Rockwell Automation BWEPRO-GR011D-EN-P User Manual

Getting Results Guide
Original Instructions

FactoryTalk eProcedure Getting Results Guide

FactoryTalk Batch Components 14.00
Rockwell Automation Publication BWEPRO-GR011D-EN-P - October 2020 Supersedes Publication BWEPRO-GR011C-EN-P - February 2017
FactoryTalk eProcedure Getting Results Guide
personal injury or death, property damage, or economic loss.
Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous
temperatures.
Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash
for Personal Protective Equipment (PPE).

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to
ATTENTION:
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
BURN HAZARD:
ARC FLASH HAZARD:
will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and
2
Preface
FactoryTalk eProcedure The eProcedure Server
The eProcedure Client

Table of Contents

introduction
About this manual ....................................................................................... 5
Document organization ............................................................................. 5
Legal Notices ................................................................................................ 5
Additional resources ................................................................................... 6
Chapter 1
What is eProcedure? .................................................................................. 11
Benefits of eProcedure .............................................................................. 12
FactoryTalk Batch Components ............................................................... 13
FactoryTalk Batch Server ..................................................................... 13
FactoryTalk Batch View ....................................................................... 14
FactoryTalk Batch Recipe Editor ......................................................... 14
FactoryTalk Batch Equipment Editor ................................................. 15
FactoryTalk Event Archiver ................................................................. 16
FactoryTalk Batch Network Editor ..................................................... 16
FactoryTalk eProcedure Client ............................................................ 16
FactoryTalk eProcedure Server ........................................................... 16
FactoryTalk Batch Material Manager ................................................. 16
Chapter 2
Set up sample demonstrations ................................................................ 20
Add sample FactoryTalk Security users ............................................. 20
Configure sample permissions for FactoryTalk Security users....... 22
Configure the sample FactoryTalk Batch Server .............................. 24
Rebuild the recipe directory ............................................................... 26
Start the Batch and eProcedure Servers .................................................. 26
Start the sample FactoryTalk Batch Phase Simulator ............................ 28
Open the sample demonstration in the FactoryTalk Batch Phase
Simulator ............................................................................................. 29
Verify PCD communications .................................................................... 29
Effects of warm boot on control steps ..................................................... 30
Summary ..................................................................................................... 31
Chapter 3
Run a recipe using eProcedure ................................................................. 34
Check the event journal ............................................................................. 37
Summary .................................................................................................... 38
3
Table of Contents
Introduction to instruction-
eProcedure Glossary
based phases
Index
Chapter 4
Create instruction-based phases .............................................................. 39
Create an instruction file ..................................................................... 39
Custom tags .................................................................................... 41
Assign an instruction file to a phase ........................................................ 42
Include a step verification signature template .................................. 43
Summary ..................................................................................................... 43
Appendix A
4

About this manual

Document organization

Legal Notices

Preface

This information was developed to introduce you to the basics of FactoryTalk eProcedure. This manual is one of a set of related manuals that describe
installing, programming, and operating the FactoryTalk® Batch system.
To review FactoryTalk Batch release notes and latest information regarding product compatibility refer to the
Center (PCDC).
The following subjects are presented in this document:
eProcedure documentation
eProcedure components
eProcedure Server
eProcedure Client
Introduction to instruction-based phases
HTML-Based instruction files
Glossary
Product Compatibility and Download
Rockwell Automation publishes legal notices, such as privacy policies, license agreements, trademark disclosures, and other terms and conditions on the
Legal Notices
page of the Rockwell Automation website.
End User License Agreement (EULA)
You can view the Rockwell Automation End User License Agreement (EULA) by opening the license.rtf file located in your product's install folder on your hard drive.
The default location of this file is:
C:\Program Files (x86)\Common Files\Rockwell\license.rtf
Open Source Software Licenses
The software included in this product contains copyrighted software that is licensed under one or more open source licenses.
5
You can view a full list of all open source software used in this product and their corresponding licenses by opening the oss_license.txt file located your product's OPENSOURCE folder on your hard drive. This file is divided into these sections:
Preface
Resource
Description
Server components.

Additional resources

Components Includes the name of the open source component, its version number, and the type of license.
Copyright Text Includes the name of the open source component, its version number, and the copyright declaration.
Licenses Includes the name of the license, the list of open source components citing the license, and the terms of the license.
The default location of this file is:
C:\Program Files (x86)\Common Files\Rockwell\Help\<product name>\Release Notes\OPENSOURCE\oss_licenses.txt
You may obtain Corresponding Source code for open source packages included in this product from their respective project web site(s). Alternatively, you may obtain complete Corresponding Source code by contacting Rockwell Automation via the Contact form on the Rockwell Automation website:
http://www.rockwellautomation.com/global/about­us/contact/contact.page. Please include "Open Source" as part of the request
text.
F
ollowing is a comprehensive list of documentation for the FactoryTalk®
Batch products from Rockwell Automation.
Installation, Quick Start, and Getting Results Guides
FactoryTalk Batch Components Installation and Upgrade Guide (BATCH-IN002)
FactoryTalk Batch View Quick Start Guide (FTBVS-QS001)
FactoryTalk Batch View HMI Controls Quick Start Guide (BATCH-QS001D)
FactoryTalk Batch eProcedure® Getting Results Guide (BWEPRO-GR011)
Provides information and procedures for FactoryTalk Batch system installation. Includes information for FactoryTalk Batch Material Manager, FactoryTalk Event Archiver, and associated FactoryTalk Batch Client and
Provides information about using FactoryTalk Batch View to create, view, and command control recipes, acknowledge prompts and signatures, view equipment phases and diagnostic information, and view profile information.
Provides a general overview of FactoryTalk Batch View HMI Controls.
Explains the basics of FactoryTalk Batch eProcedure.
6
Preface
Resource
Description
FactoryTalk Batch Getting Results Guide
Introduces the basics of automated batch manufacturing
Resource
Description
FactoryTalk Batch ActiveX Controls User Guide
Provides information and instructions for using the reference for the formulator.
FactoryTalk Batch Server.
(BATCH-GR011) FactoryTalk Batch Material Manager Getting
Results Guide (BWMTR-GR011)
User Guides
(BATCH-UM013) FactoryTalk Batch Material Editor User Guide
(BWMTR-UM001)
FactoryTalk Batch Equipment Editor User Guide (BATCH-UM004)
FactoryTalk Batch PhaseManager™ User Guide (BATCHX-UM011)
FactoryTalk Batch Recipe Editor User Guide (BATCH-UM006)
and the FactoryTalk Batch product components.
Introduces the basics of FactoryTalk Batch Material Manager.
FactoryTalk Batch ActiveX Custom Controls. Provides access to information and procedural
instructions required to configure materials and the containers to hold them. The material data is stored in the material database, which is used to create material­based recipes. This information is intended as a
Provides information on creating and maintaining an equipment database (area model). The area model is stored in a file with a .cfg file extension and is available to all other FactoryTalk Batch programs, including the Recipe Editor, View, and Phase Simulator.
Describes the integration of the FactoryTalk Batch software with the Studio 5000 Logix Designer® application and the Logix 5000™ family of controllers.
The integration simplifies the configuration and maintenance of the FactoryTalk Batch automation system, provides better communication between the FactoryTalk Batch Server and the Logix 5000 controller, and significantly reduces the programming effort required to develop the phase logic code that resides in your Logix 5000 controller.
Provides instructions on using FactoryTalk Batch Recipe Editor to create and configure master recipes for use in batch automation. The interface is based on IEC 61131-3 sequential function charts to graphically organize recipes into procedures, unit procedures, operations, and phases. Build recipes using either the SFC format or a table-based format.
FactoryTalk Batch View HMI Controls User Manual (FTBVS-UM003)
FactoryTalk Batch View User Manual (FTBVS-UM002)
Provides details about using FactoryTalk Batch View HMI Controls to monitor and interact with the production process within a FactoryTalk View SE Display Client.
Provides information and procedural instructions for using FactoryTalk Batch View in a modern and intuitive portal into a comprehensive batching solution for effective operations, leveraging its own web server using HTML5 technology to provide native connectivity into a
7
Preface
Resource
Description
FactoryTalk eProcedure Client User Guide
Provides information and procedural instructions
reference information by the operator.
system administrator and production supervisor.
conjunction with a Human-Machine Interface (HMI).
Resource
Description
FactoryTalk Batch eProcedure Administrator Guide
Provides procedures specific to FactoryTalk Batch
operators, such as the FactoryTalk Batch Server.
(BWEPRO-UM011)
Resource
Description
(BATCH-RM001)
FactoryTalk Batch PCD Programming Reference
Provides information and instructions about the
(BWEPRO-UM001)
FactoryTalk Event Archiver User Guide (BATCH­UM012)
FactoryTalk Batch View User Guide (legacy) (FTBVS-UM001)
Administrator Guides
FactoryTalk Batch Administrator Guide (BATCH-UM003)
required to create and command batches using the FactoryTalk eProcedure Client, and can be used as a
Provides information and instructions specific to the FactoryTalk Event Archiver. Intended for use by the
Provides information and instructions on how to use FactoryTalk Batch View to initiate and execute FactoryTalk Batch automation processing. FactoryTalk Batch View secured objects are located in the FactoryTalk Diagnostics and are modified using the FactoryTalk Administration Console. A system administrator can customize FactoryTalk Batch View security to meet the needs of the facility. FactoryTalk Batch View is used in
Provides instructions for configuring security and services, and implementation and use of components not typically accessed or used by batch operators, such as the FactoryTalk Batch Server.
(BWEPRO-UM011)
FactoryTalk Batch Material Manager Administrator Guide
Reference Guides
FactoryTalk Batch ActiveX Controls Library Reference Guide
FactoryTalk Batch Material Server API Technical Reference (BWMTR-RM001)
eProcedure, such as implementing security and configuring the user-defined area Active Server Page. Included are instructions for tasks specific to FactoryTalk Batch, such as configuring security and services to support FactoryTalk Batch eProcedure. Provides instructions on the implementation and use of components not typically accessed or used by batch
Provides information and instructions specific to FactoryTalk Batch Material Manager. Intended for use by the system administrator and database administrator.
Provides reference information and procedural instructions for the FactoryTalk Batch ActiveX Custom Controls.
Provides access to information regarding the interface between the FactoryTalk Batch Material Server and the FactoryTalk Batch Material Editor and FactoryTalk Batch. It is intended to be used as a reference information by those who want to develop custom interfaces.
8
Manual (BATCH-RM004)
FactoryTalk Batch PCD interface design. It is intended to be used as a reference guide.
Preface
Resource
Description
FactoryTalk Batch Server API Reference Manual
Provides information regarding the interface between the
reference by the instruction file author.
(BATCH-RM003)
FactoryTalk Batch System Files Reference Manual (BATCH-RM005)
FactoryTalk Batch eProcedure Instruction File Design Reference Manual
(BWEPRO-RM001)
FactoryTalk Batch Server and FactoryTalk Batch View — the Server Application Programming Interface (API). It is intended to be used as a reference guide by those who want to develop custom interfaces.
Provides the technical information for configuration and maintenance of a FactoryTalk Batch system. It can be used as a reference information for implementation engineers and the system administrator.
Includes information about the building of instruction files for use in equipment database creation and recipe development. This information is intended to be used as a
View or download publications at
http://www.rockwellautomation.com/literature. To order paper copies of
technical documentation, contact your local Allen-Bradley® distributor or sales representative.
9

What is eProcedure?

Chapter 1
FactoryTalk eProcedure introduction
FactoryTalk® eProcedure® is part of the FactoryTalk Batch suite of software components. As part of the FactoryTalk family, the FactoryTalk Batch components increase overall plant efficiency by delivering the visibility, control, and reporting needed to optimize manufacturing. Coordinated execution reduces rework and improves product quality and consistency. Real-time management of equipment utilization maximizes return on assets. Implementing optimized recipes and procedures, increases plant capacity. Using electronic, paperless operations improves productivity. Reduce compliance costs by using electronic batch record implementation, paperless manufacturing, and quality sign-offs. Lifting the compliance burden from manufacturing reduces inventory levels and cycle times, which greatly improves customer service.
The FactoryTalk Batch components ensure that plant floor operations are optimized, giving quick returns on net assets. New product definitions are deployed quickly into manufacturing. Production order information is accurate. Business and plant-level control systems are tightly coordinated and multiple sites operate as a team. Our completely open, configurable set of products helps you define, manage, monitor, and control manufacturing at local, remote, or contractor plants. Best of all, deploy the FactoryTalk Batch components wherever needed (one at a time or all at once) to improve productivity and plant control. The FactoryTalk Batch components include:
FactoryTalk Batch
FactoryTalk eProcedure
FactoryTalk Batch Material Manager
As one of the FactoryTalk Batch components, FactoryTalk eProcedure
manages, sequences and documents the execution of manual operations. Automating batch sheets and standard operating procedures (SOPs) through interactive web documents, eProcedure provides the control needed to rapidly deploy new products into manufacturing and the data collection necessary to achieve true plant floor to enterprise-wide integration. FactoryTalk eProcedure provides the benefits of procedure automation without the expense of equipment automation. The FactoryTalk Batch components incorporate the principles of batch and procedure automation, an approach defined by ISA’s S88.01 standard.
11
Chapter 1 FactoryTalk eProcedure introduction
Without eProcedure
With eProcedure
printout.
When the batch is complete, the completed
When the batch is complete, the electronic batch record
The data can be manually entered into a
The electronic batch record can be automatically
FactoryTalk Event Archiver.

Benefits of eProcedure

FactoryTalk eProcedure automation provides a means to automate the execution of procedural logic associated with recipes, product grade changes, computer setup, and computer shutdown procedures. Operators perform the actions on the equipment, but they are prompted and guided by eProcedure. The procedure specifies the sequence and timing of actions that can be manually performed or performed by automation equipment.
Typical procedures that can be automated using FactoryTalk eProcedure include:
Batch execution
Equipment startup and shutdown
Product changeover
Abnormal condition handling
FactoryTalk eProcedure reduces the amount of effort required to create and
maintain recipes, as well as minimizes the time required to collect and report Batch data.
The following describes a typical recipe execution process, with and without eProcedure:
A master recipe (a collection of SOPs) is maintained in written form. The master recipe includes instructions for the operator, places to enter data, and places for any required signatures.
When a batch needs to be run, the recipe is printed and given to the operator, who reads the instructions, manually sequences the process and enters the required information on the
recipe document is filed.
database for recording and reporting purposes.
A master recipe is created and maintained electronically with the FactoryTalk Batch Recipe Editor. The master recipe includes operator instructions, report data, and prompts for required approvals.
When a batch needs to be run, the operator adds a batch using the eProcedure Client, steps through the instructions, and enters the required data into the system.
contains a complete record of the entire batch process.
transferred to any ODBC-compliant database using the
FactoryTalk eProcedure can be implemented in a completely manual manufacturing facility or in a partially automated facility. With eProcedure, use all manual phases or a combination of manual and automated phases within a single recipe. Regardless of the state of automation, the implementation process is the same.
12
The FactoryTalk Batch Equipment Editor is used to define the process equipment, both manual and automated. The modular approach in defining equipment is as appropriate with manual facilities as it is in automated
FactoryTalk Batch FactoryTalk Batch Server
facilities. As part of the configuration process, attach instruction files to each of the manual equipment modules.
Instruction files are HTML files that include all of the required control steps for a phase. Each control step can include textual instructions, embedded parameter values, report fields for operator input, and submit buttons. Control steps may also include any valid HTML component.
Once the equipment is defined, and the instruction files are created, create recipes in the same fashion as a completely automated facility.
FactoryTalk eProcedure allows the operator to create and command batches from remote computers using Microsoft Internet Explorer. With eProcedure, the operator no longer needs to write processing information on a piece of paper for submission. The operator enters the data directly into the computer where the data is stored in an electronic batch record, which can later be downloaded into your ODBC-compliant database.
Chapter 1 FactoryTalk eProcedure introduction
Components
FactoryTalk Batch comes with several components that interact with each
other to design, create, configure and run batch recipes.
The FactoryTalk Batch Server is the engine that runs FactoryTalk Batch. It is
the component that controls system information, phases and recipes. The server allows integration with process-connected devices (PCDs) and third­party software packages. Prior to opening FactoryTalk Batch View, the FactoryTalk Batch Server must be running and remain active during all batch functions.
The FactoryTalk Batch Server operates as a Windows service, which means that the FactoryTalk Batch Server can be configured to start automatically and that control of the FactoryTalk Batch Server can be given to the Windows Service Manager. Because the FactoryTalk Batch Server runs as a service, it does not require an operator to log on to run. Therefore, logging on or off Windows during operation does not disrupt the performance of the FactoryTalk Batch Server.
13
Chapter 1 FactoryTalk eProcedure introduction
Batch View User Manual (FTBVS-UM002).
FactoryTalk Batch View
FactoryTalk Batch Recipe
This topic describes FactoryTalk Batch View on a Windows desktop system.
FactoryTalk Batch View is the batch recipe initiation and execution program used by the operator of the FactoryTalk Batch Automation Solution system to:
Initiate and control the batch process
Display a graphical representation of a running batch and its
Typically, FactoryTalk Batch View is intended to be used in conjunction with an HMI.
Each FactoryTalk Batch View window can be customized to suit the needs of a specific station:
Tip: The modern FactoryTalk Batch View is an innovative and intuitive user interface for your comprehensive batch solution. It leverages state-of-the-art web technologies with scalable graphics for consistent visualization across all devices and form factors. The zero-install browser simplifies administration and maintenance. As the only native client application that supports the new features in FactoryTalk Batch and eProcedure, it is the client of the future for modern batch solutions. For more information about the new FactoryTalk Batch View mobile solution, view the
FactoryTalk
associated data
Editor
Specify the columns to display
Specify the size of columns and rows
Sort and filter on one field in certain windows
Set the font for each FactoryTalk Batch View window
If the security is enabled for FactoryTalk Batch View, a system administrator can use the password protection option to:
Limit the information that is displayed
Specify the commands that are allowed at a particular station
Using FactoryTalk Batch View, an operator can respond to electronic signature requests that have been generated by report and recipe parameter deviations or by a command execute request.
The FactoryTalk Batch Recipe Editor is used to graphically create and
configure recipes.
The interface is based on IEC 61131-3 sequential function charts (SFC) that graphically organizes recipes into procedures, unit procedures, operations and phases along with any applicable comments.
In addition to the SFC view, the FactoryTalk Batch Recipe Editor offers a table view. Table-based recipes provide a mechanism for creating simple recipes that do not require a complex recipe structure or elaborate transition expressions. Additionally, you can view table­based recipes and edit all recipe parameters without having to navigate between steps.
14
FactoryTalk Batch
Equipment Editor
Chapter 1 FactoryTalk eProcedure introduction
The FactoryTalk Batch Recipe Editor allows you to specify sequences of phases. The actual phase logic must be configured in the process­connected device (PCD) while the interface to the PCD must be configured in the FactoryTalk Batch Equipment Editor.
Recipe reports can be generated in SFC and/or descriptive format.
If Recipe Approvals are enabled in the underlying area model, approval
signoffs are executed in the FactoryTalk Batch Recipe Editor.
When Recipe Version Control is enabled, a version of a recipe (a read- only, numbered snapshot of a recipe) can be saved and protected from further editing. New work-in-progress (WIP) copies of a version allow the recipe author to continue to make changes and updates to a recipe. When a versioned recipe no longer matches the underlying area model, or references a deleted or non-existent sub-recipe, it is marked as obsolete.
The FactoryTalk Batch Equipment Editor is a graphical interface through which a database of process equipment is defined and maintained (an area model).
Components defined in the FactoryTalk Batch Equipment Editor are used to interface with process-connected devices (PCDs) in the facility. During recipe configuration, the area model provides a list of available units and phase classes.
Configure phases and commands to trigger an electronic signature request when a report or recipe parameter is out of range (parameter deviation), or when specific commands are executed on a batch (such as Abort Batch or Active Step Change).
During recipe verification, the area model confirms that the designated equipment is capable of executing the procedures.
During recipe execution, resource arbitration functions use the area model to allocate equipment based on recipe and operator requests.
The area model is available to all other FactoryTalk Batch applications.
In addition to the area model, the FactoryTalk Batch Equipment Editor allows configuration of the following:
Communication functions
Electronic signatures
Enumeration sets
Data servers
Recipe approvals
Recipe version control
FactoryTalk Event Archiver functions
15
Chapter 1 FactoryTalk eProcedure introduction
FactoryTalk Event Archiver
FactoryTalk Batch Network
FactoryTalk eProcedure
FactoryTalk eProcedure
FactoryTalk Batch Material
The FactoryTalk Event Archiver’s purpose is to translate the FactoryTalk Batch
tab-delimited ASCII electronic batch record files to a user-specified file type. These electronic batch record files are maintained separately for each batch created and viewed with a word processor or spreadsheet. Many plants have standardized on one of the many commercially available Relational Database Management System (RDBMS) software packages. We recommend using a high-performance database, such as SQL Server, due to their better robustness and performance. The Archiver collects data from each electronic batch record file and stores it in the specified RDBMS database format.
The FactoryTalk Batch Network Editor is a utility that indicates where other
Editor
FactoryTalk Batch and FactoryTalk Batch Material servers are located on the
network. This network configuration allows for ease of integration with other FactoryTalk Batch components and simplifies the process of reconfiguring a multi-computer system. If FactoryTalk Batch Material Manager is also installed the FactoryTalk Batch Network Editor is also used to indicate the location of the material database.
Client
Server
Manager
The FactoryTalk eProcedure Client computer uses Internet Explorer to enable
operators to run batch recipes.
The FactoryTalk eProcedure Server provides the services to the FactoryTalk
Batch Server to enable the use of HTML instruction files. Prior to opening
FactoryTalk eProcedure Client, FactoryTalk eProcedure Server must be
running and remain active during all batch functions.
FactoryTalk Batch Material Manager is used to track material consumption in
batch recipes. It consists of two components: Material Server and Material
Editor.
The Material Editor provides an interface to help you create the material database, which consists of material, lot, sublot, container, and storage location data. The Material Server provides the communication between the material database and the FactoryTalk Batch Server. During a batch run, information about available containers is presented to the operator for binding decisions. Binding is the process of mapping steps within a control recipe to actual equipment in a plant. After a batch is run, quantities consumed or distributed are updated in the material database for use in inventory tracking.
16
Chapter 1 FactoryTalk eProcedure introduction
The Material Server consists of a group of components that work together to service various applications. The primary applications that the Material Server services are the Material Editor, FactoryTalk Batch Server, FactoryTalk Batch Recipe Editor, and FactoryTalk Batch Equipment Editor. Any third-party application can also use custom solutions based on the exposed Material Object Model (MOM).
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