Rockwell Automation FactoryTalk Batch User Manual
a
F
ctoryTalk 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
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.
temperatures.
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.
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WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
Labels may also be on or inside the equipment to provide specific precautions.
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2
Preface
PhaseManager
Area model PhaseManager
Logix Designer
Table of Contents
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
configuration
FactoryTalk Batch phases in
3
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
Data from FactoryTalk Batch
Server
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
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
4
Data from the Material Server
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
5
Chapter 6
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
Table of Contents
Index
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
6
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
Center (PCDC).
he information in this guide is for FactoryTalk Batch system designers,
T
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.
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.
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
7
Preface
Resource
Description
FactoryTalk Batch Components Installation and
Provides information and procedures for FactoryTalk
Server components.
Provides information about using FactoryTalk Batch View
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.
F
ollowing is a comprehensive list of documentation for the FactoryTalk®
Batch products from Rockwell Automation.
Installation, Quick Start, and Getting Results Guides
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)
Batch system installation. Includes information for
FactoryTalk Batch Material Manager, FactoryTalk Event
Archiver, and associated FactoryTalk Batch Client and
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.
8
Preface
Resource
Description
FactoryTalk Batch Getting Results Guide
Introduces the basics of automated batch manufacturing
Resource
Description
reference for the formulator.
your Logix 5000 controller.
sequential function charts to graphically organize recipes
FactoryTalk Batch Server.
(BATCH-GR011)
FactoryTalk Batch Material Manager Getting
Results Guide
(BWMTR-GR011)
User Guides
FactoryTalk Batch ActiveX Controls User Guide
(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)
and the FactoryTalk Batch product components.
Introduces the basics of FactoryTalk Batch Material
Manager.
Provides information and instructions for using the
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
FactoryTalk Batch Recipe Editor User Guide
(BATCH-UM006)
FactoryTalk Batch View HMI Controls User Manual
(FTBVS-UM003)
FactoryTalk Batch View User Manual
(FTBVS-UM002)
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
into procedures, unit procedures, operations, and phases.
Build recipes using either the SFC format or a table-based
format.
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
9
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).
FactoryTalk Batch eProcedure Administrator Guide
Provides procedures specific to FactoryTalk Batch
operators, such as the FactoryTalk Batch Server.
FactoryTalk Batch Material Manager Administrator
(BWEPRO-UM011)
Resource
Description
(BATCH-RM001)
FactoryTalk Batch Material Editor and FactoryTalk Batch.
those who want to develop custom interfaces.
(BATCH-RM004)
(BWEPRO-UM001)
FactoryTalk Event Archiver User Guide (BATCHUM012)
FactoryTalk Batch View User Guide (legacy)
(FTBVS-UM001)
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
Administrator Guides
Resource Description
FactoryTalk Batch Administrator Guide
(BATCH-UM003)
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)
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
It is intended to be used as a reference information by
10
FactoryTalk Batch PCD Programming Reference
Manual
Provides information and instructions about the
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.
11
Chapter 1
Software requirements
What is PhaseManager?
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)
Ti
p: 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.
13
Chapter 1 PhaseManager
FactoryTalk Batch features
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.
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.
uipment phase synchronization
• Eq
Synchronize the area model in FactoryTalk Batch Equipment Editor
with the project file in Logix Designer. Create or update an equipmen
hase once in either application and add or update it to the other
p
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.
t
14
Chapter 1 PhaseManager
Logix Designer features
Logix 5000 Controller
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
features
Use the PHASE data type to link equipment phases to higher-leve
stems.
sy
• Special instructions for equipment phases
Use instructions in phase logic provided specifically for interactin
wi
th 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 direc
mmon Industrial Protocol (CIP) messaging. The equipment phase
Co
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
l
g
t
How PhaseManager works in a FactoryTalk Batch system
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
15
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.
16
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.
Phases that contain parameter deviations
Equipment phases in Logix
Designer
Equipment phase
Chapter 1 PhaseManager
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.
synchronization
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.
T
ip: 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
•
17
Chapter 1 PhaseManager
Integration of FactoryTalk
Benefits of using
Reduced phase logic
Batch Equipment Editor
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.
with Logix Designer
PhaseManager and CIP
instead of OPC
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.
programming
18
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
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.
equipment phase and tag
configuration
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
19
Chapter 1 PhaseManager
Configuring a FactoryTalk Batch tag to reference a controller tag of any unsigned data type (USINT,
any tags that include one of these data types a communication failure occurs at the point when the
report that identifies any issues with the tag(s).
Logix Designer Data Type
Corresponding FactoryTalk Batch Equipment Editor Data
DINT, INT, SINT
Integer
DINT, INT, SINT
Enumeration
String
String
Compatible tag data types
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.
UINT, UDINT, ULINT) will result in bad communication. If you attempt to run batches referencing
tag is used.
If your system includes Logix5000 v32, you can use FactoryTalk Batch Tag Verify to produce a
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:
Types
Real Real
20
Configuring a FactoryTalk Batch tag to reference a controller tag of any unsigned data type (USINT,
any tags that include one of these data types a communication failure occurs at the point when the
report that identifies any issues with the tag(s).
PhaseManager features in Logix Designer.
used for other types of projects not based on the S88 standard.
Open phase logic in Logix
Designer from FactoryTalk
Improved implementation
Batch Equipment Editor
Chapter 1 PhaseManager
Unsigned data types introduced in Logix5000 v32 are not supported by FactoryTalk Batch.
UINT, UDINT, ULINT) will result in bad communication. If you attempt to run batches referencing
tag is used.
If your system includes Logix5000 v32, you can use FactoryTalk Batch Tag Verify to produce a
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.
T
ip: 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
Logix Designer with PhaseManager improves the implementation of
of phase logic routines
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
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
21
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.
22
Chapter 2
Tip: To fully use the PhaseManager features, install FactoryTalk Batch Equipment Editor and
Add a Logix5000 CIP data
Area model PhaseManager configuration
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
server
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.
23
Chapter 2 Area model PhaseManager configuration
synchronize by selecting the name.
project file - error messages.
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
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.
Ti
p: 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
24
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.
Name
Value
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.
Error Message
Action to Take
The revision of Logix Designer
The installed revision of Logix Designer does not support PhaseManager
higher.
to convert the file to this revision.
been corrupted.
Select a project file - error
messages
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.
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.
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
.
If error messages display when selecting a Logix Designer, use this table to
troubleshoot the issue.
The specified Logix Designer
project file was not found.
No revision of Logix Designer is
installed.
required to open the project is not
installed.
The Logix Designer project file
must be converted. The revision is
too old.
The specified file is not a valid
Logix Designer project file. The file
format is not recognized or has
The Logix Designer project file is
read-only and cannot be opened.
The Logix Designer project file
revision does not support phases.
Use revision 16.0 or greater.
The file may have been renamed, moved, or deleted after it was
selected in the Select Project File dialog box.
In Windows Explorer, navigate to the file selected in the Select Project
File dialog box
selected location.
Logix Designer is not installed on the same computer as FactoryTalk
Batch Equipment Editor.
Install Logix Designer revision 16.0 or higher on the same computer as
FactoryTalk Batch Equipment Editor.
functionality.
Upgrade the current installation of Logix Designer to revision 16.0 or
The revision of the selected Logix Designer project file is lower than
revision 16.0.
Open the selected project file in Logix Designer revision 16.0 or higher
Try to open the selected project file in Logix Designer. If it does not
open, the file format has been corrupted.
Disable the Read-Only Attribute for the selected project file. In Windows
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 installed revision of Logix Designer and the selected project file is
lower than revision 16.0.
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.
,
and verify that it still exists with the same name in the
25
Chapter 2 Area model PhaseManager configuration
Tip: After adding a data server as a Logix5000 CIP type data server, the type cannot
change the Type, delete the data server and add a new one.
Edit a Logix5000 CIP data
Assign a Logix5000 CIP data
Use these instructions to edit a Logix5000 CIP data server.
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.
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
change. No other data server types appear in the Type selection list when editing. To
displays:
server to a phase or
sequence
• 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 tha
epresents the controller connected to the piece of equipment defined
r
by this phase or sequence.
4. Select OK
.
t
26
Assign a data server to all
phases in a unit
Chapter 2 Area model PhaseManager configuration
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 tha
epresents the controller connected to all phases created in this unit.
r
t
3. S
elect OK
.
27
Chapter 3
Synchronize the area model
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
with the project file
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.
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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