RSTechED 2013

PR16 Implementing PlantPAx Logix

Batch & Sequence Manager (LBSM)

Publication Number -- Date

Copyright 2011 Rockwell Automation, Inc.

Important User Information

This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation) is intended for use only as
a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation
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responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in
this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the
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Throughout this manual we use the following notes to make you aware of safety considerations:
Identifies information about practices or circumstances
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PR16 Implementing LBSM from user perspectives

Contents
Before you begin ......................................................................................................................................... 4
About this section .......................................................................................................................................... 4
Tools & prerequisites .................................................................................................................................... 5
Introduction ................................................................................................................................................. 6
Operators Perspective.................................................................................................................................. 6
Engineers Perspective ................................................................................................................................. 6
R&D (Recipe Author) Perspective ................................................................................................................ 6
Setup ............................................................................................................................................................ 7
Start the software and open a project ........................................................................................................... 7
Operators Perspective ............................................................................................................................. 14
HMI Visualization & Navigation ................................................................................................................... 14
LBSM Reporting .......................................................................................................................................... 44
Engineers Perspective............................................................................................................................. 59
Modifying the Configuration for an Existing Phase ..................................................................................... 60
Configuring a New Phase ........................................................................................................................... 62
Connecting LBSM to the Controller Code .................................................................................................. 65
R&D (Recipe Author) Perspective ........................................................................................................... 75
Appendix: ................................................................................................................................................... 90
How to fix a controller with a red X ............................................................................................................. 90
LBSM Sample Application........................................................................................................................... 93

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Before you begin

About this section
This section provides you with an opportunity to explore the capabilities of PlantPAx Logix Batch and
Sequence Manager (LBSM) from various users perspectives. A day in the life perspective of several
system users (operator, engineer, R&D) will be explored to design, control, troubleshoot, and optimize a
running batch/sequencing production process built leveraging the capabilities of the PlantPAx controller
based solution.
The PlantPAx Demo represents a manufacturing facility consisting of three class-based premix units
followed by two class-based reactors. In this section LBSM builds sequences on the same Premix 1 unit
used by the comprehensive FactoryTalk Batch lab. As described below, this demonstrates the synergy
and migration potential between LBSM and FactoryTalk Batch.

PlantPAx Logix Batch and Sequence Manager (LBSM)

PlantPAx Logix Batch and Sequence Manager (LBSM) applications provide process management
functionality, while only requiring a Logix controller and FTView HMI for configuration and execution.
Although, LBSM is best suited for single unit systems with a finite number of sequences, the features
mirror those found in multi-unit server based systems such as FactoryTalk Batch (FTB). LBSM provides
sequence management, manual/automated procedural control, and associated visualization. New to
LBSM v1.5 is a Microsoft SQL 2005/2008 reporting application
LBSMs ability to sequence equipment with or without the Logix Phase Manager provides a platform that
can be used in nearly any application from process to packaging. When using Logix Phase Manager, a
seamless migration from LBSM to FactoryTalk Batch is possible.
PlantPAx Logix Batch & Sequence Manager is available for download from KnowledgeBase technote AID
68709.

This lab takes approximately 90 minutes to complete.

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Tools & prerequisites

Software
This hands-on lab uses the following software:
RSLogix 5000 with the PhaseManager option, v.20.0
RSLinx Classic, v. 2.59 (CPR9 SR5)
SoftLogix, v. 20.0
FactoryTalk Services Platform, v. 2.50 (CPR9 SR5)
FactoryTalk ViewSE v. 6.1
Microsoft SQL 2008
Logix Batch & Sequence Manager v1.5

Lab Files
This hands-on lab uses the following files:
PlantPAx Logix Project: PlantPAxDemo_Controller1_Master_Journal.ACD
PlantPAx View Project: PlantPAx Demo

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Introduction
Operators Perspective
This user perspective will introduce you to the manufacturing facility via simple HMI graphics and
navigation. This section will take you through the process of browsing sequences, creating a sequence,
and running the automated sequence. While the sequence is running, you will have a chance to explore
the LBSM system by interacting with the sequence through standard operator tasks. These include:
completing manual additions, initiating manual actions, hold/resume the sequence, advance/repeat steps
and more. Will end the operators perspective with a look at the new LBSM reporting application.

Engineers Perspective
System modifications may be required over time; therefore, this user perspective will introduce you to
some system engineering changes, namely how a phase is created, configured or modified, and linked to
controller code.

R&D (Recipe Author) Perspective

This user perspective will demonstrate how you as a recipe author can create and edit sequences (both
procedure and formula) independent of the plant floor equipment. Although the sequence will be
configured in LBSM, it will describe a similar process and use the same equipment that is used in the
FactoryTalk Batch lab (PR17).

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Setup
Start the software and open a project
SoftLogix Setup
The SoftLogix, RSLogix 5000 and FactoryTalk ViewSE programs should all be running and you can go
straight to the Operators Perspective section. If the programs are not running the steps below describe
how to start the project.
1.

SoftLogix should launch with the start of Windows Server 2008, if not from the start bar, open
SoftLogix.

2. Wait a minute or two for SoftLogix to initialize.

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Controller Setup
3. From the start bar, open RSLogix5000, Start > RSLogix 5000.

4. Select PlantPAxDemo_Batch_Master_Journal.ACD control file from File menu under the

recent open listings, or use File>Open menu and browse to C:\PlantPAx
Demo\CLX\PlantPAx Demo Processor ACD Files selecting the
PlantPAxDemo_Batch_Master_Journal.ACD file.

Please verify that you opened the correct ACD file. Observe the RSLogix 5000 title bar to verify that
the proper file was opened as shown:

Note: If the wrong file is opened and downloaded in the next step, an error will occur.

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5. From the communications menu, select Communications > Download.

6. Select Download

7. From the communications menu, select Run Mode.

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8. Check that the controller has the correct time by right-clicking on the controller name to bring up
its properties pages, select the Date/Time tag and select Set Date, Time and Zone from
Workstation if the controller time is incorrect.

9. Minimize RSLogix5000.
HMI Setup - Client
10. From the Desktop select the PlantPAx Client icon or from the start menu select Start >
FactoryTalk View Site Edition Client and complete step 10 and 11.

11. In the FactoryTalk View SE Client Wizard dialog select the FTView SE Client.cli client file in
the most recently used configuration files window.
12. Press the Run button.

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Enable LBSM
13. When the HMI client opens, maximize the screen and select the Core Process General button
which will open the Process Overview display.

14. On the Process Overview display select the CPG Batch SetupReset button.

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15. Click on the box to Enable Logix Batch & Sequence Manager for Premix 1 Tank, then Click
Close. The FactoryTalk Batch Server should not be running as shown below.

16. Setup is now complete.

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Operators Perspective
This user perspective will take you through the process of browsing sequences, creating a sequence, and
running the automated sequence using LBSM. While the sequence is running, you will have a chance to
explore the LBSM system while interacting with the sequence through standard operator tasks. These
include: completing manual additions, initiating manual actions, hold/resume sequencing,
advance/repeat steps and more. The user will also enable LBSM reporting and look at the preconfigured
reports.

HMI Visualization & Navigation

Security & Login
Logix Batch & Sequence Manager leverages standard FactoryTalk View security. The default application
has been configured according to the base PlantPAx library object security model. For more details, refer
to the LBSM users manual.

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1. From the Overview Display button bar, select the Login

quadrant of the display.

button in the top right hand

2. At the log on prompt, Log In as the Operator with User ID = BatchOper with the Password =
Operator and click OK.

3. Select the CPG Menu button to return to the standard CPG navigation bar versus the FactoryTalk
Batch specific navigation bar.

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HMI Application
This section of the lab will familiarize you with basic HMI application.
1. Display the Sequence Control Window. To display the Run-Time Sequence window open the
Premix 1 display by selecting the Premix 1 button from HMI navigation bar..

The Premix 1 screen will open.

Then click on the magnifying glass to open the Sequence Control Window.

The Display Sequence Control window will open:

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2. Click on the Display Selection List.

3. Select Product D if it has not already been selected.

Now the sequence shown is for Product D.

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4. Start the sequence, by clicking on the Start icon

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found on Product D Sequence Display.

5. Note (a) that the sequence has transitioned from the Idle state to the Running state, and (b)
the sequence command buttons (Hold, Stop, Abort) are now activated.
Sequence State

Sequence Control
buttons

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Run the Sequence

We will continue to run, monitor, and interact with the sequence that was started above.
1. The first step, step 0, Initialization completes, the sequence then transitions to step 1 where
Additions 1 and 2 are dispensed automatically and the agitator starts when sufficient volume has
been added to the tank. The sequence progress is represented as shown below. Sequence
control activity can also be monitored on the dynamic process graphic. Shown at the bottom of
the page.

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2. A significant amount of information is available for the operator. Lets look at the screen in detail.
Highlight shows current step

Black dot indicates that phases is

complete for this step

Green boxes indicate active phases in this

step

Phase Sequence State Indicators

a. A rectangular outline highlights the current step

b. A green box indicates that the phase, in that step, is active
c.

A black dot indicates that the phase, in that step, is complete

d. A green box with a black dot indicates that the phase has completed its actions but is still
active. Typically this will be seen for phases that transition several steps such as
agitation.
e. The indicators at the far left display the current phase state.

The vertical axis displays the configured equipment and current phase status.

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A key to the indicators can be found by clicking on the Sequence State

displays the following:

which

The sequence state diagram is both functional and a key to the control icons.
3. Once both Material 1 and 2 additions are complete, the sequence progresses to Step 2, where
Material 3 is added also while agitating.

The Display Sequence Control windows has been size such that most of Premix 1 display is visible
and allows the process actions to be observed.

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4. The sequence progresses to Step 3, after the Material 3 addition is completed. At this point
agitation stops, recirculation begins (see PreMix display), and a Manual phase is initiated. The
blinking, orange, Manual Phase indicator and an exclamation mark indicate operator attention is
required.

5. Clicking on the blinking Manual phase box

displays the Prompt
Popup. Or you can click on the Respond to Manual Prompt Request button.

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The Manual input window opens:

6. After reading and performing the actions indicated in the Prompt popup, the operator would enter

a Lot Number and acknowledge the prompt by clicking on the checkmark.

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7. The sequence progresses to Step 4, where Agitation while Circulating contents takes place. The
time setpoint is a formula parameter of the Agitation phase, therefore the phase will complete
when time has expired. The Recirculation phase has completed the transition requirements but
will continue until the Agitation phase is also complete.

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8. When the required agitation time has expired, the sequence progress to Step 5, where another
Manual action, by the operator is required. Clicking on the Manual box
displays the Prompt popup, where this time, the operator is prompted to take a sample and enter
the results.

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9. Enter a value for the actual pH, 7.5 and press the ENTER key. After entering the data,
acknowledge the prompting by clicking on the green checkmark.

10.

The sequence transitions to step 6 and transfers the contents out of the tank.

In the PreMix display note the open valve, pump on and the tank level dropping.

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11. After the tank is empty, the sequence is complete. No steps are active, the sequence state is
Complete and the Reset button is active.

12. Pressing RESET SEQUENCE

returns the sequence to the Idle state.

13. Close the Product D Sequence Display by clicking on the red X

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Run the Sequence

Lets run another sequence to show the functions LBSM provides to the operator for additional sequence
interaction and control. We will explore the Pause and Skip, Hold/Resume, and Manual Phase control
features.
Pause and Skip
1. Click on the Display Sequence Control Window button in the lower left of the Premix 1 display.

the lower left

The Run-time Sequence window will appear. Click on the Display Selection List button.

2. Select Product G

, the Run-Time Sequence display will open.

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3. Notice that for this product, Pause points have been configured into the sequence

Commands

Pause points

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4. START a sequence of Product G

5. When step 1 is reached acknowledge the manual step.

6. Lets suppose that during the first material additions, Step 2, the operator wanted to check the
tank before continuing with the timed agitation in Step 3. Note that there is a configured pause
point between Step 2 and Step 3. Therefore, the operator can select Request sequence to
pause at next pause point. Click this button.

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7. At the end of the material additions, Step 2, we see that the sequence has paused, being
indicated by a green bar and pause point. Furthermore the Step Control buttons are now active.

8. The operator can continue to select Request sequence to pause at pause point or one can
select to enable Auto Pause, where the sequence will automatically pause at every configured
pause point. Lets go ahead and Pause sequence at each pause point by checking the
appropriate box.

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9. At this point, the operator can step forward to the next pause point or continue from this point.
Lets continue from this point by pressing Resume Sequence.

10. The sequence progresses with the timed agitation, Step 3. At the end of the time agitation, the
sequence is again paused. Lets assume that after checking the tank contents, the operator
needed to repeat the timed agitation. Press the Skip to Previous Pause Point button.
Notice that the sequence has indexed back to the previous pause point (which could be more than
one step).

11. Continue the sequence by pressing RESUME SEQUENCE.

12. The same process works for skip forward; again noting that a user can skip as many steps as
needed to get to the next configured pause point.

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Hold and Resume

1. After the timed agitation, continue the sequence by pressing RESUME SEQUENCE.
2. After Matl 3 is added in Step 4, continue the sequence by pressing RESUME SEQUENCE.

3. Acknowledge the manual prompt, Step 5, by pressing ACKNOWLEDGE.

The sequence will again stop at a pause point.

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4. Before pressing RESUME SEQUENCE to step on to step 6, read the next steps instructions and
be prepared to put the sequence in Hold. RESUME SEQUENCE and move to step 6 when
ready.
5. Now, suppose during the timed mixing cycle, Step 6, the operator needs to stop the circulation

and check the connection on the transfer pump. Press HOLD

phases into their respective hold states.

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to transition all active

You can view the Premix Overview process graphic to see that the recirculation has stopped.

Valve is closed and pump is stopped

Note: The Sequence Status and Control screen can be displayed by pressing the
Sequence Button in the lower left corner of the process graphic.
This button allows one to easily toggle between sequence display / control and the
process graphic.
This button shows the current sequence, the sequence state, and the current step.

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6. After tightening the Tri-Clamp on the pump, the operator can continue the sequence by pressing

the RESTART SEQUENCE button.

7. If you check the Premix Overview process graphic, you will see that the recirculation has
continued from where it left off.

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Manual Control
1. Suppose, that after the timed agitation completes in Step 6, we need to take another sample,

because of the pump failure. Step Back

The sequence should appear as follows:

and Resume

the sequence at Step 5.

2. Now suppose that after taking and analyzing a sample, the operator needs to add more Material
3. Click on MATL 3 ADDITION in the phase listing and the Manual Phase Control popup
appears.

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3. Take ownership of the phase by pressing ACQUIRE.

4. Click on the setpoint field and enter a setpoint of 23.7 Kg and then click OK. Also enter a
tolerance of 5 %.

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5. Then press START Phase.

6. The addition begins, which can be seen both on the Premix Overview process graphic and by the
phase status on the Manual Phase Control popup.

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7. After completing the addition, the phase transitions to Complete.

8. Reset the phase back to the Idle state by pressing RESET.

9. Release the phase from manual control by pressing RELEASE Equipment.

the Manual Phase control window.

Manual Phase Control can be initiated anytime, with or without a sequence running.
Furthermore, the sequence can be in any state, (e.g. running, held) for manual phase
control.

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and close

Abort Sequence
1. At this point we realize the sequence cannot be salvaged and needs to be aborted. Press

ABORT

. Click Yes to confirm this decision.

2. All phase activity aborts and the sequence transitions to the Aborted state.

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3. Press RESET to return the sequence to the Idle state.

4. The sequence and system returns to Idle.

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LBSM Reporting
Recently release is the Logix Batch & Sequence Manager v1.5 reporting add on. This new feature
uses a modified database from the FactoryTalk Batch reporting package to store data from the LBSM
batches running in the controller. Lets take a look.
Note: LBSM Reporting currently only works with FactoryTalk ViewSE.
The following reports are pre-developed.

010 Batch Listing

Provides a list of batches that meet a users search or query criteria
020 Batch Summary
Offers batch specific summary information on batch data (step time) and setpoint vs. actual
030 Batch Detail
Offers batch specific detailed information on batch data (step times, parameters, reports).
070 Batch Execution
Review a specific batchs step execution times in a bar chart format.
080 Duration Comparison
Compare the durations of multiple batches in a bar chart format.
1. To enable LBSM Reporting select the Configure Premix LBSM button in the lower left quadrant
of the Premix 01 display.

2. This brings up the Premix Tank Unit Configuration popup, the three buttons on the bottom half
of the popup are used for LBSM Reporting.

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3. Select Click Here to Start Report Generation

4. This brings up the small display below. This display contains VBA code that takes the data from
tags running in the controller and places it in the XML files and a SQL database. This data
consists of parameters and report tags and other batch information such as date and time, phase
state, etc. Dont close this display for the remainder of this section. Its display properties are set
for cache after displaying, always running always updating, this keeps the batch data updating
even when the display is not visible.

5. The Click Here to ABORT Report Generation button will close and uncache the Report
Generator display and stop archiving the batch data.

6. The final button on the Premix Tank Unit Configuration is Report Viewer
.
Selecting this button brings up a display that can be used to look at the XML file version of the
batch reports. These XML files are stored in the Report Location you see at the top of display.
Selecting a file name on the left will display the report in a Webbrowser control on the right.

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7. Go back to the FactoryTalk View client Premix 1 display and select the Display Sequence
Control Window button.

8. From the Run-time Sequence window select Display Selection List and select Product D and
run two batches.

9. Now we will use Internet Explorer to look at the batch reports, we will do this two ways first using
Windows Internet Explorer, then using a display in FactoryTalk ViewSE containing the Microsoft
Webbrowser control. Start Internet Explorer, the home page is set for the report page.
Selecting Batch Report on the left brings up the batch reports for FactoryTalk Batch and
selecting LBSM Reports brings up the reports for LBSM. Since both are using the same
BatchHistoryEx database there is overlap between the reports (if you have time feel free to look
at both). Select LBSM Reports to display the reports.

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NOTE: It may take a couple of minutes to get all the services loaded and running.
10. The second way to look at the reports is to create a display containing the Microsoft Webbrowser
control pointed to the report page URL. In the FactoryTalk ViewSE project there is such a
display. In the upper right on the navigation bar select the LBSM Reports button.

11. The LBSM Reports display appears with the five LBSM reports.

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Report Query Header

Before we look at the reports lets first get familiar with the query capability of the report system.
Each report uses this similar query method at the top of the report
1. Start Time/End Time
The reporting
system first filters all searches based on time. All sub-filter lists (Batch ID, Recipe Name,
Process Cell, & Unit Name) are trimmed based on the user selection of time. You should
consider time to be the master search criteria.

Null selections are available for both start and end time. These can be used to search
from the beginning of time (start time null) or to most recent time (end time null).

Standard Microsoft Reporting Services Date/Time syntax

is used. Selecting the Calendar
icon allows you to search in more detail or simply type
date and/or time into the box. The minimum data required is the date.

2. Batch ID Filter
The Batch ID is the user defined name given to a
batch at runtime. This filter allows the user to trim the query list to those matching the specified
text. Expand your filter capability through use of the asterisk (*) wildcard at any point in the filter.
3. Recipe Name
The Recipe Name is the name to which the batch
recipe is saved. The Recipe Name dropdown list is populated in real-time by listing all recipe
names run during the user specified time frame. By default, all items in this drop down are
selected. Any individual line items can be selected/un-selected by checking/un-checking the box
next to the name. Alternatively, the user can select all/un-select all by checking/un-checking the
select all check box.

Batch Listing Report

Now that we are familiar with the query header, lets perform our first batch list search.

1. Select 010-BatchListing

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2. The report will open with the following query header and the two reports that were just run
displayed. Notice that the default Start Time is 24 hours before the current time, hence any batch
run in the last 24 hours would be displayed.

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3. To see a listing of all the batches in the database select the Null checkbox to the right of the Start
Time.

4. . In the Recipe Name drop down list check the Select All box.

5. From the top right side of the report, select View Report

6. All the batches that have been archived to the database are now displayed.

7. If time allows try filtering the batches by using the Start Time Calendar.
NOTE: As you select dates and complete the Batch ID Filter, the remaining dropdowns
are updated to reflect your search criteria.

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8. Notice that for each line item, a set of two hotlink icons are shown. These enable quick
navigation to other reports that keep you in context of the specific Unique ID (unique identifier
for each batch.) of that line. As their names indicate the Batch Summary Report icon will open
up the batch summary report for the selected batch and the Batch Detail Report icon will open
the batch detail report for the selected batch.

- Batch Summary Report

- Batch Detail Report

Batch Summary Report

We will use what we have learned to look at the Batch Summary Report.

1.

Select LBSM Reports and then select 020-Batch Summary

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2. The report will open with the following query header shown in the upper part of the display below.
Notice that there are several different selection fields from the Batch Listing report page; these are
Recipe Name, Process Cell, Unit Name and Unique ID. In our example we only have one process
cell and one unit, if there were more units, like Premix and Reactor units seen earlier then there
would be multiple selections for Unit Name. The Recipe Name selection field is used to narrow
down what recipes you want to look at and the Unique ID field select the batch to look at.

Once the unique id for the batch is selected click on the

button and the
summary report for the selected batch will be displayed. Clicking on the plus-sign will expand the
data that is shown.

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Batch Detail Report

If more detail is require than supplied by the Batch Summary Report, the Batch Detail Report can
supply it.

1. Select LBSM Reports and then select 030-Batch Summary

2. This report will open with the same query header as the Batch Summary Report. Selecting a
batch to view is done the same way as with the Batch Summary Report.

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3. Once the batch is select and the report appears, clicking on the plus-sign will expand the data
that is shown. This report shows the parameters and reports that were recorded for the batch.

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Batch Execution Report

Better understanding the details of batch execution can lead to optimization of cycle time. It can also
give a clear picture of what happened during the product run.

1. Select LBSM Reports and then select 070 Batch Execution

2. This report will open with the now familiar query header. Select a batch as have been done in the
earlier steps.

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3. As shown below there is a bar graph showing the total time each of the six phases ran in the
Product D recipe.

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Batch Duration Comparison Report

The Batch Duration Report allows comparison of batch executions time.

1. Select LBSM Reports and then select 080 Duration Comparison

.
2. Using the same steps as above select a date, recipe(s) and unique id(s). Since on this report the
execution time of batches is being compare you can select multiple batches. Below show the
report with two batches selected . Product D has two manual steps in the recipe, the longer run
time of Batch ID 8 was due to taking longer to perform the manual steps.

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The Operators Perspective is now complete!

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Engineers Perspective
System modifications may be required over time; therefore, this user perspective will introduce you to a
couple of system engineering changes. In this lab, we will modify an existing phase and add a new
phase to the system.

Security & Login

1. From the Overview Display button bar, select the Login

quadrant of the display.

button in the top right hand

2. At the log on prompt, Log In as the Engineer with User ID = Engineer with the Password =
Engineer and click OK.

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Modifying the Configuration for an Existing Phase

The Requested Equipment Change

In recent research, R&D has found that limiting the rate of material 1 addition to each sequence will
improve the quality of the product. They have made this change request to engineering.
Engineering can easily accommodate this request by adding a new sequence parameter called Flow
Rate in KG/Sec for the material 1 addition phase. Lets take a look at how we can update LBSM.

1. LBSM phase configuration is performed from the Engineering HMI display. From the Premix 1,
display select Configure Premix LBSM.

Select the Wrench and Motor on the Premix Tank Unit Configuration popup to display the
Equipment Configuration Window.

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2. Once on the Engineering screen select a phase to modify. Suppose it has been determined
that product consistency is improved when the rate, at which Matl 1 is added, is specified as a
sequence parameter. Select MATL 1 ADDITION from the phase listing to display the Phase
Configuration screen.

3. First, check phase

(for phase parameters) in the third, available, real parameter location.
Add the parameter FLOW RATE to the phase. Press ENTER. Tab over and enter Kg/Sec for
the engineering units. Press ENTER. Leave the Scaled box unchecked, since the same flow
rate would be used, regardless of sequence size.

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We have now completed this LBSM configuration change for R&D. Keep in mind that
additional control code would also need to be added into the system, but the lab will not cover
that change.

Configuring a New Phase

The Requested Equipment Change

The Quality department has requested that all products running on Premix_01 take advantage of the
newly installed Steam in Place (SIP) system. This ensures a quality product.
Engineering has developed standard SIP phase logic, and would now like to add this functionality into the
LBSM system. Lets take a look at how we can update the LBSM equipment configuration

1. Continuing from above, SIP now needs to be configured in LBSM, thus making a SIP phase
available for use in sequence configuration.
2. From the Premix_01 equipment configuration screen, Select the next open box, below the
existing CIP phase.

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3. Type STERILIZER for Equipment Name. Type SIP for Phase Name. Press PAGE DOWN to
save both entries. (Page Down is an alternative to pressing Enter after each entry. Page
Down downloads all information on the screen.)

4. Under Real Parameters configuration, Check PHASE and add MINUTES for the Parameter
Name. Continue by entering MIN for the Engineering Units (EU). Press PAGE DOWN.

5. Check PHASE and add SECONDS for the Parameter Name. Continue by entering SEC for
the Engineering Units (EU). Press PAGE DOWN.

6. We have now added the new configuration for SIP and have included two setpoints for time delay

on the step. Close the configuration window by clicking on the red X.

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7. Click on the Run-Time Sequence Window button.

Notice that SIP is now included in the listing of phases.

You have successfully configured a new piece of equipment in LBSM. Now we will connect it
to the controller code that runs the equipment.

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Connecting LBSM to the Controller Code

LBSM interfaces to user developed logic, in an automation controller (e.g. CLX), through
a defined data structure. The application logic can be written with or without the use of
the PhaseManager instruction set.
This demo application uses the PhaseManager interface so that the same phase can
easily be managed with either a FTB (FactoryTalk Batch) or a LBSM (Logix Batch and
Sequence Manager) system.
Coding phases is beyond the scope of this session, but we will look at the interface and
data structures then import a pre-developed SIP Phase.
1. Open the previously minimized PlantPAxDemo_Batch_Master_Journal.acd RSLogix 5000
project.

NOTE: Each of the following activities will be done to the online running controller.
There is no need to shut your process down to make these connection to LBSM.
2. Coding phases is beyond the scope of this session, but we will look at the interface and data
structures then import
3. Select Controller Tags and scroll down to the _Equipment tag.

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4. Expand the _Equipment tag and note this is an array. Each member of the array aligns with a
position on the Phase Configuration display. For example, the phase Matl 1 Addition phase
aligns with EquipmentPhase[3] and the SIP phase you created above aligns with
EquipmentPhase[9]

5. Now lets import a pre-developed SIP phase. Right-Click on UP_PREMIX_01_Basic_Phase,

and select Import Equipment Phase.

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6. Browse to the C:\PlantPAx Demo\LBSM folder.

7. Select the PM01_SIP.L5X import file, and then click the

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button

8. On the import screen, leave the default values and click

9. When prompted, Select Finalize all edits in Equipment Phase, then select

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10. The new SIP phase will be added into the project tree.

11. When PhaseManager is used, an interface routine is added to each PhaseManager program.
This interface routine translates general LBSM commands to PhaseManager commands. Now
lets import this interface routine. Right-Click on the PM01_SIP routine and select Import
Routine.

12. Browse to the C:\PlantPAx Demo\LBSM folder.

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13. Select the LBSMIntfc.L5X import file, and then click the

button

14. In the Import Configuration dialog box, select Tags.

15. Change the alias for ThisPhase to PM01_SIP

16. From the Your_Phase_Name_Here Operation pull-down menu, choose Discard.

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17.
We will now assign the Premix_01 SIP phase pointer. This is the primary way LBSM
connects to this specific PhaseManager phase. Therefore, from the EP Alias For pull-down
th
menu, Select _Equipment[0,9] from the list. (Remember SIP was assigned to the 9
equipment position in the previous section when the SIP phase was configured in LBSM.)

18. Select Other Components and replace the Final Name with PM01_SIP

19. Click OK to import the configuration.

20. When prompted, Select Finalize all edits in Equipment Phase, then select

21. When the interface routine successfully imports, right-click on the PM01_SIP phase and select
Properties.

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22. Under the Configuration tab, Use the dropdown to set LBSMIntfc as the Prestate routine, and
Select OK.

You have now successfully linked the LBSM engine to this specific PM01_SIP
PhaseManager phase.
In an earlier section we defined 2 input parameters for the SIP phase, Minutes & Seconds.
We need to now map these values into the PhaseManager phase.
23. Double-click the LBSM_Intfc routine under the PM01_SIP phase to open the routine.
24. Select the second rung as shown in the picture below, and then click the Start Pending Rung
Edits from the toolbar.

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25. Change the Destination tag address of the first move instruction to Minutes and change the
destination tag address of the second move instruction to Seconds

26. Select Finalize all edits in the Equipment Phase from the toolbar.

27. When prompted, select YES to complete the edit.

You have now successfully mapped the input parameters from LBSM to the PM01_SIP
PhaseManager inputs.
The Engineers Perspective is now complete!

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R&D (Recipe Author) Perspective

The goal of an ISA88 based batch management & control system is to separate the sequence from the
equipment. This user perspective will demonstrate how you as a recipe author can create and edit
sequences (both procedure and formula) independent of the plant floor equipment.

The Requested Sequence Changes

1. Lab tests have shown that we can maintain product quality while reducing cost by adding less of
Matl 1.
2. Testing has also shown that less separation occurs, if we continue to circulate the tanks contents
while the operator is taking a sample.
3. Next, we can eliminate a build-up issue if Matl 3 is added in two stages rather than all at once, as
is currently done.
4. Finally, we will add the SIP step into the product sequence to satisfy the new request from the
quality department.
We will be making these procedural and formula changes next, using the LBSM Sequence Editor.

LBSM Sequence Editor

The LBSM Sequence Editor is used to create and configure sequences. All configurations are performed
from a HMI client display. In LBSM, the user can create/edit either a master sequence for the unit or edit
sequence already loaded into the unit.
Navigate to the Sequence Editor
1. LBSM recipe configuration is performed from the Engineering HMI display. From the Premix 1,
display select Configure Premix LBSM.

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2. The LBSM Sequence Management display appears.

3. Select the Display Master Sequence Edit Selection Window button

under Premix
01. When the popup opens, select Product D, by clicking on the appropriate button.

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4. Now, lets make the desired set-point adjustment for the Matl 1 Addition in Step 1. Begin by
clicking on the green box at the intersection of Step 1 and Matl 1 Addition.

The sequence display shows steps on the horizontal axis and phases on the vertical
axis. A green box, at any intersection of step/phase, indicates that the phase will execute
in that step.

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The Step Edit screen opens.

Take a moment and familiarize yourself with this screen.

The blue triangle, on the top row, indicates the step currently being edited, in this case
Step 1. Highlighted green phases are those phases that are executed in this step.
The blue triangle on the left hand side points to the phase being configured. Highlighted
green step numbers above, indicate all steps that have the selected phase configured in
them.
The top data box is the step configuration window. This allows the user to name each
step, assign timeouts and fault propagation, and enables a pause point.
The parameters and selections in the working area of the screen are configurations for
that phase instance. Finally, the checkmark enables or activates the phase in this step.

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5. To change the amount of Matl 1 click on the set-point field and enter the desired amount 195.3
in the data entry pop-up followed by OK.

6. Close the Step Edit display by clicking on the red X in the upper right hand corner of the
screen.

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7. Now, lets address the second new requirement, which was, to continue circulating the tanks
contents while a sample is being taken (which occurs in Step 5.). Begin, as before, by clicking
on the intersection between the Recirc phase and Step 5.

8. Check the Active box to enable this phase while in this step.

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9. We have now completed the second requirement of adding circulation while the also sampling the
contents. Note again the completed step and the significance of the various indicators on this
display.

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10. Close the Step Edit display and return to the Sequence Edit display by clicking on the red X
in the upper right corner of the Step Edit screen.

11. For the third requirement, Split the Material 3 Addition, before and after the Hand Addition, we
need to add a new activity between what is currently Steps 3 & 4. To insert a step, first enter the
Insert/Delete Step Mode by checking the appropriate box on the Sequence Edit

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12. Next insert a new step by checking the box between Steps 3 & 4.

Note the position of the + and - buttons. Selecting + will insert a step between two
existing steps, while selecting - will delete the existing step.
13. Click Insert.

14. Add another Material 3 addition to the new Step 4, by clicking on the intersection between Step
4 and the Material 3 Addition phase.

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15. Enable the phase, enter 12.5 Kg and 5% tolerance for the addition, and provide a Step
nd
Description such as 2 Matl 3 Add.

The completed step configuration should appear as follows:

To save entries and edits, be sure to press ENTER while on the field. Alternatively, all
entries can be made, then press PAGE DOWN, which will save all page edits.

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16. Note, by the green highlight, that Material 3 is also added in Step 2. Click Step 2 to change the
amount of Material 3 added in that step.

17. Change the amount of Material 3 added in Step 2 from 25 kg to 12.5 kg (since we are now
adding the other half in Step 4). The completed step configuration should appear as follows.

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18. Close the sequence edit windows and navigate back to the Premix 01 screen. Open the runtime

detail screen by clicking on the magnifying glass in the bottom left hand corner.
19. Select the Display Selection List, and from the popup select Product D to load the updated
master sequence for the Premix_01.

20. You should now see the 3 changes we just made in the newly loaded Product D sequence.
th

But wait! We forgot the 4 sequence change request which was to add the SIP step into
the sequence! No problem, we will edit the runtime sequence and save it back to the
master sequence.
21. Now, lets address the last new requirement, which was, to add an SIP step into the sequence

(which occurs in Step 8.). Select the Edit the currently running sequence

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button.

22. Begin, as before, by clicking on the intersection between the SIP phase and Step 8.

23. The blank step configuration window will appear. Change the Step name to SIP Step, Select
the Active checkbox, and enter a value of 30 into the Seconds Parameter field.
24. Press the Page Down key to download all changes on the page.

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25. Close the window by selecting the Red X

26. Now we need to save the runtime sequence back to the master sequence list. Select the Save
current recipe as master recipe button.

27. Select Product D.

28. When prompted to confirm the save, select Yes.

29. We are now ready to run a new sequence which would execute with the requested sequence
modifications, those being:

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a. Changing the amount of Matl 1 added from 250 kg to 195.3 kg.

b. Continue to circulate the tanks contents while also taking a sample in Step 5.
c.

Adding a new step and splitting the Matl 3 addition between Step 2 and a new Step 4.

d. Added a new SIP step at the end of the sequence in step 8.

The R&Ds (Recipe Author) Perspective is now complete!

If you choose, you can re-run the modified sequence by following the Operators perspective and
selecting the Product D sequence.

This completes this lab section on Logix Batch & Sequence Manager

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Appendix:
How to fix a controller with a red X
1. A red X in the controller slot means there was a problem. Follow this section for how to resolve a
red X in the controller as shown here for slot 2:

2. Select the controller with the red X, then right-mouse click to remove it.

3. The Remove Module window appears, please check the Clear Chassis checkbox and select OK.

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4. The warning message appears, select OK.

5. Select the empty slot that was removed and right-mouse click to Create a new module.

6. Follow the wizard to create a new controller whether slot 2 or slot 3. For this example we are
showing slot 2 only. Do the same for slot 3 if needed. Select OK.

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7. In the General window, change the Memory Size to 8192, then select Next.

8. Take the default on NT System window, and select Finish.

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9. From the start bar, launch RSLogix5000, Start > RSLogix 5000.

10. Return to the Setup section for instructions on downloading the project file to the controller.

LBSM Sample Application

If you have time and would like to look at the sample application that comes with LBSM when you
download the files from technote AID 68709, follow these steps.
1. Close the FactoryTalk ViewSE client.
2. Close the open RSLogix 5000 project that we have been using for this lab.
3. From RSLogix 5000 do a file open and go to C:\LBSM V1.5-01\Controller\Sample Projects\With
Journal\LBSM_Sample_V1_5.ACD.
4. Download this project to the controller in slot 4, when done set it to Run. Check the time.

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5. Select Start and FactoryTalk View Site Editoin Client and from the wizard select
LBSM_Reporting.cli and Run.
6. This will bring up FactoryTalk ViewSE project that comes with LBSM reporting.
7. From here you can run batches and enable reporting. Use Internet Explorer to look at the
reports. Raise your hand if you have any questions.

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