Rockwell Automation FactoryTalk Batch User Manual

FactoryTalk Batch

PhaseManager

User Guide

FactoryTalk Batch Components 14.00

Rockwell Automation Publication BATCHX-UM011E-EN-P - October 2020

Supersedes Publication BATCHX-UM001D-EN-P - February 2017

User Guide

Original Instructions

FactoryTalk Batch PhaseManager

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 personal injury or death, property damage, or economic loss.

ATTENTION: 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 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: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Preface

PhaseManager

About this manual.......................................................................................	7
Intended audience ......................................................................................	7
Legal Notices................................................................................................	7
Additional resources ...................................................................................	8
Chapter 1
Software requirements..............................................................................	13
What is PhaseManager? ............................................................................	13
FactoryTalk Batch features..................................................................	14
Logix Designer features.......................................................................	15
Logix 5000 Controller features ...........................................................	15
How PhaseManager works in a FactoryTalk Batch system.....................	15
Common Industrial Protocol (CIP) ....................................................	16
Equipment phases in Logix Designer.................................................	17
Equipment phase synchronization.....................................................	17
Integration of FactoryTalk Batch Equipment Editor with Logix
Designer................................................................................................	18
Benefits of using PhaseManager and CIP instead of OPC......................	18
Reduced phase logic programming....................................................	18
Eliminates duplicate equipment phase and tag configuration........	19
Compatible tag data types ..................................................................	20
Open phase logic in Logix Designer from FactoryTalk Batch
Equipment Editor ................................................................................	21
Improved implementation of phase logic routines...........................	21

Area model PhaseManager configuration

FactoryTalk Batch phases in Logix Designer

Chapter 2
Add a Logix5000 CIP data server..............................................................	23
Select a project file - error messages..................................................	25
Edit a Logix5000 CIP data server ............................................................	26
Assign a Logix5000 CIP data server to a phase or sequence..................	26
Assign a data server to all phases in a unit........................................	27
Chapter 3
Synchronize the area model with the project file...................................	29
Save the area model and select a data server ....................................	30
Select phases and synchronize............................................................	31
Review results and save files ...............................................................	32
Results of creating equipment phases in a project by synchronizing
...............................................................................................................	33

Table of Contents

Logix Designer equipment phases in the area model

Open an equipment phase in Logix Designer from FactoryTalk Batch
Equipment Editor ......................................................................................	35
Project file equipment phase changes ......................................................	36
Synchronize to update equipment phases in the project file ...........	36
Updated project file..............................................................................	37
Deleted parameters and reports ........................................................	38
View synchronization issues ....................................................................	38
Cannot Synchronize messages - create or update project................	39
Chapter 4
Synchronize to create phases in the area model .....................................	41
Save the area model and select a data server ....................................	42
Select phases.........................................................................................	43
Select a phase and unit to synchronize ..............................................	43
Create a new phase and select a unit ..................................................	45
Phases in the area model...........................................................................	46
Synchronize to update phases in the area model .............................	46
View synchronization issues .....................................................................	47
Cannot synchronize messages - create or update area model ........	48

Data from FactoryTalk Batch Server

Chapter 5
Phase Logic programming model............................................................	49
Download parameters (input parameters) request ...............................	50
Phase parameter tags array................................................................	50
Types of download parameter requests ............................................	50
Download all parameters (input parameters) ..................................	50
Download a range of parameters (input parameters) ......................	51
Download a single parameter (input parameter)..............................	51
Download the parameters configured for download on start.........	52
Download the parameters configured for download on transfer of
control ..................................................................................................	52
Download report limits.............................................................................	52
Types of download report limits requests..........................................	53
Download all report limits information.............................................	53
Download limits configuration for a single report ...........................	53
Upload report overview..............................................................................	54
Report array..........................................................................................	55
Electronic batch record entries...........................................................	55
Types of upload report requests..........................................................	55
Upload all reports (output parameters)..............................................	55
Upload a range of reports (output parameters).................................	56
Upload a single report (output parameter) ........................................	56

	Table of Contents
	Upload the reports configured for upload on transfer of control	....57
	Upload the reports configured for upload on terminal state ...........	57
	Send message to the operator and clearing message requests...............	57
	Send message to operator values.......................................................	58
	Clear currently displayed message to operator values .....................	58
	Acquire resource request ..........................................................................	58
	Types of acquire requests ...................................................................	58
	Acquire a single resource value ...........................................................	59
	Acquire multiple resource values........................................................	59
	Release resources........................................................................................	59
	Types of release requests .....................................................................	59
	Release a single resource values..........................................................	59
	Release multiple resource values .......................................................	60
	Release all currently acquired resources values................................	60
	Phase communication ..............................................................................	60
	Completion of messages......................................................................	61
	Process send and receive messages ....................................................	61
	Types of messages to other phases .....................................................	61
	Send a message to one or more linked phase values.........................	61
	Send message to one or more linked phases and wait values .........	62
	Message removal .......................................................................................	62
	Cancel a single message......................................................................	62
	Cancel all messages..............................................................................	63
	Receive message from linked phase request ............................................	63
	Download batch data values ......................................................................	63
	Generate an electronic signature request ................................................	65
	PXRQ instruction values............................................................................	65
	How phase tag requests map to PXRQ requests.....................................	68
	Chapter 6
Data from the Material Server	Standard attributes...................................................................................	72
	Material standard attributes ..............................................................	72
	Lot standard attributes.......................................................................	72
	Container standard attributes ............................................................	73
	Custom attributes ......................................................................................	74
	Material custom attribute ...................................................................	74
	Lot custom attribute ............................................................................	74
	Container custom attributes...............................................................	75
	Considerations for writing material phase logic .....................................	75
	Phase process diagram ........................................................................	76
	FEED_COMPLETE report parameter values...............................	79
	Recipe execution requests .........................................................................	79
		5

Table of Contents

Download data from container currently in use ..............................	80
Upload container data into container currently in use....................	80
Download data from material in container currently in use...........	80
Upload material data into material in container currently in use ...	81
Download data from lot in container currently in use......................	81
Upload lot data into lot in container currently in use ......................	82
Download a container selection priority for the current binding...	82
Upload a container selection priority for the current binding........	83
Download sufficient material data ....................................................	83
Material database requests.......................................................................	83
Download one attribute of a material ...............................................	84
Upload one attribute of a material.....................................................	85
Download lot attributes......................................................................	85
Upload lot attributes ...........................................................................	86
Download container attributes..........................................................	86
Upload container attributes ...............................................................	86
Download container priority assignments .......................................	87
Upload container priority assignments ............................................	87
How phase tag requests map to PXRQ requests.....................................	88

Index

Preface

About this manual

Intended audience

Legal Notices

This manual provides usage instructions for the FactoryTalk Batch PhaseManager. It 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 Product Compatibility and Download Center (PCDC).

The information in this guide is for FactoryTalk Batch system designers, process engineers, and control engineers who are using PhaseManager to develop a batch automation system with FactoryTalk Batch and Logix Designer to develop phase logic for Logix 5000 controllers.

PhaseManager can also be used by Logix Designer users who do not use FactoryTalk Batch and only want to create sequence routines and develop code for a specific piece of equipment that may be incorporated into a FactoryTalk Batch system. In this case, see the Logix Designer online help for information on how to use Logix Designer with PhaseManager outside the context of a Batch system.

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.

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

Preface

Additional resources

product's OPENSOURCE folder on your hard drive. This file is divided into these sections:

•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.

Following is a comprehensive list of documentation for the FactoryTalk® Batch products from Rockwell Automation.

Installation, Quick Start, and Getting Results Guides

Resource	Description

FactoryTalk Batch Components Installation and	Provides information and procedures for FactoryTalk
Upgrade Guide	Batch system installation. Includes information for
(BATCH-IN002)	FactoryTalk Batch Material Manager, FactoryTalk Event
	Archiver, and associated FactoryTalk Batch Client and
	Server components.
FactoryTalk Batch View Quick Start Guide	Provides information about using FactoryTalk Batch View
(FTBVS-QS001)	to create, view, and command control recipes,
	acknowledge prompts and signatures, view equipment
	phases and diagnostic information, and view profile
	information.

FactoryTalk Batch View HMI Controls Quick Start	Provides a general overview of FactoryTalk Batch View
Guide	HMI Controls.
(BATCH-QS001D)

FactoryTalk Batch eProcedure® Getting Results	Explains the basics of FactoryTalk Batch eProcedure.
Guide
(BWEPRO-GR011)

		Preface

	Resource	Description

	FactoryTalk Batch Getting Results Guide	Introduces the basics of automated batch manufacturing
	(BATCH-GR011)	and the FactoryTalk Batch product components.

	FactoryTalk Batch Material Manager Getting	Introduces the basics of FactoryTalk Batch Material
	Results Guide	Manager.
	(BWMTR-GR011)

User Guides

Resource	Description

FactoryTalk Batch ActiveX Controls User Guide	Provides information and instructions for using the
(BATCH-UM013)	FactoryTalk Batch ActiveX Custom Controls.

FactoryTalk Batch Material Editor User Guide	Provides access to information and procedural
(BWMTR-UM001)	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 material-
	based recipes. This information is intended as a
	reference for the formulator.
FactoryTalk Batch Equipment Editor User Guide	Provides information on creating and maintaining an
(BATCH-UM004)	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.
FactoryTalk Batch PhaseManager™ User Guide	Describes the integration of the FactoryTalk Batch
(BATCHX-UM011)	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.
FactoryTalk Batch Recipe Editor User Guide	Provides instructions on using FactoryTalk Batch Recipe
(BATCH-UM006)	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	Provides details about using FactoryTalk Batch View HMI
(FTBVS-UM003)	Controls to monitor and interact with the production
	process within a FactoryTalk View SE Display Client.

FactoryTalk Batch View User Manual	Provides information and procedural instructions for
(FTBVS-UM002)	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
	FactoryTalk Batch Server.

Preface

Resource	Description

FactoryTalk eProcedure Client User Guide	Provides information and procedural instructions
(BWEPRO-UM001)	required to create and command batches using the
	FactoryTalk eProcedure Client, and can be used as a
	reference information by the operator.
FactoryTalk Event Archiver User Guide (BATCH-	Provides information and instructions specific to the
UM012)	FactoryTalk Event Archiver. Intended for use by the
	system administrator and production supervisor.
FactoryTalk Batch View User Guide (legacy)	Provides information and instructions on how to use
(FTBVS-UM001)	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
	conjunction with a Human-Machine Interface (HMI).

Administrator Guides

Resource	Description

FactoryTalk Batch Administrator Guide	Provides instructions for configuring security and
(BATCH-UM003)	services, and implementation and use of components not
	typically accessed or used by batch operators, such as
	the FactoryTalk Batch Server.
FactoryTalk Batch eProcedure Administrator Guide	Provides procedures specific to FactoryTalk Batch
(BWEPRO-UM011)	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
	operators, such as the FactoryTalk Batch Server.
FactoryTalk Batch Material Manager Administrator	Provides information and instructions specific to
Guide	FactoryTalk Batch Material Manager. Intended for use by
(BWEPRO-UM011)	the system administrator and database administrator.

Reference Guides

Resource	Description

FactoryTalk Batch ActiveX Controls Library	Provides reference information and procedural
Reference Guide	instructions for the FactoryTalk Batch ActiveX Custom
(BATCH-RM001)	Controls.
FactoryTalk Batch Material Server API Technical	Provides access to information regarding the interface
Reference	between the FactoryTalk Batch Material Server and the
(BWMTR-RM001)	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.
FactoryTalk Batch PCD Programming Reference	Provides information and instructions about the
Manual	FactoryTalk Batch PCD interface design. It is intended to
(BATCH-RM004)	be used as a reference guide.

		Preface

	Resource	Description

	FactoryTalk Batch Server API Reference Manual	Provides information regarding the interface between the
	(BATCH-RM003)	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.

	FactoryTalk Batch System Files Reference Manual	Provides the technical information for configuration and
	(BATCH-RM005)	maintenance of a FactoryTalk Batch system. It can be
		used as a reference information for implementation
		engineers and the system administrator.
	FactoryTalk Batch eProcedure Instruction File	Includes information about the building of instruction
	Design Reference Manual	files for use in equipment database creation and recipe
	(BWEPRO-RM001)	development. This information is intended to be used as a
		reference by the instruction file author.

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.

Chapter 1

PhaseManager

Software requirements

What is PhaseManager?

PhaseManager is a collection of features that integrates the FactoryTalk® Batch software with the Studio 5000 Logix Designer™ application and the Logix 5000™ family of controllers. The integration of these products simplifies the configuration and maintenance of the FactoryTalk Batch automation system, provides a superior means of 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 the Logix 5000 controller.

There are no specific software requirements to run PhaseManager in controller PAC firmware.

•FactoryTalk Batch version 8.00 or later (to integrate PhaseManager with FactoryTalk Batch)

•Firmware version 18 or later on ControlLogix 5570 and CompactLogix 5370 family of controllers (to support PhaseManager programs and routines)

•Firmware version 32 or later on ControlLogix 5580 and CompactLogix 5380 family of controllers (to support PhaseManager programs and routines)

•Logix Designer version 18 or later - to edit PhaseManager programs and routines, and for synchronization with FactoryTalk Batch

Equipment Editor (to edit PhaseManager programs and routines)

Tip: Software Platform\Hardware Compatibility Matrix: For the latest compatibility information for the Rockwell Automation software suite of products, consult Rockwell Automation Product Compatibility and Download Center.

In FactoryTalk Batch Equipment Editor, create a phase class to represent a group of equipment that performs a minor processing activity in a manufacturing plant, and create a phase when a specific instance of a phase is added to a unit.

Chapter 1

PhaseManager

PhaseManager is a collection of features in FactoryTalk Batch, Logix Designer, and an addition of capabilities in the Logix 5000 family of controllers that extend the concept and definition of phases to the Logix Designer software and the Logix 5000 family of controllers.

An equipment phase is a special kind of program. A state machine built into the program manages the state of the equipment phase. The state specifies which routine the phase executes. The phase can be commanded to change states, and change the routine it is executing. Equipment phase programs have input and output parameters. Parameters can be configured as Sequencing parameters, marking these tags as requiring data to be supplied from an internal sequencer (Equipment Sequence Manager) or external sequencer (FTBatch).

PhaseManager adds an equipment phase object to the Logix 5000 family of controllers and gives the ability to create equipment phases in the Logix Designer programming software. Create or update equipment phases in Logix Designer by adding or modifying them directly in the project, or by synchronizing the project with an area model that contains PhaseManager phases. Likewise, create or update phases in the area model by synchronizing with a Logix Designer project file that contains PhaseManager equipment phases.

FactoryTalk Batch features PhaseManager adds these features to the FactoryTalk Batch software:

•Common Industrial Protocol (CIP) support

The FactoryTalk Batch Server can sequence equipment phases in Logix 5000 controllers using the industry standard CIP (Common Industrial Protocol). In FactoryTalk Batch Equipment Editor, add a Logix 5000 CIP data server for each Logix 5000 controller that contains PhaseManager equipment phases.

•Equipment phase synchronization

Synchronize the area model in FactoryTalk Batch Equipment Editor with the project file in Logix Designer. Create or update an equipment phase once in either application and add or update it to the other application by synchronizing the FactoryTalk Batch area model with its corresponding Logix Designer project file.

•Navigation from FactoryTalk Batch Equipment Editor to phase logic in a Logix Designer project

Directly navigate from a phase in FactoryTalk Batch Equipment Editor to corresponding phase logic in the Logix Designer project file.

Chapter 1

PhaseManager

Logix Designer features

Logix 5000 Controller features

How PhaseManager works in a FactoryTalk Batch system

PhaseManager adds these features to the Logix Designer programming software:

•Equipment phase as a type of program

Add equipment phases to Logix Designer projects.

•PHASE data type

Use the PHASE data type to link equipment phases to higher-level systems.

•Special instructions for equipment phases

Use instructions in phase logic provided specifically for interacting with the FactoryTalk Batch Server and sequencing a PhaseManager equipment phase.

PhaseManager adds these features to the Logix 5000™ family of controllers:

•Equipment phase objects

Equipment phase objects in the Logix 5000 family of controllers communicate with the FactoryTalk Batch Server through direct Common Industrial Protocol (CIP) messaging. The equipment phase objects embed the Phase Logic Interface (PLI) capabilities into all Logix 5000 controllers, eliminating the need for separate PLI code in the project.

•Equipment Phase State Model

Modularize and organize equipment phase logic by developing the code for each S88 state in a routine. Using this programming structure provides consistency of implementation throughout the project.

PhaseManager features work together to provide a seamless workflow that improves the designing, troubleshooting, and commissioning phases of the development life cycle. This discussion includes some background information about the components of FactoryTalk Batch systems and how FactoryTalk Batch terminology and concepts are implemented in FactoryTalk Batch and Logix Designer.

In a FactoryTalk Batch system using PhaseManager, the FactoryTalk Batch Server provides batch control, including recipe execution, allocation and arbitration of equipment, binding of resources, and generation of journals. Use FactoryTalk Batch Equipment Editor and FactoryTalk Batch Recipe Editor

Chapter 1

PhaseManager

Common Industrial Protocol (CIP)

to configure the FactoryTalk Batch system. Use Logix Designer to program the phase logic code that defines the behavior of equipment phase states, including Running, Stopping, Aborting, Holding, Restarting, and Resetting. PhaseManager links a phase in FactoryTalk Batch Equipment Editor to a corresponding equipment phase and its phase logic in Logix Designer.

PhaseManager uses the Common Industrial Protocol (CIP) as the communication mechanism between the FactoryTalk Batch Server and the Logix 5000 controller. In FactoryTalk Batch, each Logix 5000 controller is represented as a CIP data server that was added and configured in FactoryTalk Batch Equipment Editor. Logix5000 CIP data servers require FactoryTalk® Linx™ for the CIP communications from the FactoryTalk Batch Server to the controller.

The FactoryTalk Batch Server and Logix Designer communicate with the Logix 5000 controller by sending and receiving CIP (Common Industrial Protocol) messages through FactoryTalk Linx.

Chapter 1

PhaseManager

Equipment phases in Logix Designer

Equipment phase synchronization

FactoryTalk Batch Equipment Editor provides the ability to create a model of the equipment in a manufacturing plant. The phases defined in FactoryTalk Batch Equipment Editor define the capabilities of a piece of equipment, or what the equipment can do. When adding an instance of a phase class to a specific unit, create a phase. Each phase represents a unique piece of equipment that can perform the processing activity described by the phase.

Using Logix Designer with PhaseManager, can also create equipment phases in Logix 5000 controllers. An equipment phase in Logix Designer is a type of program that represents both the specific piece of equipment and its capabilities, or the processing activity it performs. The Logix Designer equipment phase is a combination of the FactoryTalk Batch phase and the phase it was created from. PhaseManager adds special Relay Ladder Logic (RLL) and Structured Text instructions to Logix Designer used when developing phase logic to interact with the FactoryTalk Batch Server, and for internally manipulating the equipment phase objects in the Logix 5000 controller.

With PhaseManager, create a phase in FactoryTalk Batch Equipment Editor or edit the definition of equipment phases, including parameters and reports, in either FactoryTalk Batch Equipment Editor or in Logix Designer and synchronize them in FactoryTalk Batch Equipment Editor. FactoryTalk Batch Equipment Editor contains the tools to view synchronization status and manage the synchronization process.

Tip: These types of phases must be initially created and edited in FactoryTalk Batch Equipment Editor and added to Logix Designer through the synchronization process:

•Material phases

•Phases that contain control strategies

•Phases that contain parameter deviations

Chapter 1

PhaseManager

Integration of FactoryTalk Batch Equipment Editor with Logix Designer

Benefits of using

PhaseManager and CIP instead of OPC

Reduced phase logic programming

PhaseManager adds the ability to double-click a phase in FactoryTalk Batch Equipment Editor and open its corresponding equipment phase in Logix Designer to view and edit its phase logic.

Place the pointer over a phase that is assigned a CIP data server, the pointer changes to the Logix Designer equipment phase symbol, indicating to doubleclick to open Logix Designer.

PhaseManager improves existing functionality, and how using PhaseManager and the Common Industrial Protocol (CIP) differs from using FactoryTalk Batch with the OPC communication protocol.

Without PhaseManager, a control engineer must implement the Phase Logic Interface (PLI), which is a set of ladder logic (RLL) routines that provides the controller interface to the FactoryTalk Batch Server and executes the command handshake protocol required by the server to communicate with the controller. This communication protocol is implemented using OPC and communication tags or other memory locations in the controller to hold commands, requests, and other data needed by the PLI. When OPC is used, the FactoryTalk Batch Server is compatible with any type of controller, including Logix 5000 controllers, PLC-5s, or controllers manufactured by any vendor.

In Logix Designer with PhaseManager, the functionality associated with the PLI is embedded into the Logix 5000 controller by means of equipment phase objects and instructions. Since PhaseManager implements the PLI functionality in the Logix 5000 controller, do not implement PLI routines when using PhaseManager to create and maintain equipment phases in the FactoryTalk Batch system.

Chapter 1

PhaseManager

Eliminates duplicate equipment phase and tag configuration

With PhaseManager, the FactoryTalk Batch Server communicates with the Logix 5000 controller through direct CIP (Common Industrial Protocol) messaging targeted at the new objects in the Logix 5000 controller. CIP messaging provides a faster and more reliable communication mechanism, a preferred connectivity path, and increased throughput. The combination of embedding the PLI functionality in the Logix 5000 controller and using CIP messaging for communication provides a seamless integration between FactoryTalk Batch, RSLogix5000, and the Logix 5000 family of controllers.

All commands previously supported from the FactoryTalk Batch Server to the controller, such as sending a parameter value to the controller, are also supported by PhaseManager. Likewise, all requests from the controller to the FactoryTalk Batch Server, such as the controller requesting a new parameter value, are also supported by PhaseManager. How these commands are sent is different when PhaseManager is used, due to the use of CIP messaging.

In a FactoryTalk Batch system using the OPC communication protocol and the Logix Designer programming software, manually enter communication tag data for each of the ten standard tags and for each parameter, report, and additional request tag on each phase in FactoryTalk Batch Equipment Editor. In Logix Designer, manually create the corresponding tags. Each Tag Name entered in Logix Designer must match the Tag Item Name entered in FactoryTalk Batch Equipment Editor. Additionally, in Logix Designer manually create the tags required for the PLI and FactoryTalk Batch Server communications.

In a FactoryTalk Batch system using Logix Designer with PhaseManager, the FactoryTalk Batch Server communicates directly to the equipment phase objects in the Logix5000 controller; therefore, it is not necessary to enter any communication tag data in either application. In FactoryTalk Batch Equipment Editor, tag names that match the parameters and reports defined on the phase are automatically created for each phase.

PhaseManager creates phases in FactoryTalk Batch Equipment Editor or equipment phases in Logix Designer, and synchronizes the FactoryTalk Batch area model with the Logix Designer project file. When synchronizing the area model with the project file, data types and tags are automatically created for each equipment phase and for all parameters and reports in Logix Designer. It is not necessary to enter this information twice, in FactoryTalk Batch and in Logix Designer, as is required if OPC data servers are used with FactoryTalk Batch.

Any new equipment phases added in Logix Designer, or modifications to existing equipment phases in Logix Designer, can also be transferred to the

Chapter 1

PhaseManager

FactoryTalk Batch area model when the FactoryTalk Batch phases are synchronized with the Logix Designer project.

Unsigned data types introduced in Logix5000 v32 are not supported by FactoryTalk Batch. Configuring a FactoryTalk Batch tag to reference a controller tag of any unsigned data type (USINT, UINT, UDINT, ULINT) will result in bad communication. If you attempt to run batches referencing any tags that include one of these data types a communication failure occurs at the point when the tag is used.

If your system includes Logix5000 v32, you can use FactoryTalk Batch Tag Verify to produce a report that identifies any issues with the tag(s).

Compatible tag data types The data types of the input and output parameter tags defined in Logix Designer must be compatible with the data types supported in FactoryTalk Batch Equipment Editor. These data types are supported:

Logix Designer Data Type	Corresponding FactoryTalk Batch Equipment Editor Data
	Types
Real	Real
DINT, INT, SINT	Integer
DINT, INT, SINT	Enumeration
String	String

Chapter 1

PhaseManager

Open phase logic in Logix Designer from FactoryTalk Batch Equipment Editor

If your system includes Logix5000 v32, you can use FactoryTalk Batch Tag Verify to produce a report that identifies any issues with the tag(s).

PhaseManager gives the ability to double-click a phase in FactoryTalk Batch Equipment Editor and directly view and edit its phase logic in Logix Designer. Logix Designer opens to the equipment phase in the project file that corresponds to the phase selected in FactoryTalk Batch Equipment Editor. It is not necessary to manually open Logix Designer and navigate to the equipment phase to view or edit the phase logic for a phase in FactoryTalk Batch.

•If the phase has a corresponding equipment phase in Logix Designer with existing phase logic, Logix Designer opens the project file to the Running routine of the equipment phase.

•If the phase has a corresponding equipment phase in Logix Designer, and the phase logic has not been developed yet, Logix Designer opens the project file to the equipment phase.

•If the phase does not have a corresponding equipment phase in Logix Designer, Logix Designer opens the project file for the CIP data server

that is assigned to the phase.

Tip: To open the Logix Designer project file from FactoryTalk Batch Equipment Editor, the correct revision of Logix Designer must be installed on the same computer as FactoryTalk Batch Equipment Editor with an activation for each product.

The PhaseManager activation is included in the Logix Designer Professional Version, but other versions of Logix Designer require a separate PhaseManager activation to enable the PhaseManager features in Logix Designer.

Improved implementation of phase logic routines

Logix Designer with PhaseManager improves the implementation of equipment phases in Logix 5000 controllers. Using OPC and the PLI, a phase is typically executed in a single relay ladder logic (RLL) routine that implements logic for all of the active states defined by the S88 standard. These active states include Stopping, Starting, Running, Holding, Aborting, and Restarting.

Tip: PhaseManager also provides an additional active state in Logix Designer, Resetting, that can be used for other types of projects not based on the S88 standard.

PhaseManager supports a modularized approach to developing state routine logic by facilitating the development of each active state in its own routine. PhaseManager represents an equipment phase as a type of program in Logix Designer. Since programs can contain multiple routines, develop a separate routine for each active state required for the equipment phase. Developing

Chapter 1

PhaseManager

separate routines for each active state also provides the ability to develop each routine in different programming languages.

Use other Logix Designer program features when developing equipment phase logic. These features include the ability to use timing diagnostics information, Max and Last Scan, for debugging equipment phases in Logix Designer, and the ability to configure a fault routine for the equipment phase.

Chapter 2

Area model PhaseManager configuration

Add a Logix5000 CIP data server

Use FactoryTalk Batch with PhaseManager to configure the area model in FactoryTalk Batch Equipment Editor, or develop the phase logic in Logix Designer. If designing an entire FactoryTalk Batch system, use FactoryTalk Batch Equipment Editor to create an area model that describes the capabilities of the equipment, down to the phase level, and optionally use the synchronization feature to create corresponding equipment phases in the Logix Designer project file.

This section describes how to configure data servers and phases in FactoryTalk Batch Equipment Editor so these PhaseManager features can be used:

•CIP for FactoryTalk Batch Server communications to the Logix5000 controller

•Synchronization of phases in the FactoryTalk Batch area model with the Logix Designer project file

•Ability to open phase logic in Logix Designer from the phase in

FactoryTalk Batch Equipment Editor

Tip: To fully use the PhaseManager features, install FactoryTalk Batch Equipment Editor and Logix Designer on the same computer.

To configure the FactoryTalk Batch system with PhaseManager:

•Add Logix5000 CIP data servers

•Assign a Logix5000 CIP data server to PhaseManager phases

After these configuration tasks are completed, if the Equipment Phases in Logix Designer have not already been created, synchronize the FactoryTalk Batch area model with the Logix Designer project file.

Add data servers either before creating the rest of the elements in the area model, or after defining the process cells, unit classes, phase classes, operation sequence classes, and resources in the area model. Define at least one data server before creating the specific phases from the phase classes or specific operation sequences from the operation sequence classes.

If possible, create the project file in Logix Designer before adding a Logix5000 CIP data server. Specify the project file when adding a Logix5000 CIP data server to detect errors more easily when designing the system.

Chapter 2	Area model PhaseManager configuration
	Prerequisites
	• Configure device shortcuts in the FactoryTalk Administration Console
	for all controllers that FactoryTalk Batch communicates with
	PhaseManager or SequenceManager objects.
	• Install and configure FactoryTalk Linx. (For more information, refer to
	FactoryTalk Linx Help.)
	• Create an Application in the FactoryTalk Directory. (For more
	information, refer to FactoryTalk Help located in the FactoryTalk
	Administration Console.)
	• Add a FactoryTalk Linx data server to the FactoryTalk Application.
	Adding a data server to an application provides a link between a
	hardware device containing tags and the FactoryTalk Directory. (For
	more information, refer to FactoryTalk Help located in the FactoryTalk
	Administration Console.)

To add a Logix5000 CIP data server

1.Select Start > Rockwell Software > Equipment Editor.

2.Select Edit > Data Server to open the Data Servers dialog box.

3.Select Add to open the Add Data Server dialog box.

4.In the Name box, type a name for the data server.

Tip: The name should easily identify the Logix 5000 controller that this data server represents. Using the type of Logix 5000 controller and its location in the chassis as the name, or the unit that this controller connects to in the plant as the name, may help to easily identify the controller.

When synchronizing the area model with the Logix Designer project, this name displays in the Synchronize Logix5000 Data Servers dialog box. Choose which data server to synchronize by selecting the name.

5.Select Logix5000 CIP for the Type.

6.(optional) To create phases or operation sequences in the area model before completing the remaining information in this dialog box, select OK to close this dialog box. Finish adding information about the data server later.

7.To enable synchronization between the .acd file and the area model, select Browse, navigate to a project .acd file that contains the phase for the controller this data server represents. The file's revision and

controller type display in the boxes.

Tip: The Logix Designer project file must be revision 16.0 or higher.

To resolve any error messages that appear when selecting a project file, see Select a project file - error messages.

8.In the FactoryTalk Linx Controller Shortcut box, select Browse to locate the device shortcut for communicating with the specified controller.

Alternatively, type the path to the shortcut using this format:

RNA://Global/UsersApplicationName/FTLinxAreaName/Fa

ctoryTalkLinx/ShortcutName

9. (optional) Select More to display the Timeout and Retries boxes.

Chapter 2

Area model PhaseManager configuration

10.The default values are the recommended settings for these boxes. Adjust these values for the speed of the network.

Name	Value

Timeout	How often the FactoryTalk Batch Server attempts to contact the controller. The range
	of valid values is 500 to 100000 milliseconds. The default is 8000.
Retries	The number of times the FactoryTalk Batch Server tries to contact the controller
	before dropping the connection. The valid values appear in the list. The default is 4.

Timeout * Retries = Length of time the FactoryTalk Batch Server attempts to contact the controller before losing the connection.

11.Select OK to close the Add Data Server dialog box.

12.Select OK to close the Data Servers dialog box.

Select a project file - error messages

If error messages display when selecting a Logix Designer, use this table to troubleshoot the issue.

Error Message	Action to Take
The specified Logix Designer	The file may have been renamed, moved, or deleted after it was
project file was not found.	selected in the Select Project File dialog box.
	In Windows Explorer, navigate to the file selected in the Select Project
	File dialog box,and verify that it still exists with the same name in the
	selected location.
No revision of Logix Designer is	Logix Designer is not installed on the same computer as FactoryTalk
installed.	Batch Equipment Editor.
	Install Logix Designer revision 16.0 or higher on the same computer as
	FactoryTalk Batch Equipment Editor.
The revision of Logix Designer	The installed revision of Logix Designer does not support PhaseManager
required to open the project is not	functionality.
installed.	Upgrade the current installation of Logix Designer to revision 16.0 or
	higher.
The Logix Designer project file	The revision of the selected Logix Designer project file is lower than
must be converted. The revision is	revision 16.0.
too old.	Open the selected project file in Logix Designer revision 16.0 or higher
	to convert the file to this revision.
The specified file is not a valid	Try to open the selected project file in Logix Designer. If it does not
Logix Designer project file. The file	open, the file format has been corrupted.
format is not recognized or has
been corrupted.
The Logix Designer project file is	Disable the Read-Only Attribute for the selected project file. In Windows
read-only and cannot be opened.	Explorer, navigate to the selected file in the Select Project File dialog
	box. Open the Properties dialog box for the file and verify that the
	Read-Only Attribute is not selected.

The Logix Designer project file	The installed revision of Logix Designer and the selected project file is
revision does not support phases.	lower than revision 16.0.
Use revision 16.0 or greater.	Upgrade the revision of Logix Designer to 16.0 or higher. Open the
	selected project file in Logix Designer to convert the file to the
	upgraded revision.

Chapter 2

Area model PhaseManager configuration

Edit a Logix5000 CIP data server

Assign a Logix5000 CIP data server to a phase or sequence

Use these instructions to edit a Logix5000 CIP data server.

To edit a Logix5000 CIP data server:

1.Select Edit > Data Server. The Data Servers dialog box opens.

2.Select the data server definition to be edited, and select Edit. The Edit Data Server dialog box opens.

3.Make any required changes and select OK to return to the Data

Servers dialog box.

Tip: After adding a data server as a Logix5000 CIP type data server, the type cannot change. No other data server types appear in the Type selection list when editing. To change the Type, delete the data server and add a new one.

4.(optional) To delete a data server, select the data server to delete and select Remove.

•If the data server is not assigned to any phases, this message displays:

•If the data server is assigned to phases, the Remove Server dialog box opens, displaying these phases and unit tags associated with the data server.

The displayed unit tags and phases, as well as their parameter, report, and limit tags are deleted when the data server is removed.

•Select Yes to delete the data server and remove all associated phases and tags.

After adding a Logix5000 CIP data server, assign it to each phase or sequence that represents a piece of equipment connected to the controller specified in the controller network path of the Logix5000 CIP data server.

To assign a Logix5000 CIP data server to a phase or sequence:

1.Select Start > Rockwell Software > Equipment Editor.

2.Select the phase or sequence icon in the Design View area and select

Edit > Properties. The Edit Phase dialog box, General tab displays.

3.From the Data Server list, select the Logix5000 CIP data server that represents the controller connected to the piece of equipment defined by this phase or sequence.

4.Select OK.

Chapter 2

Area model PhaseManager configuration

Assign a data server to all phases in a unit

When creating a unit, assign a data server to the unit. This data automatically assigns to all phases subsequently created in that unit.

To assign a data server to all phases in a unit:

1.Select the unit icon in the Design View area and select Edit > Properties. The Edit Unit dialog box, General tab displays.

2.From the Data Server list, select the Logix5000 CIP data server that represents the controller connected to all phases created in this unit.

3. Select OK.

Chapter 3

FactoryTalk Batch phases in Logix Designer

After the Logix5000 data servers are added and assigned to phases, create the same phases in the Logix Designer programming software by synchronizing the area model with the Logix Designer project file.

This section describes how to synchronize the FactoryTalk Batch area model with the Logix Designer project file when the phases in FactoryTalk Batch Equipment Editor are created and corresponding equipment phases in Logix Designer are needed. Phases based on these types of phases must be initially created in FactoryTalk Batch Equipment Editor and added to Logix Designer through the synchronization process:

•Material based recipe phases

•Phases that contain control strategies

•Phases that contain parameter deviations

The features to configure these types of complex phases are unique to the FactoryTalk Batch product. Logix Designer does not have the configuration features to enable material phases, control strategies, or parameter deviations. For that reason, configure these phase classes and phases in FactoryTalk Batch first, and then follow the instructions in this chapter to synchronize the area model with the Logix Designer project file. When corresponding equipment phases in Logix Designer are synchronizing, the appropriate configuration of parameters, reports, and tags on these complex phases are automatically created on the equipment phases in Logix Designer.

Tip: Phases are created in Logix Designer as equipment phases.

Synchronize the area model with the project file

After equipment phases are created in the Logix Designer project, begin developing phase logic for them in Logix Designer.

Use these instructions to synchronize the area model with the project file.

Before you begin:

•Install Logix Designer and FactoryTalk Linx on the same computer as FactoryTalk Batch Equipment Editor.

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