManager™ product
within the controller. In the controller, Phase Manager™ allows for simple and efficient equipment phase creation with faster and
more reliable communications. As a preferred integration component, a benefit of seamless and efficient integration with other
Rockwell products has been provided with FactoryTalk Batch® and now, SequenceManager™. For aid in application design with
HMI displays for units and equipment phase logic, Rockwell has made available a no-cost batch application toolkit. For other
batch visualization displays, there is a download available from the Rockwell Knowledge Base.

For the unit operation component of the ‘Procedural Control’ model, Rockwell now provides a firmware option within the
controller called, SequenceManager™ which happens to be the main focus for this lab. The use of SequenceManager™ is
predicated upon the use of the PhaseManager™ product to define the lower level component of the S88 ‘Physical’ model with
the equipment phase.

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The S88 Physical Model and the Modular Components in the Unit
For the S88 ‘Physical’ model, an equipment ‘Unit’ is typically identified as a major equipment piece where a major processing
activity will occur - usually represented by a physical or chemical change in the material contained within the unit. The
“Equipment Phase/Module” is usually identified as the collection of equipment responsible for a minor processing activities
that can occur within the unit.

For best design of each minor processing activity, asking the following question may assist in deriving the optimal modularity for
your design:
“What is the equipment capable of?”
With a proper design of units, equipment phases, equipment modules and control modules, the batch control system will greatly
benefit later in the recipe design where the “Procedural Control” model becomes the focus. No rework and improved long-term
maintenance becomes hallmark benefits of good modular design.

In the design for the procedural control model, it is here where the ordering and sequencing of the equipment phases will be
determined along with recipe specific parameters (formula values), reports and transition conditions. The level of modular
success at the procedural model will be dependent upon the foundation set forth initially during the ‘Physical’ model design.

Just imagine the modularity in the use of your process equipment when assembly and sequencing is made extremely flexible.
The modular usage of equipment phases will be achieved by the proper interpretation and application of the S88 batch standard
for the physical model design. The next two displays may help illustrated this modular concept. The following illustrates with
both, the automated and manual (human illustration) equipment phases shown in blue:

The modular use of these equipment phases can be best achieved with the proper interpretation and application of the S88
batch standard for the ‘Physical’ model in your design. The next diagram illustrates the flexibility that modularity provides in the
use of your process equipment when both, assembly and sequencing of such equipment is changeable at any time by an editing

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tool within the FactoryTalk Batch® product, or Logix Designer for a SequenceManager™ equipment sequence:

With PhaseManager™ as Rockwell’s preferred integration tool for creating the equipment phase, it is SequenceManager™
and/or FactoryTalk Batch® that are the tools for creating procedures. An equipment phase is mapped, or linked to recipe
‘Phases’ – the first level entity in the ‘Procedural Control’ model. SequenceManager™ can create ‘Operations’ – the second
level entity of the ‘Procedural Control’ model. For greater scalability, FactoryTalk Batch® can create operations, or use
SequenceManager™ operations called equipment sequences. In addition, FactoryTalk Batch® can create unit procedures and
procedures to cover all levels of the S88 ‘Procedural Control’ model.

Rockwell’s Preferred S88 Integration starting with PhaseManager™ Equipment Phases

For automated batch processes, PhaseManager™ was released for ControlLogix in version 15 (CPR 9) to provide a
fully integrated S88 component within the controller for an equipment phase. The FactoryTalk Batch® server could
communicate with this newly integrated feature using an enhanced protocol, CIP, other than traditional OPC as
shown below,

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This PhaseManager™ integration was carried beyond the controller and into the FactoryTalk Batch® product to fully
exploit this new equipment phase functionality for S88 procedures at the ‘Operation’ level. The FactoryTalk Batch®
equipment editor was enhanced with improved integration and a simplification of the workflows to create and manage
these new firmware equipment phases. The following diagram shows the link between the FactoryTalk Batch®
equipment editor’s phase instance in a unit and the PhaseManager™ controller code and object
T300_AGITATE_PHASE:

For a closer look in Logix Designer at a PhaseManager™ equipment phase reveals specific routines and
attributes below:

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In addition, Logix Designer provides a standard equipment phase interface for direct communications and control
of a PhaseManager™ equipment phase in the controller:

An equipment phase object is a special Logix firmware program that can be quickly created as shown below in
an older version of Logix:

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What makes PhaseManager™ equipment phases beneficial for the user are a few of the following attributes:
- Simply right-click on a Logix 5000 task and select New Equipment Phase…
- Each equipment phase has built-in phase tags requiring no need for design, creation, testing, or management
- Each equipment phase contains its own internal programmable logic interface (PLI) that enforces S88 states and rules in
communication and control with the phase. No need to design, create, test, or manage a PLI - it’s a black box.
- Each equipment phase has built-in phase state routines that are executed according to the S88 state machine rules
o Aborting, Holding, Resetting, Restarting, Running, and Stopping
o Additional non-S88-state routines include: Fault and Prestate
- Premier integrates with other Rockwell Products such as, SequenceManager™, or FactoryTalk Batch®

A few other things to note about a PhaseManager™ equipment phase:

a. Contains all the components for direct FactoryTalk Batch® or Sequence Manger™ to equipment phase
communications and control
b. Embeds the communication mechanisms, thus replacing an OPC PLI and building special tag structures
c. Executes at an order of magnitude faster than an OPC counterpart
d. No “handshaking” or read back of writes required; communications are 100% reliable
e. Provides an ‘Inhibit’ option

For the PhaseManager™ equipment phase within Logix Designer, there are special equipment phase instructions:

• PhaseManager™ equipment phase logic instructions used in the state routines

– PSC, PFL, PPD, PRNP, PXRQ

• Sequencing instructions used outside of the Equipment Phase (e.g. in another Program)

– PCMD, PATT, PDET, PCLF, POVR

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Rockwell’s Latest Preferred Integration with SequenceManager™ Equipment Sequences
More recently with the addition of SequenceManager™ to version 28 of ControlLogix, the Studio 5000 Logix
Designer became a new environment for creating single-unit procedures, or operations that run in the controller.
Learning to create and run a SequenceManager™ equipment sequence is a focus of this lab. It is important to note
that SequenceManager™ builds upon the existing PhaseManager™ product – only working with these types of
equipment phases, and not OPC phases. The following display provides a brief illustration for the design environment
within Logix Designer:

For the SequenceManager™ equipment sequence within Logix Designer, there are special equipment sequence
programming tools and instructions:

SequenceManager™ equipment sequence programming tools used in the ‘Diagram’ design workspace (shown above, left
to right):
Add step and transition pair
Add Disconnected Step
Add Disconnected Transition
Add Simultaneous Divergence with Elements (parallel branches, AND logic)
Add Selective Divergence with Elements (decision branch, OR logic)
Add Simultaneous Convergence
Add Selective Convergence

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Both the design environment and the run-time environment exist within Studio 5000 Logix Designer, but using Logix
Designer as the HMI interface to equipment sequences is not very practical for daily production. Therefore, to
enhance the preferred integration of SequenceManager™ with FactoryTalk View SE, three ActiveX controls exist to
bring similar command and control of the equipment sequence(s) to the HMI as shown below,

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Continuing the integration path for SequenceManager™ equipment sequences, ControlLogix version 29 and greater support
integration with the FactoryTalk Batch® product to expand your batch system’s capabilities beyond single-unit control and
leverage the full feature set of Rockwell’s premier batch control software – FactoryTalk Batch®. This is presented in a different
lab.

FactoryTalk Batch®, SequenceManager™, and PhaseManager™ all follow the S88 state transition rules
The S88 standard defined states and state transitions are enforced and followed by Rockwell batch products such as,
PhaseManager™ equipment phases, SequenceManager™ equipment sequences, and FactoryTalk Batch®:

done Restart
Holding Held Restarting Paused
Resume
Hold done programmed
breakpoint
done Start Pause
Resetting IDLE Running Pausing

done Stop Abort

Abort
Stopping Aborting
Active / Transient State
done done
Quiescent State

Terminal State
Complete Stopped Aborted
Phase Commands
Reset Phase Logic Initiated

This equipment phase state diagram can be seen within Logix Designer via monitor equipment phase:

Here, you could command and control a PhaseManager™ equipment phase via Logix Designer.

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Overview of Rockwell’s preferred integration batch products - FactoryTalk Batch®,
SequenceManager™ and PhaseManager™

FactoryTalk Batch® is Rockwell Automation’s ANSI/ISA-88.01 comprehensive and fully scalable batch solution. It
can span a batch control system comprising a single unit upwards to many units with complex networking and
equipment arbitration requirements. It provides a very powerful recipe management system, coordination and
arbitration of recipe execution across one-to-many units, arbitration of shared resources, electronic batch records,
equipment classes, and more. It can span 100% manual batch control to a fully automated batch control system, or
some combination in between.

Manual batch control is provided through the FactoryTalk Batch® eProcedure product which automates the once
paper and clipboard SOPs into a modern electronic manual instruction with a web user interface (UI) leveraging html,
html5, and JavaScript. In addition, the Material Manager component of the batch product provides just-in-time
material control, and container binding aligned to business rules and best practices. Material and container
properties can be leveraged throughout the batch control system dynamically for improved inventory and batch
system control. In addition, customers are aided by a pre-built comprehensive reporting package based in SQL
Server using up to eleven pre-built SSRS batch reports. These reports include material track and trace reporting.

Newer to the FactoryTalk Batch® suite is a modernized UI that is scalable and platform independent leveraging user-
defined localizations. It is Rockwell’s next generation user interface (UI) for FactoryTalk Batch® that’s available as a
thin client for use on mobile phones, tablets, and PCs. Also, the FactoryTalk Batch® suite maintains its legacy
ActiveX controls, and preferred controller integration with SequenceManager™ and PhaseManager™ providing
multiple options for the end user.

PhaseManager™ was Rockwell’s first integration of batch into the controller. It leverages equipment phases as a
firmware option to allow greater reliability, efficiency and speed when building a modern batch control systems.
PhaseManager™ was first made available in the release of ControlLogix version 15. PhaseManager™ used
Rockwell’s proprietary communications to increase communication speeds with the controller by nearly an order of
magnitude over OPC communications. Today, SequenceManager™ is Rockwell Automation newest batch offering
in the controller. SequenceManager™ provides the operation component of the procedural model that leverages the
sequencing of phases linked to PhaseManager™ equipment phases within the controller. SequenceManager™ is
not directly compatible with OPC phases, or controllers that do not fully support PhaseManager™.

SequenceManager™ was introduced in 2016 with Logix Designer v28.0 to provide a controller-base batch solution
for single unit operations. For SequenceManager™ the development environment is contained within the Logix
Designer application. The batch execution engine for the equipment sequence is part of the controller which allows
batch sequencing to occur closer to the process equipment, process I/O, and controller backplane. This proximity
provides advantages for faster transition time, and equipment phase commands when using SequenceManager™.
This provides a real advantage for time-sensitive procedures, or batches requiring extremely fast batch cycle times.
Possibly, the greatest benefit for SequenceManager™ is to aid skid manufacturers. SequenceManager™ allows
machine builders to develop fully tested skids that end user may easily integrate into their pre-existing FactoryTalk
Batch® control system.

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How Rockwell’s preferred integration products fit across all magnitudes of S88 batch processing?
For the control module components of the physical model, one option for our customers is Rockwell’s library of
process objects. This library provides pre-designed, tested, documented and supported equipment control for control
modules and UI displays with known performance characteristics within its recommended guidelines.

This library is downloaded from Rockwell’s PCDC website. Simply search “PlantPAx Process Library” at:
https://compatibility.rockwellautomation.com/Pages/home.aspx

For the equipment module/phase component of the S88 physical model, Rockwell’s preferred option is the use of
PhaseManager™ firmware within the ControlLogix controller for specific versions and editions of ControlLogix.
PhaseManager™ allows for simple and efficient equipment phase creation with faster and more reliable
communications than its OPC counterpart. As a preferred integration component, both, seamless and efficient
integration with newer Rockwell products continue to be developed in the evolution process with our latest product
being SequenceManager™. It’s these scalable and progressive options with ever-increasing integration that
Rockwell provides customers with an ability to extend the product suite’s usability beyond the established benefits of
S88 and modular design.

For the unit recipe, or operation component of the S88 procedural model, Rockwell provides a firmware option within
the controller called, SequenceManager™ which happens to be a main focus for this lab. What is not part of this lab
is how SequenceManager™ integrates with the FactoryTalk Batch® product. In this lab, SequenceManager™ is
used apart from the FactoryTalk Batch® product for single-unit batching only. There is another lab that focuses on
SequenceManager™ integration with FactoryTalk Batch® called, “Distributed Batch Deploying Controller-based
Sequences with FactoryTalk Batch.” FactoryTalk Batch® can extend SequenceManager™ beyond single-unit
batching to highly networked multi-unit batching, as well as, class-based recipes.

For aid in application design and visualization, Rockwell has made multiple options available to customers such as,
embedded integration within Logix Designer, a downloadable batch application toolkit, and 3 HMI ActiveX controls for
integration of SequenceManager™. It is Rockwell’s preferred integration, tools, and scalability that aid our customers
to help them meet any batch requirement now or in the future.

The FactoryTalk Batch® View HMI Controls, the FactoryTalk Batch® View, the SequenceManager™ ActiveX
Controls, and the SequenceManager™ Event Client are all available for download at Rockwell’s PCDC site:
https://compatibility.rockwellautomation.com/Pages/home.aspx

The Batch Application Toolkit is available as an Accelerator Toolkit (reference KB # 575778) and on the
website:
https://www.rockwellautomation.com/en_NA/support/product-selection-
configuration/overview.page?pagetitle=Control-Systems-Configuration-
Tools&docid=01503dfdb8a20bf09c86944a6f44364b#tab2

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For batching across multiple units, the FactoryTalk Batch® solution is something that must be consider. It
coordinates multiple units, equipment phases and material storage locations for one or more control recipe
sequences from start to finish. FactoryTalk Batch® provides Rockwell’s most powerful interface for developing,
editing and managing recipes for the plant including class-based recipes. Class-based recipes are a very
advantageous mechanism for reducing the overall number of recipes to build, test, manage and maintain. Class-
based recipes can greatly reduce system cost and complexity.

The FactoryTalk Batch® suite includes eProcedure for managing all manual processing SOPs and capturing relevant
data, associated times, and user actions to store in an electronic batch record – ending all need for endless
paperwork. These manual tasks can be combined with automated tasks within a FactoryTalk Batch® recipe
sequence. FactoryTalk Batch® allows for electronic signatures tied to specific events, or actions, and parameter
deviations for either, manual, or automated phases. Also, the FactoryTalk Batch® can utilize MaterialManager for
tracking all materials, lots, and sub lots that are used within one or more batches. A powerful feature of material
manager is the dynamic material container tracking and binding within a recipe to follow the most appropriate
business rules for material usage throughout the plant. Another benefit of MaterialManager is the availability of data
to track and trace materials, or batches usage across specific equipment or material lots used. To learn more about
FactoryTalk Batch®, please consider our other batch lab offering this week. The following is an overview of
Rockwell’s scalable batch products:

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SequenceManager™ - the Operator Perspective

When a full-feature batch control system using FactoryTalk Batch® is not desired for your small batch (single
unit) processing, then Rockwell provides a small, yet scalable batch solution with the SequenceManager™
product.

SequenceManager™ is an effective batch solution for single-unit batch processes. Whether your recipes might
one day require multi-unit coordination to produce a batch, or simply grow beyond single-unit batching, any pre-
existing SequenceManager™ operation in the controller can integrate into Rockwell’s full-feature FactoryTalk
Batch® product.

The SequenceManager™ product is a controller-based batch solution built in firmware and programmed using
Logix Designer. As a firmware solution, the memory footprint is greatly reduced when using
SequenceManager™ over other custom batch solutions while the speed of execution is unmatched. As a
controller-based solution, batch cycle times for an operation can be reduced due to less dependency upon
communications outside the controller’s backplane.

SequenceManager™ is part of Rockwell’s scalable and integrated batch solution story. SequenceManager™
helps facilitate the building of unit operations within the controller. It is analogous to an operation within the S88
“Procedural Control” model. It is the latest part of Rockwell’s batch solution story that builds upon Rockwell’s
existing integrated batch technology within the controller - PhaseManager™.

For a while now, PhaseManager™ has been a part of Rockwell’s premier integration for scalable batch with the
FactoryTalk Batch® product. It has been a Rockwell offering since version 15 for ControlLogix. It provides
premier integration of S88 equipment phases in firmware. A PhaseManager™ S88 enabled equipment phase
integrates easily with Rockwell’s FactoryTalk Batch®, and now, the SequenceManager™ product.

Let’s get Started - Running a Sequence in FactoryTalk View SE

Initially, let’s quickly explore the different displays within this demo to better understand S88, the process, and the user interfaces
(UI) within this HMI for process and batch. Once familiar with the batch process displays, experience the full user interface (UI)
by running several unit operations previously built using SequenceManager™. These unit operations in the controller are called
equipment sequences.

1. To begin, the Process Overview display should be full screen on your desktop. To illustrate the use of
SequenceManager™ in this lab, it will be limited to the single unit named, Premix 1:

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2. The ‘Premix 1’ unit has been pre-designed with two controller-based equipment sequences (single-unit
operation recipes) using SequenceManager™. On the ‘Process Overview’ display, click on the ‘Premix 1’
button in the display’s navigation menu bar shown below,

Or simply select the “Premix 1” unit label on the equipment display,

Either action will cause the display to navigate to a detailed process display for the ‘Premix 1’ unit as shown,

Observe the overall process detail display above. It shows the various control module equipment (i.e. valves, pumps,
motors, etc.) associated with the Premix 1 unit, and both, upstream and downstream, flow paths. These control modules
come from the Rockwell’s library of process objects (version 3.5). The newer library, version 4, was employed in a different
batch lab labeled, “Distributed Batch Deploying Controller-based Sequences with FactoryTalk Batch.”

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 In the Premix 1 process display at the right of the Premix 1 tank object, observe the ActiveX control which is the ‘Sequence
Summary’ ActiveX control,

This ActiveX control is a recipe list box showing all pre-built equipment sequences for the Premix 1 unit. It has built-in
command buttons to take ownership and command an equipment sequence. In laymen terms, one might think of it as a
batch list or master recipe list for all batch operations built within the controller.

Observe the display navigation menu bar which allows one touch navigation to other important process and operational
displays that an operator might need such as Premix 3, Reactor 1, etc. Notice that none of these other unit displays provide
any batch interface to sequences like Premix 1 display; no equipment sequence exists for these other units.

3. Select the ‘Sequence Controls’ button in the display menu bar next to the ‘Premix 1’ button
.

This will launch a pop-up display that provides full control of the equipment sequences within the controller. This
pop-up display uses Rockwell ActiveX controls for the SequenceManager™ UI designed exclusively for use in
FactoryTalk View with premier integration up to version 31 of the Logix firmware.

This pop-up display uses all three SequenceManager™ ActiveX controls (e.g. sequence summary, sequence
detail, and sequence parameter) that are available for download on Rockwell’s PCDC website. Each control is
designed for a specific purpose within FactoryTalk View SE providing full operational control of
SequenceManager™ equipment sequences. These controls provide all the same operational functionality that
exist within Logix Designer for SequenceManager™ as shown below,

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 In this pop-up display, each control is named in bold by its referenced name at the top:
• Sequence Detail Control
• Sequence Summary Control
• Sequence Parameter Control

Note: The SequenceManager™ ActiveX controls only work in FactoryTalk View SE, other HMIs are not
supported with these controls. External command exists for SequenceManager™ that can provide other HMI
an interface with limited use and functionality of an equipment sequence. Currently, these controls work with
View SE and the L7 Logix firmware between versions 28 and 31.
FactoryTalk Batch® version 13 integrates with SequenceManager™ starting in version 29 firmware for the L7
controllers.

4. In the ‘Sequence Summary Control’ ActiveX, select the equipment sequence, ‘Premix_01_Prod_A,’ by
double clicking on it. Selecting a sequence will give the sequence focus and activate command buttons that
are relevant for the sequence such as, the “Take Ownership” button or others listed in the command button
menu.
Selecting a sequence will link all other ActiveX controls such as, the ‘Sequence Detail Control’ to this sequence. Unlike
legacy ActiveX controls, this linkage is aided by minimal VBA code in the display. The controls are designed to
automatically synchronize with the logon user of the FactoryTalk View client. The context within the other controls will be
link to the selected equipment sequence.

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 Whenever a sequence is owned by an operator, commands become enabled within the control to reflect any
valid S88 command option to the HMI logon user. These command options will change dynamically to always
enforce the ANSI/ISA-88.01 state rules for batch and the FactoryTalk security permissions of the logon user.

Again, the sequence summary control provides a list of available single-unit recipe operations, or equipment
sequences that were pre-built using SequenceManager™ within a controller through Logix Designer. These
sequences may be used by an operator, or a program, or FactoryTalk Batch®:

8. Quickly observe some of the information and control features within the ‘Sequence Detail Control’ since a
sequence was selected,

The ‘Sequence Detail Control’ allows similar operator commands as seen in the ‘Sequence Summary Control’ (e.g. start,
stop, hold, restart, abort, pause a sequence, etc.), but extends the feature set by providing a means for active-step changes

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 within the sequence, forcing a transition state to be true within the sequence, or running a phase in manual mode. To
explore these additional features at a later time, please reference Appendix E: “Advanced Operator Interactions with
SequenceManager™” for more details.

Note: Auto scroll is a visualization enhancement that will automatically move the SFC view for the active
phase step(s) as the recipe sequences onward, usually a top-to-bottom direction. To experience the same
auto-scrolling feature in Logix Designer, it must be enable through the menu ‘Tools>Options…’ setting.

9. Take a closer look at the steps within the sequence. Each step has a direct link to a PhaseManager™ phase
within the controller. The name at the top of each step is an alias assigned by the recipe author when a step is
added into a sequence. One may think of this alias as a descriptive label for the operators since it will be the
name for the phase step that appears in the operation level procedure, or recipe. The name shown in the middle
of the step is a linked PhaseManager™ phase that exist within the controller. For example, look at the step
labeled Addition_01 in the ‘Sequence Detail Control’ snippet shown below,

Find this step’s controller linked PhaseManager™ phase in the Studio 5000 Logix Designer snippet below:

.
The PhaseManager™ phase, PM_ADDITION_01, is linked by the equipment sequence step, Addition_01.
Notice the various state routines for the PhaseManager™ equipment phase (e.g. Running, Holding, Restarting, etc.). These
fully support the S88 standard.

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10. In the sequence summary control, select the sequence ‘Premix_01_Prod_B’ by double-clicking on it:

11. Observe the 3rd control titled, “Sequence Parameter Control” in the pop-up display. This control will display
tags for the sequencing parameters and step tags within the selected sequence – you’ll learn more about these
tags shortly. For now, select the filtering list box drop-down, “Show: All,” at the lower left corner:

This ‘Show: All” drop-down box provides filtering options for quicker sorts on all parameters, or smaller subsets of
parameters such as only those associated with sequencing parameters, step tags, selected steps, or active steps:

Note: there are no active steps since the recipe was never started.
Select a filter option of Show: Step Tags,

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Please notice usage type as either, ‘Step output,’ or ‘Step input,’ as defined under the ‘Usage’ column.

One may think of a ‘step output’ type tag as a report value for the equipment phase such as an amount totalized at the end
of a material addition task. Whereas, a ‘step input’ type tag can be thought of as an operating parameter or recipe formula
for control modules associated with the equipment phase such as a set point value to a PID controller, or an amount target
setpoint for a totalizer. The step input tags will hold recipe specific parameters for the process to help create the product
desired. This product could be a stand-alone finished product, or an intermediary product to a larger batch control system
using multiple upstream and downstream units under FactoryTalk Batch® control.
Also note that sequence step tag names will begin with the sequence step name, or alias. Observe the sequence step
output tag, Addition_01.ACTUAL_01, where ‘Addition_01’ is the sequence step name (green) as shown below:

The sequence step tags are linked to the input and output tags of their correspondingly linked PhaseManager™ equipment
phase. For this ‘Addition 01’ sequence step, the linked PhaseManager™ equipment phase is named, PM_ADDITION_01.
The next component part to complete the step tag name comes directly from the equipment phase parameter named,
ACTUAL_01, within the controller’s equipment phase, PM_ADDITION_01, and shown below (green):

Sequencing parameter tags names are different than the step tags. Similarly, they may exist as “Input” or ‘Output’ type
tags, but they do so without the need for the ‘Step’ name component, or the equipment phase parameter. This makes
sense when you consider that these parameters exist one layer higher in the ANSI\ISA-88.01 procedure model – the unit
operation level, not the phase, or step level within the operation. Let’s explore this more by filtering on the ‘Sequencing
Parameters.’
The sequencing parameter named, A_OR_B, is displayed for the ‘Premix_01_Prod_B’ sequence as shown below,

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Try changing the “Show:” filter to observe differences in what is shown for each filter (e.g. All, Active Steps, Selected steps,
Step Tags, and Sequencing Parameters),
The ‘Value’ column presents a parameter’s current value. Any idea why the ‘Step output’ tags have a symbol in
their row:

This symbol, indicates that a value has not been provided, or assigned to the step tag defined as a step output. This
will change whenever the step completes, and values are reported for these step tags.
The ‘Initial Value’ is a value that can be loaded into the adjacent value column whenever the ‘Initialize Tags’ command is
used before running a sequence. Both the ‘Value’ and ‘Initial Value’ tags are editable for a ‘Step input’ tag when the
external access property is set for ‘Read/Write’ tags.

Note: Appendix A contains a description explaining each of these sequence parameter columns.

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12. Enough said for now, it’s time for a little activity. Start with the first sequence in the list, select it by double-
clicking on the ‘Premix_01_Prod_A’ sequence within the sequence summary control,

Within the sequence detail control, try changing the zoom control from 100% to 80% to watch the SFC shrink,

Please click on the Take Ownership button to acquire the ‘Premix_01_Prod_A’ sequence, which will give you,
the acting operator, complete control to command the sequence. Notice that the Owners setting went from “None” to
‘Operator’ in both controls below,

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13. Notice in the sequence detail control when ‘Owners’ become ‘Operator,’ the ‘Set ID’ and ‘Start’ buttons
have become active options for the operator to choose,

14. Setting a sequence ID is optional, but suggested. Try this by clicking on the ‘Set ID’ button . This action
will display the Set Sequence ID pop-up dialog shown below,

Enter any ID where alpha-numeric and “_” characters can be used like ‘YYYYMMDD_ProdA_Premix_01_A1.
Click the Apply button when done. Each sequence that is started will be assigned an internally generated
unique ID by the controller whether a SequenceID exist, or not.

15. A nice feature in the sequence detail control is the button for Auto Scroll at lower left. When pressed, the active
steps in the sequence will always have focus and be visible when the sequence is running.

Click on the Auto Scroll button once to enable it.

Don’t do this again, it acts as a toggle – disabling the auto-scroll feature.

16. Please move the ‘Sequence Controls’ pop-up display to the right of your screen to expose more of the
process equipment feeding the Premix 1 unit, as shown below:

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17. Try using the sequence summary control within the “Premix 1” unit display to command the selected batch,
Premix_01_Prod_A:

Start the sequence by clicking on the Start button . Watch the process start a raw material feed.

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18. Back to the ‘Sequence Controls’ popup display, notice the Sequence Summary shows the initial step and initial
transition,Tran_000, which have fired, so a start command went to the Addition_01 step and Tran_001 causing
them to go active and running:

When the Addition_01 step goes running, look at the Raw Material 1 process line to observe pump PMP101
and its associate valves and totalizer within the Premix 1 process display,

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 The PhaseManager™ phase, PM_Addition_01, has running logic for the addition of Raw Material 1 into the Premix 1 tank.
Once finished, the Addition_01 step will go to a “complete” state after the material addition of a 100 KG is reached and all
devices are put into a safe state (e.g. valves closed, pumps stopped, etc.). This complete state for the step is simply a
reflection of the PhaseManager™ phase, PM_Addition_01, going to complete.

Next, the sequence will transition to two phases in parallel following the Addition_01 step. These steps are Additon_02 and
Agitate, as shown below:

19. Wait for ‘Addition_01’ to complete. Once ‘Addition_02’ and ‘Agitate’ steps begin running, verify that Raw
Material 2 is flowing into the unit – see that control modules, PMP102 and FQ102, are energized:

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20. Select the Hold command to temporarily suspend the running of the batch,

21. Once the sequence is held, observe that the equipment has been put into a safe state. Raw Material 2
totalizer has stopped totalizing with an accumulated value that should be below the set point value of
100 KG.
Within the sequence parameter control, observe the “Value” for each step output of the Addition_01 phase;
remember, data values were assigned upon the completion of the phase earlier in the equipment sequence execution:

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22. Now, select the ‘Restart’ command button for the equipment sequence,

After restarting, the process should look like this,

Once the Addition_02 step completes, the Addition_03 step will be started while the Agitate phase continues to run,

Upon completion of the delivery of Raw Material 03 by the Addition_03 phase logic, the sequence will transfer to the next
step in series which is the Transfer_Out step. The Agitate phase is not included in transition expression (Tran_003). As a
result, when the transition fires, the sequence will send a stop command to the Agitate phase as shown below,

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23. The ‘Transfer_Out’ phase and sequence step will start running. Observe the unit level begins to decline as the
valve and pump equipment are energized for flow of materials,

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24. This sequence is complete when the ‘Transfer_Out’ phase completes, notice that the end step will turn green
and the state will go to “Complete” for the sequence,

25. Before resetting the sequence to return to an ‘Idle’ state, consider looking at the “Name” and “Value” columns in
the Sequence Parameter control. All the step output tags now have valid values that were populated once each
step completed; they are the reported values for the phases,

26. The ‘Reset’ button will become an active command option in the Detail or Summary controls for a completed
equipment sequence,

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 Click on the ‘Reset’ button to reset the sequence, putting it back to the “Idle” state. When you do this the “Step
output” values will go back to a “no value” condition with the symbol .

27. Click on ‘Release Ownership’ button to release ownership of the sequence. Once released, another
operator, or the FactoryTalk Batch® server could take ownership to run the sequence in the controller for that
unit.

28. There is a second sequence to be run in the Sequence Summary control. Give this a try by double clicking on
the ‘Premix_01_Prod_B’ sequence,

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29. The Sequence Detail Control displays ‘Premix_01_Prod_B’ equipment sequence. This sequence has a different
structured flow path. It has selective branching after the ‘Addition_01’ step. The path will go through ‘Tran_002’
or ‘Tran_003’ depending on the value for the sequencing parameter ‘A_OR_B’ tag. This type of branching must
contain mutually exclusive transitions where only one branch transition can evaluate true at any given time,

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30. Click on the Take Ownership button , then the Set ID button and give the sequence a name of
your choice,

31. In the sequence parameter control, find the Input named, A_OR_B, where the current value is 0. The
sequence requires a value 1, or 2 to transition Change the Initial Value to 2 by clicking in the Initial Value cell
and typing ‘2’, hit the Return key which will bring up a Confirm Change dialog,

Click on the Yes button so the Initial Value will now be 2,

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32. At the bottom left of the sequence parameter control is a list filtering drop-down box labeled “Show:” Please
click on its drop-down arrow to list the filtering options. Click on “Sequencing Parameters.” This sequence
has only one sequencing parameter named, A_OR_B,

Note: An “Input” parameter does not belong to any sequence step; it is an entity of the sequence itself which
contains the steps linked to PhaseManager™ phases.

33. Try different filtering options to observe the result. One option requires that a step be selected by the mouse,
another requires that the step not be idle and unconnected, but active. When done, return the setting to “All.”

34. With “All” selected for the “Show:” filter option, find and click on the “Initial Value” cell for the tag,
Addition_01:SETPOINT_01. Change it to 100.0 - entering 100 into the Initial Value cell, then hitting the
return key, then selecting “Yes” to confirm the change when prompted:

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35. Go back to the Sequence Detail Control and select the More button, this will add another layer of command
buttons,

36. The desired button for our next action is the “Initialize Parameters” button on the left, select it. After selecting
this button, the values within the initial value column are placed into the value column for any “Input” or “Step
input” tag,

37. Observe in the sequence parameter control that the value for “A_OR_B” is the same as the initial value of 2,

38. We are now ready to run this sequence. Like before, move the sequence controls popup display to the right so
you can see the unit’s material addition process equipment, and the SFC for the running sequence.

39. Select the Start button to start the sequence.

The sequence begins by adding “Raw Material 1” as before, but takes the path through transition Tran_003. While the
sequence is running notice that on the expanded command bar there are buttons to pause the sequence, which will pause
the sequence after the current running step completes. There is a button to resume the sequence after a pause or hold and
buttons to do an active step change and force a transition. These are displayed in the screen capture above.
Observe that the sequence takes the path through transition Tran_003.

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40. Let the sequence run to completion and the click the Reset button to reset it, click the Release

Ownership button to release ownership of the sequence.

41. To reinforce everything that’s been learned, please run another product A. Once done, run another product B
recipe using a sequence parameter, A_OR_B, value of 1 instead of 2 to take a different path within the recipe.
This will give you at least 4 recipes to look at in the batch reports.

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SequenceManager™ the Engineer’s Perspective

SequenceManager™ – an equipment sequence in firmware

In this section, you will learn how to run an equipment sequence within Logix Designer as well as, create, and modify a
sequence. You will gain a better understanding for how PhaseManager™ phases are used by SequenceManager™. Lastly, you
may explore how the SequenceManager™ ActiveX controls are configured for use in FactoryTalk View SE.
Let’s understand how SequenceManager’s™ equipment sequence exist in the ControlLogix environment of Logix Designer.
▪ An equipment sequence is a procedure-oriented operation manipulating a finite quantity of ingredients to produce a
finite quantity of product. It is a state driven program, meaning it doesn’t execute with each scan of the controller, but
only when commanded.
▪ An equipment sequence accomplishes a series of actions as a S88 unit operation existing in ControlLogix firmware. It is:
o A new firmware program: An equipment sequence is new type of program.
o A program containing a special SFC routine labeled, Diagram: A special SFC-like language helps build
the order and conditions to execute PhaseManager™ equipment phases in the Diagram routine.
o A program with sequencing parameters: Input and output parameters expose data for equipment phases.
o A program with sequence commands: Special firmware instructions exist for the equipment sequence to
help expose them to program, or external control.

Below, a sequence program is shown in the controller organizer as a new symbol,

Important Note: We do not recommend that any sequence program, or PhaseManager™ phase program exist
within the continuous Main Task. Instead, they should be used as periodic or event task outside the Main Task.

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A new set of controller instructions exist for equipment sequences to command them internally, or externally. These new
instructions are limited and listed below. Unfortunately, the use of these instructions is outside the scope of this lab.

Note: Sequencing instructions are supported in Ladder Logic and Structure Text languages.

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Logix Designer SequenceManager™ Environment for Equipment Sequences

Explore the Logix Designer environment with equipment sequences.

1. Close the FactoryTalk View Client by clicking on the X on the top far left and clicking ‘Yes’ when prompted,

2. Launch Studio 5000 from the desktop, , by clicking the Studio 5000 icon. Open the recent project,
SMgr_PlantPAx_v3_5_2019.ACD, in Logix Designer as shown below,

It will open in the Offline state, change to Go Online,

It should change mode:

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3. On the left side of the screen is a Controller Organizer, find the “UP_Premix_01_FTBatch” task to open as
shown below,

This periodic task contains specialty programs from both, PhaseManager™ and SequenceManager™ products, that
allowed you to operate the previous batches. We are briefly reviewing the underlying code for these batches to provide you
some context for better understanding in the next few steps. These equipment sequences were originally created to run
with FactoryTalk Batch®, but they can be used independent of FactoryTalk Batch® as we have been doing in this lab.

4. Expand and observe a PhaseManager™ phase inside the “UP_Premix_01_FTBatch” task. In particular, the
PhaseManager™ phase, PM01_RECIRC, and the equipment sequence program, Premix_01_Prod_B,

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 Each PhaseManager™ phase may contain state routines that enforce the S88 state transitions, and a pre-state routine that
always scans prior to any state routine evaluation, and finally, local tags.
A SequenceManager™ equipment sequence consists of only two items - the “Parameters and Local Tags” folder and the
“Diagram” routine.

5. Expand the program, PremIx_01_Prod_A, and double click on “Parameters and Local Tags” to open the
Monitor Tags / Edit Tags window,

Notice, there is a column named, “Sequencing,” between the “Usage” and “Value” columns. This “Sequencing” column
only appears for PhaseManager™ phases or equipment sequences within ControlLogix. Whenever sequencing is selected
for a tag, the tag can be accessed externally. In this example, none of the sequencing check boxes are checked as a
default which means the tags are local to this sequence only,

6. Double click on “Diagram” to open the sequence diagram at the right,

When online, the new diagram view has a similar look and feel as the sequence controls that were used before to run
equipment sequences as batches for the Premix 1 unit. Notice the command menu for buttons such as, take ownership,
set the sequence ID and command the sequence at the top of the SFC diagram. The large middle section is the sequence
diagram and the very bottom is the Tag Editor. Use the scroll bar on the right you can see that each step in the
equipment sequence that is linked to equipment phases within the task,

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 The command menu provides all the command button functionality to allow you to use Logix Designer to fully leverage and
command an equipment sequence.
Now, let’s switch to another project that controls a different part of the plant. It uses a different HMI server, and a different
controller with a different project file.

7. Close the current project that’s open by selecting File -> Close from the menu options. Once closed, open the
SeqMgr_Soup_2019.ACD by selecting it from the recent list,

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8. The newly loaded project file will be in Offline mode, please change this to Go Online,

9. The mode should change to Rem Run,

Can you find the equipment sequences under the Controller Organizer, and what controller task(s) are they under?
Is the Main Task where SequenceManager™ equipment sequences and PhaseManager™ phases should be located? No.
Please see the following note:

Note: These equipment sequences and phases should never be put under the Main Task (continuous). This
was done in this demo to illustrate what not to do; these programs should exist under periodic or event tasks.

It might be obvious that this project consists of 3 SequenceManager™ equipment sequences:

Premix_1_Vegetable_Soup;
Premix_2_Vegetable_Soup;
Premix_1_Clean.

The remaining programs within the main task are the PhaseManager™ phases used by these equipment sequences.

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10. Launch the other HMI client for “Soupline” by double-clicking the shortcut on the Windows desktop labeled
“Soupline Demo,”

=>
This HMI client interface should be displayed once the client loads. It is a very simple display that uses the 3 ActiveX
controls for SequenceManager,

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Understanding more about Equipment Sequence

The current need is to create a new equipment sequence for the production team. It will be a “Premix_2_Clean”
sequence. Before creating the new equipment sequence, briefly explore the existing equipment sequences
while learning how to use Logix Designer to run them. Remember, you have already explored how to use the
View SE HMI control display to acquire, command, and observe the controller sequences while watching the
process equipment respond in the other process demo.

Before creating the new sequence, take a moment to examine an existing sequence to learn more about a very
powerful feature that was not observed in the previous demo. In running the recipe for this new process, there
will be an opportunity to observe a simulated process failure, and to recover from it as an operator.

1. Expand the sequence, Premix_1_Vegatable_Soup, by a double-click on Diagram to open it in the design

window at the right,

This equipment sequence, Premix1_Vegetable_Soup, uses an advanced feature of SequenceManager™ that

has not been reviewed in detail - expressions. Let’s take a minute to understand more about expressions…
A powerful capability for parameters in a sequence is called, expressions, which extend capabilities beyond the standard
value assignment to a parameter. Expressions can provide complex operands as well as references to other controller tags
allowing for more dynamic process influences to determine a value at any given time. Look at the blue highlighted

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 expression in the screenshot above for the Premix_1_Vegatable_Soup sequence, and step input, Add_Boullion:Amount
shown above.

An expression for this “Add_Bullion:Amount” tag references another steps input tag to determine its value. In this
expression, “Add_Water:Actual_amount.Value * 0.25” was configured, what is going on? This expression is referencing
the step output value from the previous phase named, ‘Add_Water,’ to determine the correct concentration of material for
the ‘Add_Boullion_Amount’ step’s input parameter – a 25% ratio.
Let’s examine another use for an expression. Please change the tag filter to show Sequencing Parameters,

which provides…

Notice, there are two usage type (Input) sequence parameters and one usage type (Output) parameter.

The input tag for the one named, Type_of_Soup, is used in the sequence (recipe) to determine the kind of soup to make -
Cajun or Home-style. The input tag named, Target_Soup_Amount, is the set point for how much soup to make. Finally, the
output tag named, Actual_Soup_Amount, receives its value from an expression to reference the ‘Empty_Tank’ equipment
phase tag named, Actual_Amount, that records the actual amount of soup transferred from the unit once it is empty.

Note: Sequence input and output tags don’t show up in the previous standard batch reports. Only step input
and step output tags associated with the PhaseManager™ phase will show up in these reports. Why?
These reports were created long before SequenceManager™ was ever conceived, but after
PhaseManager™. So, two new batch reports were added to the FactoryTalk Batch version 13 collection.

2. It is now time to schedule and start a recipe manually within Logix Designer. Manually change the sequencing
parameter named ‘Type_of_Soup’ to have an ‘Initial Value’ equal to 2 for ‘HomeStyle’ as shown below:

Enable Logix Designer’s ‘Auto-Scroll’ feature, select Tools\Options…

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 Select the ‘Equipment Sequence Editor,’ then enable checkbox for Auto-Scroll,

Select OK.

3. Observe the command and status bar shown below. Running a sequence from here is nearly identical to
running it from the sequence controls (ActiveX) within a FactoryTalk View SE display. Select the “Take
Ownership” button to acquire the sequence. There is one difference, a prompt will popup asking for intent to
take ownership of the sequence,

Select Yes to take ownership.

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4. Next, give the sequence any ID you would like. Select the ‘Set Sequence ID button,’ and enter your ID in
the text window (see blue highlighted text), and hit enter on the keyboard to apply the value as the new
Sequence ID. In this example, the text entered is highlighted in blue,

Notice the value entered is shown at lower right of the command bar,

5. Previously, the ‘Type_Of_Soup’ sequence parameter’s initial value was set to “2,” for home-style soup. Now,
click on the Initialize values…button to move the new initial value into the “Value” column,

6. Scroll down to the bottoms of the parameter display to confirm the new value was updated to replace the old.
Before:

After Initialize it should be updated as seen below:

If the old value is present on the display before and during the Initialize command, you will need be sure the mouse cursor is
off the Initial Value cell, or Value cell, otherwise the update will not be seen.

7. Click on the Start button to start the sequence and watch the recipe until it stops running.

The ‘Add_Homestyle_Spice’ equipment phase (sequence step) was coded to experience a one-time initial
phase failure. Phase failures are potential process condition which the process engineer anticipated in the
design of the equipment phase to monitor during execution. These would be abnormal situations that could
require attention during the running of a sequence.

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 A phase failure occurs when a PhaseManager™ “PFL” instruction is energized for an equipment phase upon some

abnormal process condition existing. A white flag in a red circle is the symbol for this type of undesired phase failure.
As the sequence transitions from states of running to holding to held following a phase failure, usually, other actively running
equipment phases within the same unit operation are commanded to hold and their control modules commanded into a safe
state. The process temporarily suspends in the recipe execution, until the abnormal process condition is alleviated.

8. To resume a sequence following a phase failure and the Held state, select the Clear Failure button in the
command bar. In real life, an operator would do an action to correct the failure condition first.

The phase can be programmed to return to a similar point in the running logic it was operating at the time of the failure. It
can also be to go other places in the running logic, or even start from the initial step of the running logic.

9. Once the failure is cleared select the Restart button to restart the sequence.

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10. When the sequence is complete, look at some of the data (e.g. step tags). Notice, the step tag output values
are populated with data that the PhaseManager™ phase reported such as, actual amount added.

11. Time to complete our use for this sequence. Please select the Reset button to reset the sequence. Now,
notice the data for the sequence is reset to the defined initial value,

Changes to…

Also, notice that the last values set for the sequence parameter (e.g. Type_Of_Soup) is unchanged. A sequence
maintains the last parameter setting(s) as shown below,

11. Click the Ownership button to release ownership,

Note: If this system used FactoryTalk Batch, and the ownership of a sequence was acquired and owned by
the operator, then the FactoryTalk Batch® server would wait indefinitely trying to acquire the resource –
waiting until it is released by the operator before obtaining ownership to command.

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Create a New Sequence
In this part of the lab you will create a new sequence to clean Premix 2 tank. All the equipment phases that are needed exist
since no new processing equipment was added to the unit or area. Due to the modular benefits of the S88 batch standard,
simply creating a new sequence. The pseudo steps in this sequence have been determined by R&D and engineering to be the
following:

1. Add water using the Add_Liquid_PM2 equipment phase.

2. Add detergent/sterilizer using the Add_Small_Tanks_PM2 equipment phase.
3. Agitate the solution until the equipment is clean using the Mix_PM2 equipment phase.
4. Drain the tank, use the Dump_PM2 equipment phase.

The sequence will require an Input for the amount of water needed. Using expressions, you will configure this sequence input
parameter and reference it to the amount value of other ingredients used by the material addition phases.

When you assign a phase to a step, the editor automatically generates all necessary step tag and links them to its associated
phase parameter. It is clear to the control engineer that each step input tag must have data to pass to the phase for it to
run. Just fill in the required data, or configure an expression to get the data from other derived sources and tags. Similarly, step
output tags receive data from the equipment phase recording what actually happened in the process.

1. Go offline with the project. In Logix Designer, click on Rem Run ->Go Offline.

2. Right-click on Main Task and select Add->New Equipment Sequence.

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3. The New Equipment Sequence dialog opens, enter “Premix_2_Clean” for the new sequence name and click
OK.

4. The new sequence has been added to the Main Task and since the Open sequence diagram check box was
checked the sequence diagram opens up.

5. Expand Premix_2_Clean by clicking on the plus sign,

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6. Click on Tran_000 + to give the transition the focus.

7. Notice the action toolbar . Add a step and transition

by clicking on the “Add Step and Transition Pair” button to add the following in the sequence design
area,

Notice that all connections were automatically made and the step is assigned a default step name, “Step_001” which has
focus, so just type over it with a new step name.

8. Typing ‘Add_Water’ renames the step. Click off the step to confirm your edit. This default transition condition
will be automatically assigned to the newly added transition with the step name reference, but this transition
expression can be changed anytime during editing.

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9. In this step, assign the appropriate equipment phase by double clicking on ‘Phase…’, then single-click to
enable the drop-down list of PhaseManager™ phases. Scroll down to select Add_Liquid_PM2. Click off the
phase to complete the linking, as well as, the edit.

10. The ‘Add_Water’ step no longer contains the “X” with the red circle because all required connections are made,

11. Notice the step tags (input and output) were created automatically in the Tag Editor as seen below,

The new step tag name is generated by a combination of the step name, ‘Add_Water,’ a colon, and lastly, the equipment
phase parameter name. Also, the new step tag data type (SEQ_REAL) is matched with the associated equipment phase
(Add_Liquid_PM2) parameter type.

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12. Add another step by selecting the Tran_001 transition, then click on the ‘Add Step and Transition Pair’
button as before.

Name the new step, ‘Add_Soap’ and associate it to the phase named, ‘Add_Small_Tanks_PM2’

Becomes…

The newly created ‘Add_Soap’ step tags (Input and Output) were created automatically as shown below,

13. Select the Tran_002 transition to add another step below it by selecting the ‘Add Step and Transition Pair’
button. Name the new step, ‘Scrub,’ and associate it to equipment phase, Mix_PM2, as seen below,

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14. Finally, add the last step in series, ‘Empty_Tank,’ just as you’ve done before. Associate the equipment phase,
‘Dump_PM2,’

15. Optional, you may skip to the next step. If at any time a connection is broken between a step and a transition,
click the circle of the transition and with the left mouse button pressed, drag it to the semi-circle of the step (the
final step in the screen capture below). The circle or semi-circle will turn green indicating when to click on
the first point and release the button when on the second point. For simultaneous and selective bars you drag
the cursor to the bar and it turns green. This is how you connect elements when they are added separately.

16. Optional, you may skip to the next step. If the SFC for the sequence gets too unwieldy, and out of alignment,
there is a built-in feature to help. So, click and drag one of your steps to the far right, and click off of the
step onto the whitespace.

Move another step’s transition to the far left, and click off of it. Does your SFC sequence look unpleasing?
If so, fix it by following the next set of instructions…

In the sequence design area, please click on any step, or transition. Now, click Ctrl-A to select all elements
(steps and transitions.) Finally, select Edit->Layout Selected Elements. This will align everything automatically
for you will little effort.

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17. The sequence flow path and steps are correct, but there needs to be some sequencing parameters. In the
sequence tag editor, apply the filter “Show:” for Sequencing Parameters,

Right-mouse click in the empty tag area of the editor, and select New Parameter…

18. Give the new parameter the name ‘Amount_Water.’ The “Usage” will remain “Input Parameter”, “Data Type”
remains “SEQ_DINT” and “External Access” is “Read/Write”. If “External Access’ is set to “Read’ you are unable
to enter data into the tag as was done in earlier steps. Click Create button to create the new tag.

Special data types are

required for parameters tags
because they have special
properties.

Special types….

19. The new parameter has been created.

20. Give the ‘Amount_Water’ tag an initial value of ‘25000’ and select enter on the keyboard,

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21. The tag, ‘Amount_Water,’ is a sequence parameter with the ‘Usage’ type of ‘Input’. Once created you can link a
lower level step tag with this higher level sequence parameter through an expression. Begin by copying the
name of the sequencing input parameter by selecting it and right-mouse click > Copy:

or hot key: Ctrl-C

22. Change the tag filtering to ‘Selected Steps’ and select the ‘Add_Water’ step,

Expand the ‘Name’ or ‘Expression’ column widths, if needed.

23. Instead of giving the step an initial value, select the expression field for ‘Add_Water:Amount’ as shown:

24. Paste or type in the ‘Amount_Water’ sequence parameter name then add the extension ‘.Value’ shown
below:

Click off the entry box cell to another tag’s cell to finalize the new value as shown below,

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25. Select another step, ‘Add_Soap,’ to display all its step tags below,

26. Give the expression a value of 3 for the ‘Add_Ingredient’ parameter to represent soap addition (1=Cajun spice,
2=Homestyle, 3=Soap), type in ‘3’ in the expression box and click off the cell to another tag’s cell to finalize the
edit,

27. Next, create an expression for the ‘Add_Soap:Amount’ step tag as shown below,

Paste, or type in the ‘Add_Water’ sequence input tag** and add the ‘.Value’ extension and multiple it by 7% of
the mixture, so multiple it by ‘* 0.07’
** Notice, the entire list of tags to select are the same as what is listed in the equipment sequences ‘Parameters and Local
Tags’ folder:

Only tags listed here may be used

for reference in an expression.

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30. Click off the expression cell to another tag’s cell to finalize the edit,

31. Think about what you just did. You made the formula input for the soap amount dependent upon a percentage
of the recipe formula value for the desired water amount. Could there be a better option to improve upon this
idea?

How about making the soap amount dependent upon the actual amount of water (step output tag) added to the
unit rather than the amount of water (step input tag) desired? Wouldn’t this create a more accurate mixture in
the end? The answer is, yes.

To make this improvement, change the expression for the ‘Add_Soap:Amount’ to use
‘Add_Water:Actual_Amount.Value’ as shown below,

Finalize the edit by selecting off the expression cell to another cell,

32. Now, select the ‘Scrub’ step, click on the Initial Value cell for ‘Scrub:Mix_Time’ and enter a constant value ‘40’
directly into the step input tag,

33. Click the ‘Verify Controller’ button to verify the project, then save your project by clicking the Save
button,

then,

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 then,

For how to do an on-line update of a newly built equipment sequence, see Appendix B. It documents
exporting a new equipment sequence, then importing it into a running controller. This will work for a physical,
or real controller, but unfortunately, our virtual controller through Logix Emulate does not allow this without
taking the controller offline.

34. This draws to an end the completion for your lab If you have extra time, feel free to download the saved .acd file
to the controller, and run the new equipment sequence as shown below,

Another option is to continue onto the next section to learn about our standard batch reports using SQL Server reporting
services (SSRS). This does not include the two new reports for batch.

Reminder – complete any surveys for this lab, thank you!

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SequenceManager™ a Manager’s Perspective (an extra-time section)

Each sequence can create an electronic batch record (EBR). Some pre-existing EBR data from your sequences has
been logged into a SQL database by services running in the Sequence Manager™ Event Services Console. This
section provides a brief look at the SQL batch reports for the data generated from those sequences.

After the release of FactoryTalk Batch® version 13.0, there was a post-release update for the batch history and
reporting to correct some database anomalies and include two new batch reports. These reports and the new SQL
database are the same FactoryTalk Batch® Reporting installed from the new FactoryTalk Batch® version 13.02
install DVD.

The older database and reports could be created when running the SequenceManager™ Event installation. Those
reports are listed here:

Below is a brief description of each report.

▪ 010 – Batch Listing
o Provides a list of batches that meet a user’s search or query criteria
▪ 020 – Batch Summary
o Offers batch specific summary information on batch data (step time) and set point vs. actual1
▪ 030 – Batch Detail
o Offers batch specific detailed information on batch data (step times, parameters, reports), abnormal state
changes, batch failures, FactoryTalk Alarms & Events, set point vs. actual, and out of tolerance values.
▪ 040 – Material Usage1
o Offers material specific consumption information including: batch that consumed it, quantity and lot
consumed, total consumption over period of search.
▪ 050 – Forward Tracking1
o Enables you to find all batches that consumed a material lot or used a piece of equipment.
▪ 060 – Backward Tracing1
o Enables you to trace all ingredients consumed and equipment used by a specific batch.
▪ 070 – Batch Execution
o Review a specific batch’s step execution times in a bar chart format.
▪ 080 – Duration Comparison
o Compare the durations of multiple batches in a bar chart format.
▪ 090 – Batch Exceptions

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 o Review all batches with exceptions. Includes abnormal state changes, FactoryTalk Alarms & Events, batch
failures, out of tolerance values1

Note: The Knowledge Base AID # 62367 has a link to download the Batch Reporting application containing a
user manual describing the Batch Reports in detail. Previously, to install the sequence report application go
to the Product Compatibility and Download Center and search for SequenceManager™ Event Client. This
PCDC installation will load the older database and reports, not the newer files in the FactoryTalk Batch®
v13.02 batch history database and reports install.

2. In this lab, the FactoryTalk Batch® version 13.02 installation was used to get the newer database and reports.
Rockwell is working to provide a means to get this database and report update without needing the FactoryTalk
v13.02 install DVD. The two new batch reports added are as follows:
• 100 – Operation Sequences
o Provides a new report specifically for operation sequences that are equipment sequences leveraged by
FactoryTalk Batch®
• 110 – Event Summary
o Offers users an ability to search anything in the batch record

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 The new table for batch reports look like this in SQL Server 2016:

3. One way to access the SQL reports is through a link and popup display in the HMI. To observe this, please
click on the Batch Report button on the right side of the menu bar. This will open a display containing a
Microsoft Web browser control pointed to the report’s URL. It can take a few seconds to open the first time,

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4. Please take a look at some of the reports, before moving on to the engineering part of the lab. From the Batch
Reports display, click on the link to the 010-Batch Listing report.

5. This opens up the Batch Listing report. To list all control recipes stored in the database until the current time,
check the Null box next to the Start Time,

Select the View report option at the far right to update the report…

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 Your report should list similar batches shown below plus those that were run earlier in the lab:

Note: The “Batch ID Filter” (Sequence ID in our case) and “Recipe Name” text box and drop down list can be used to filter
the batch list as seen in the following:

6. From this Batch Listing report you can click on Batch Reports to go back to the main browse report page,

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7. A different option for navigating elsewhere is to use one of the icons to the right of the sequence to go straight to
another report.

The four reports links are associated to the links in the Batch Report browse table as:
▪ 020 – Batch Summary
▪ 030 – Batch Detail
▪ 060 – Backward Tracing See note
▪ 070 – Batch Execution

Note: 060 – Backward Tracing report requires use of Material Manager or specific naming conventions
during design of the FactoryTalk Batch® area model. This naming convention can be found in the user
manual for the reporting application. Currently this report and the other material tracking reports will not work
with SequenceManager™ because tags are auto-assigned names that don’t follow the require naming
convention.

Click on the Batch Summary icon for any one of the batches that are listed,

8. This will open the Batch Summary report similar to what is shown below,

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 An equipment sequence is similar to a S88 operation, so the sequence name is place under the “Operation” column. Step
names appear under the “Phase” column. The Batch Summary reports the completion state of the sequence, the sequence
duration, start and end times and the start and end times for each step. Next we’ll look at the detail report.

9. From the Batch Summary report click on the Batch Detail icon, under the Rockwell
Automation logo. This will open the Batch Detail report ahown below,

Some differences in this report over the Batch Summary are the “Recipe Parameter” and “Report Parameter” data which
can be observed in detail for each phase.
Because these reports are standard SQL reporting service report, they could be used as templates, then customized to your
needs.

10. The last report to look at is the Batch Execution report. From the Batch Detail report click on the Batch
Execution icon to open the report shown below. This report shows, using bar graphs how long the operation ran
and how long each step in the operation was active.

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This ends the extra portion of the lab, but for the truly adventuresome, we have more. Several appendices have been added for
further learning. There are sections that expand upon this lab learning new concepts in engineering and operation of equipment
sequences. There are other appendices that provide instruction for the setup of the SequenceManager™ EBR services. These
all could be very helpful if you are currently using, or planning to use SequenceManager.

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Appendix A - Sequence Tag Overview

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Appendix B – Engineering: Making Online updates for new Equipment Sequences
Rockwell’s hard controllers allow for online updates, but Studio 5000 Logix Emulate does not. The following demonstrates how
to export a sequence from one controller, or emulate to import into another controller. This was mentioned in an earlier part of
the lab, but not demonstrated.

1. Right click on Premix_2_Clean and select Export Equipment Sequence.

2. Export to the Desktop.

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3. Select Offline then Go Online with the controller.

4. Select Upload

5. If the system prompt you, you don’t need to save the changes, select No.

6. Go to Logix Designer, right click on Main Task and select Add -> Import Equipment Sequence.

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7. From the Desktop select, Premix_2_Clean.L5X and click Open.

8. The Import Configuration window give you various options and information. We can just accept the default, click
OK.

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9. Premix_2_Clean has now been added to the running controller. This only works in hard controllers, not emulate.
Emulate will require an offline download for the new sequence to be added.

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Appendix C - Engineering: Creating a new Sequence using copying
This might be done when you expand capacity for you existing recipes at the plant by adding a new unit that’s similar or identical
to an existing unit with equipment sequences. The control modules and equipment modules, and even equipment phases would
be similar, or identical as was well. They will be separate and unique unless some already exist as shared equipment.
In this example, building new control modules, equipment modules and equipment phases is outside the scope and time limits of
this lab. Therefore, we will demonstrate how to copy equipment sequences making them unique, but the underlying control
component and simulation will borrow from what already exist.

Copy and Modify an Existing Sequence

Use the editing features of Logix Designer to copy an existing equipment sequence and use it to create a new and separate
equipment sequence.

1. Maximize the Logix Designer window and take the project offline by clicking on Rem Run -> Go Offline.

2. Click on the Logical Organizer tab at the bottom of the Controller Organizer.

3. Expand ‘Premix_1’ and ‘Premix_2 ‘to see the various phases and the equipment sequencer contained in the
folders. Logix Designer’s Logical Organizer is an efficient way to organize equipment sequences.

4. Click on the Controller Organizer.

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5. All the phases and equipment sequences are here too.

6. Select the Premixer 1 phases with a suffix, _PM1,

7. Right click and select Copy.

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8. Right click on the Main Task and select Paste.

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9. The phases have been added. These new copies have a “1” appended to the end of their name.

10. Correct the name by right clicking on a phase and selecting Properties.

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11. Change PM11 to PM3 and click OK when done.

12. Correct the name for the remaining phases with the PM11 suffix to PM3. Upon completing, the new equipment
phases should look like these below:

Note: At this point all the equipment phase programs are copied and names updated, but if this was a real
project the logic implementing their routines would still references Premix_1 I/O. On an actual project the
control engineer would need to update the phase logic so Premix_3 phases are monitoring and controlling
the control modules for the Premix 3 unit. Updating the phase logic is beyond the scope of this lab.

13. Right click on Premix_1_Vegetable_Soup and select Copy.

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14. Right click on Main Task and select Paste.

15. The copied equipment sequence has been added, with a modified name.

16. Right click on Premix_1_Vegetable_Soup1 and select Properties.

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17. Correct the name to “Premix_3_Vegetable_Soup, click Apply when finished. Notice there is more you can do
on this tab, but we will stick to just the name change.

18. Click on the Configuration tab and verify the check box Generate sequence events is checked. This check
box must be checked in order to generate event journals that are archived to the Batch Reporting database.
This is easy to overlook and not caught until you notice the sequences are appearing in the reports.

Also, it is on this tab that you can set the Unit ID, change it to “3” and click OK when done.

19. We now have the desired new equipment sequence,

Let’s change how these are organized in the controller.

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20. Click on the Logical Organizer.

21. Right-click on ‘Logical Model SILC_Training_Project’ and select Add New Folder.

22. The New Folder dialog window opens. Even though the title at the top says New Program, the Use as Folder
check box tells Logix Designer to create a folder.

23. Type in the name “Premix_3” and click OK.

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24. You have now added the folder under which you can organize the phases and equipment sequencer for
Premix_3.

25. Select the PM3 phases, right click and select Cut. Click ‘Yes’ to confirm.

Note: You could also use drag and drop to move the phases to Premix_3 folder.

26. Right click on Premix_3 and select Paste.

27. Do the same to add Premix_3_Vegetable_Soup to the Premix_3 folder. The folder should look like the screen
capture below.

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28. Expand Premix_3_Vegetable_Soup.

29. Double click on Diagram to open the Diagram window,

Note: While the sequence looks like a sequential function chart (SFC), it is actually a sequencing diagram
with special properties and parameters. It is a new component of Logix Designer and the L7x and L3y
controller family.

The equipment sequence is correct, except that it is calling the wrong phases. Since we copied the sequence for PM1 it is
calling PM1 phases instead of PM3 phases.

30. Click on the ‘Add_Water’ phase and double click on the pull-down menu and select the appropriate phase,
‘Add_Liquid_PM3’ in this case.

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31. This is the only change needed for this step. Note that the transition relates to the step name, not the associated
phase name.

32. Using the same procedure, change the phase references in the remaining steps. When finished the diagram
should look like the screen capture below.

33. All the associated parameters and expressions are still good, no need for any changes.

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34. Since the PM3 equipment phases and equipment sequence were re-organized in the Logical Controller they
were placed in the Unscheduled Task folder in the Controller Organizer. Go to the Controller Organizer and
move them to the Main Task. You can Cut/Paste or Drag/Drop to do this task, below we’re showing Cut and
Paste.

35. Click on the Verify Controller button to verify the controller.

36. Select Offline ->Download to download the project to the controller.

37. Select Download when prompted. Select ‘Yes’ when the download is done to put the controller online.

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38 Minimize Logix Designer and expand the HMI window if it has been minimized. Notice that the new
sequences are not displayed in the Sequence Summary control.

39. Click the Reload button to update the Sequence Summary control, the new sequences
are now present.

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40. Double click on Premix_3_Vegetable_Soup, the Sequence Parameter and Sequence Detail control will now
show the parameters and sequence diagram for Premix_3_Vegetable_Soup.

41. If you have time you can enter a value for ‘Actual_Soup_Amount:Initialize Value’ and run the sequence.
Since the phases simulation is simple and doesn’t refer to any real equipment the sequence will run without
issues.

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Appendix D - Engineering: Adding and Configuring the SequenceManager™ ActiveX Controls for FT View SE
In this section of the lab we will take a look at how to add and configure SequenceManager™ ActiveX control in FactoryTalk
View SE. You can download the SequenceManager™ ActiveX controls from the Rockwell PCDC site, search for
SequenceManager™ as shown below. The installation will install the ActiveX controls and a service used by the controls to
communicate with the controller.

1. Start FactoryTalk View SE Studio by going to the desktop and double clicking the Studio 5000 icon or
going to the start page and selecting the Studio 5000 icon as described earlier. From the Recent

Project list select SoupLine , for those with good eyes notice that a FactoryTalk View SE
project icon is two monitors for a View SE Station Network project.

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2. Under Graphic -> Displays double click on ‘soup_line’ to open the soup_line display.

3. The controls are already added to the display, but if you were going to add the controls you would select
Objects -> ActiveX Control…

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4. Next on the display you would outline the location of the control, once the outline is on the display the Insert an
ActiveX Control dialog pops up. Scroll almost to the bottom and you come to the SequenceManager™ controls.

From the dialog you would select one of the controls to add it to the display. This has already been done on our display,
let’s now look at how you configure the control.

5. On the open ‘soup_line’ display right click on the Sequence Summary Control (second control under the
picture of the tanks) and look to the right to see the Property Panel.

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6. Certain properties must be configured in order for the ActiveX control to communicate with the controller, these
properties are common among all 3 controls. The items highlighted below in yellow are properties specific to this
particular control and include column content controls,

Below is a description of the critical communication properties required for SequenceManager™ to communicate with the
controller. Remember SequenceManager™ is a controller-based batch solution and talks directly to the Logix controller.
▪ ControllerPath – this path is specific to the workstation on which the SequenceManager™ Server Service application is
communicating to the controller, it tells SequenceManager™ where the controller is located.
▪ ControllerShortcut – this is the RSLinx Enterprise shortcut to the controller and is created in the FactoryTalk Service
Platform or FactoryTalk ViewSE Studio.
▪ DataServePath – this is the FactoryTalk path to the RSLinx Enterprise data server.
▪ SeqMgrServerPortNumber – the communication port number used by the SequenceManager™ server Service
application, this is set when you install the service and cannot be changed.

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7. If you have time, please examine the properties for the Sequence Parameter Control and Sequence Detail
Control.

8. In order to double click on a sequence listed in the Sequence Summary Control and have it displayed in the
Sequence Detail Control, you need to add a few lines of VBA coding. To do this you need to set the
“ExposeToVBA” property of the control to “VBA Control” which has been done already. Now, right click on the
Sequence Summary Control and select VBA Code.

9. This opens the VBA development environment to the SeqMgrSummaryControl1_doubleClicked subroutine.

Here you enter the following code highlighted below, this has already been done for the project.

Note: The subroutine names will start with the name of the control, which is user configurable.

10. For the “Select Step” filter in the Sequence Parameter Control to work the following line of code is needed for the
SeqMgrDetailControl_stepSelectionChanged subroutine.

11. Close the VBA development window when done looking at the code by clicking on the Red X

upper right corner and then close FactoryTalk View Studio by clicking its Red X.
This complete our look at the SequenceManager™ ActiveX controls, the SequenceManager™ Controls Reference
Manual has more information on how to use the controls.

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Appendix E - Operations: Advanced Interactions with SequenceManager™
The Sequence Detail control provides standard commands (e.g. start, stop, hold, restart, abort, pause a sequence, etc.) similar
to those on the Sequence Summary, but it extends the feature set by providing a means for active-step changes within the
sequence, forcing a transition state to be true within the sequence, or running a phase in manual mode. These will be
demonstrated using the recipe.

1. Next let look at how manual mode and active step change can be used in an abnormal situation. Double click on
sequence Premix_01_Prod_A to select it.

2. Click on the Take Ownership button , enter an ID for the sequence and select the Start button to
start the sequence. Allow Addition_01 to add some material to the tank.

3. We were a little over eager to start the next batch and the premix tank was not been clean-in-place (CIP) before
we started this sequence, we need to abort the sequence before more material is wasted in an off spec batch. Select

the Abort button .

4. This aborts the sequence, but we need to empty the tank, to do this we will do an active step change to the

Transfer Out phase. Begin by selecting the Enter Manual button this changes the sequence’s mode to
Manual. Select the Addition_01 step. When a step is selected while in manual mode it displays the manual phase
control pop-up, which allows you to command the individual step. Looking at the control you see that the command
are the same as the sequence commands.

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 5. Next select the Step Change button which will open the Change Active Steps dialog.

6. Scroll down until the Steps to deactivate: area is completely visible and select the Add button. Which brings
up the Select steps to deactivate dialog box and check the box by Addition_01, click off the step to exit the
dialog,

7. Now select the Add button to the right of Steps to activate:. This opens the Select steps to activate dialog
box. Check the Transfer _Out phase check box and click off the dialog to close it. There was only one step
available for deactivation, but multiple steps available for activation.

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8. We forgot a step scrolling up to the Status: box you see the message Step being deactivated has to be idle.
If you have used FactoryTalk Bath Active Step change feature you will find the status messges in
SequenceManager™ Active Step change dialog more informative than the messages with FactoryTalk Batch®
active step change feature. Look for these features in FactoryTalk Batch® in the future.

9. Go back to the SFC view and postion the sequence so the step and step command dialog are visible and select
the More button. The dialog does a flip and you see five new command buttons, select the Reset button.

10. This clears the Status: message box and now allows the active step change to take place by selecting the
Apply button at the top. You should now see the message that the active step change was successful.

Select the Cancel button to close the Change Active Steps dialog.

11. Scroll down to the Transfer_Out step and select it. The will bring up the maual phase control, select Start
button to start the step. The step will run to completion and empty the tank.

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12. When complete select the More button and then the Reset button to put the step back to Idle.

13. The step is now back in the Idle state, but the sequence itself is still in the Running state. To put the sequecne

back to Idle, first select the Exit Manual button , this puts the sequence pack into Automatic mode

, but the transition is not firing and the sequence state is still Running.

14. There at least three way to get the sequence to go to competion we are going to make use of the Force
Transition feature. First select the transition below the Transfer_Out step. This will enable the Force

Transition button on the far right of the command buttons.

15. Select the Force Transition button. A confirm command dialog will appear, select the Yes button.

16. The transition fires and the sequence goes complete. Select the Reset button to put the sequence back to Idle,
followed by the Release Ownership button to release the sequence. The force transition feature is tool that can
be use to advance a sequence if there is a problem with a transition not firing.

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Appendix F - More Details on SequenceManager™ Archiving
Data from a sequence can be archive to a SQL database. This is done by two services that are installed when you install the
“Sequence Manager Event Services Console”. One service, “Sequence Manager Event Client Service” takes the data from the
controller and writes it to a firmware output (.RAW) text file. The other service, “Sequence Manager Event Archiving Service”
takes the data from the RAW files and parses it to an event journal (.evt) file, which is then archived to the SQL Server database.
The process is shown in the diagram below.

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1. We are going to take a look at the Event Service Console and its configuration setting. If the Event Service
Console is at the bottom of the screen click on it to bring it to the desktop.

If it has been closed follow these steps to open it, right click on Event Services Console on the Desktop
or click the Windows Start Button and from the Start Page right click on the Event Services Console icon

. Select Run as administrator, the Sequence Manager Event Services Console will open and allow
the user to make changes to and command the services.

2. If the services are running click on the Stop buttons to stop them

3. The Console is used to start and stop the service which are set for automatic startup when the console is
installed, we now want to look at the “Settings”. Click on the Sequence Manager Event Client Service
Settings… button.

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4. The setting page for this service opens. Here you see the paths for the raw event files and application log file,
shown are the default paths, the folders shown are created when you install the service. The other boxes,
except the controller path setting contained the default values. The one item that must be configured is the
controller path, this is done by clicking on the Add button and drilling down to the controller, similar to setting the
path in Logix Designer. The service can handle more than on controller.

5 Click the Cancel button to close the settings page .

6. Next click on the Settings button for the Sequence Manager Event Archiving Service Settings.

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7. The settings page for this service opens. The installation creates the folders and fills in the path and setting
except for the “Database Connection String”. To create this string you click on the Browse button, which opens
the wizard to create a new data source. Once the database connection string is configure you would click OK
and the services are ready to run.

8. Click the Cancel button to close the settings page .

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9. Using Windows File Explorer drill down to the ‘ArchivedEventFiles’ folder, follow this path
C:\ProgramData\Rockwell\Sequence Manager\EventServices. This folder contains the event files generated
from the sequences. Files in the “RawEvents’ and “EventFiles” folders are created when a sequence is running
and then deleted once the sequence completes and is reset to idle.

The screen capture below shows part of an event (.evt) file.

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Appendix G - Setting the Event Client Service Controller Path
This section will help set up the SequenceManager™ data archiving. Previously, the FactoryTalk Batch® product v13.02
was run on this machine to install only the batch reporting (database and 11 reports). The same database schema is used
by SequenceManager™ archiving as the other Rockwell batch product, FactoryTalk Batch, to report batch data.

1. Right click the Event Services Console icon on the Desktop or click the Windows Start Button

and from the Start Page click on the Event Services Console icon, , then select “Run as
administrator,”

. The Sequence Manager Event Services Console will open.

2. Click on the Settings… button in the upper right-hand corner of the console display.

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3. This opens the Sequence Manager Event Client Service Setting page. If a controller definition pre-exist
within the “Controller Connection Configuration” list, but it is no longer valid, or the connection “Unknown,”
then delete it. Select the path, then click on the Delete button.

4. Here we can look at adding two different types of connections – one pertinent for the lab, the other pertinent
for a production environment. For this lab it will be a Logix 5000 Emulate connection, the other will be for a
hardware Logix controller.

To add a new controller connection, click on the Add button (next to the Delete button) to
open the ‘Browse For Controller’ popup display.
First shown is a hard controller connection, not something used in this lab:

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For this hardware Logix controller connection, you might select the plus (+) sign next to AB_ETHIP-1, Ethernet.
Next you might click on the plus (+) sign next to IP address (in this case 192.168.1.113) for this particular example to
select the controller slot 01, 1756-L75 Logix5575.
Finally, you might click on the OK button to accept the choice and close the popup display.

As a result, the path to the hard controller is added and you may configure some properties for that connection,

Shown below is another example, but for adding a Logix Emulate connection similar to what we use in this lab. Select
the Add button.

With the ‘Browse For Controller’ popup display shown below, you might select the plus (+) sign next to the AB_VBP-1,
1789-A17/A Virtual Chassis, as seen below:

Next, you might select the 02 controller slot in the Studio 5000 Logix Emulator as shown below,

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Finally, select the OK button to close the ‘Browse For Controller’ popup display.
The controller connection will be set, click OK to accept the defaults,

Once the connection is set, the Sequence Manager Event Service Console will be displayed as shown,

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 The Event Client Service will knows where to find raw sequence data to move to PC storage for the archiving service.
The archiving service will move the sequence data to a SQL Server database with reporting service.
This archiving service is the second part of the above display (bottom half).

5. On the Event Services Console click on the top ‘Start’ buttons to start the Event Client Service. It takes
a few seconds for the Good Connection(s) box to turn green; it will initially show red under Lost
Connections. The following is what is desired about 5-10 seconds after starting:

6. Located at mid-lower right in the Event Services Console display, please click on the red X Settings…

button, to begin configuration for the event archiving service,

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7. The service setting popup display will be presented, select another red X Browse button,
to allow the creation of the Database Connect string,

8. A data source configuration display will popup, select the Machine Data Source tab, and FactoryTalk
Batch® Events which was created previously by installing the reporting database from the FactoryTalk
Batch® v13.00.02 product installation,

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9. Select the OK button to set the ODBC database connect string for the archiving service, as shown below
(red arrows):

Select the OK button to close the Archiver Service Settings display and get back to the Event Services Console
display,

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10. Select the Start button for the Event Archiving service,

11. Once the service is running, you may close the console by selecting the close button,

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 Appendix H - SequenceManager™Help
Online help on how to use SequenceManager™ and PhaseManager™ can be found by clicking on the Logix
Designer Help-Contents menu item and from the Logix Designer Online Help dialog expanding About Equipment
Phase and Equipment Sequences as shown below.

Publication XXXX-XX###X-EN-P — Month Year Copyright© 2019 Rockwell Automation, Inc. All rights reserved.
Supersedes Publication XXXX-XX###X-EN-P — Month Year

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