Minerals Applications

Course CH112

Chapter 11 Minerals Applications

TABLE OF CONTENTS

Chapter 11 Minerals Applications.......................................................................................................................1 11.1 General Information ......................................................................................................................1

11.1.1 Description..........................................................................................................................1 11.1.2 Objectives ...........................................................................................................................1 11.1.3 Reference Documentation ..................................................................................................1

11.2 Lesson 1 – Minerals Libraries (BMI Libraries).............................................................................2 11.2.1 Description..........................................................................................................................2 11.2.2 Objectives ...........................................................................................................................2 11.2.3 Libraries overview..............................................................................................................2

11.2.3.1 Library: BMIConst .............................................................................................3 11.2.3.2 Library: BMISupport..........................................................................................4 11.2.3.3 Library: BMIAdapations ....................................................................................4 11.2.3.4 Library: BMIStandard ........................................................................................5 11.2.3.5 Library: BMILib_WeighFeeder .........................................................................6

11.2.4 Learn the different object types ..........................................................................................7 11.3 Lesson 2 – Application and Variable Structure of BMI Applications...........................................8

11.3.1 Description..........................................................................................................................8 11.3.2 Objectives ...........................................................................................................................8 11.3.3 Application and Variable Structure ....................................................................................8

11.3.3.1 Variable Structure...............................................................................................9 11.3.3.1.1 Data Types.............................................................................................9 11.3.3.1.2 Variable and tag naming......................................................................16

11.3.3.2 Application Structure .......................................................................................17 11.3.3.2.1 Control Modules ..................................................................................17 11.3.3.2.2 Single Control Modules for I/O-signals ..............................................18 11.3.3.2.3 Single Control Modules for Group Objects.........................................21 11.3.3.2.4 Interlock (glue) logic for Group Objects .............................................24

11.3.4 Learn to understand the application and variable structure ..............................................26 11.4 Lesson 3 – Add I/O-signals and connect them in the application ...............................................27

11.4.1 Description........................................................................................................................27 11.4.2 Objectives .........................................................................................................................27 11.4.3 Type and categories of I/O-signals ...................................................................................27

11.4.3.1 Add I/O-signals that are not integrated with the operator station.....................28 11.4.3.2 Add I/O-signals that are integrated with the operator station...........................33

11.5 Lesson 4 – Insert a motor in an existing group............................................................................42 11.5.1 Description........................................................................................................................42 11.5.2 Objectives .........................................................................................................................42 11.5.3 Procedure ..........................................................................................................................42 11.5.4 Practical exercise ..............................................................................................................43

11.5.4.1 Creation of variables ........................................................................................44 11.5.4.2 Creation and configuration of Control Module Instances ................................44 11.5.4.3 Programmation of interlock logic.....................................................................44 11.5.4.4 Connection of I/O-variables to I/O-channels ...................................................45

Course CH112 Chapter 11: Minerals Applications

1

Chapter 11 Minerals Applications

11.1 General Information

11.1.1 Description

This chapter describes how Minerals Applications (BMI Applications) are configured and programmed.

11.1.2 Objectives

On completion of this chapter you will be able to:

• Know the Minerals Libraries (BMI Libraries) that are used as a base for application programming

• Know the different object types and its basic functionality from the controller point of view

• Describe the application and variable structure of Minerals Applications.

• Add I/O-signals and integrate them in the application.

• Insert a motor in an existing group

• Program motor interlocks

11.1.3 Reference Documentation

• Minerals Library Product Guide

• Reference Manuals for the following object categories: • Basic Objects • Group Objects • Consumer Objects • Loop Objects • Dosing Objects • Report Objects • Communication Objects


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11.2 Lesson 1 – Minerals Libraries (BMI Libraries)

11.2.1 Description

This lesson describes the Minerals Libraries (BMI Libraries) that are used to program Minerals applications.

11.2.2 Objectives

On completion of this lesson you will be able to:

• Describe the Minerals Libraries (BMI Libraries) that are used as a base for application programming.

11.2.3 Libraries overview

Before application development can be started the following BMI Control Builder Libraries must at least be inserted in your project: • BMIConst • BMISupport • BMIAdaptions • BMIStandard

When weighing feeders are part of the application the following library has to be inserted as well: • BMILib_WeighFeeder

The official name of the complete library set is called ControlIT AC800M Minerals Library and contains all the controller software modules that are used to configure BMI applications (main focus being in Minerals Industry) with ControlIT AC800M controllers.

See also the Product Guides

These libraries are inserted automatically when inserting the BMI Libraries

This library is always (per default) inserted in your project.


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11.2.3.1 Library: BMIConst

The library BMIConst, contains all (project) constants that are used in the other BMI Libraries.

Each constant has a Name, that is used to connect the constant value in the other BMI Libraries.

In the example above, the selected project constant is called cBMI.MOT.M1_txt.

• The Default value is ‘Not Available’

• The data Type is string.


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11.2.3.2 Library: BMISupport

The library BMISupport, contains specific Function Blocks that can be used in BMI applications in addition to the standard function blocks delivered with the system libraries.

11.2.3.3 Library: BMIAdapations

The library BMIAdaptions, contains specific Function Blocks that are used and required by some of the software modules in the BMIStandard Library.

It also contains specific Control Modules, that can be used in BMI applications as an extension to certain Object Types, providing LCB – Local Control Box functionality (local control of the object via push buttons).

The password to the BMIAdaptions Library is public, so that users can modify the code according to their needs (e.g. project specific LCB – Local Control Box functionality)


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11.2.3.4 Library: BMIStandard

The library BMIStandard, contains the actual set of purpose-build, typical, software modules that are used to configure the BMI applications.

These software modules have been developed with the ABB Control Builder M Professional programming tool, as Control Modules Types (CM). The Control Modules are compliant with the IEC 61131-3 standard.

These software modules comprise the Minerals Library, and are grouped in seven different object categories: • Basic Objects • Group Objects • Consumer Objects • Loop Objects • Dosing Objects • Report Objects • Communication Objects

A separate Reference Manual is available for each object category, providing more details.


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Exeptional two software modules have been developed as Function Block Types:

For further details, see the Reference Manual for Group Objects.

11.2.3.5 Library: BMILib_WeighFeeder

The library BMILib_WeighFeeder, contains thesoftware modules that are used to configure weigh feeder objects in the BMI applications.

To become a Weigh Feeder Control proportioning function when designing an application one Control Module Instance WFC will be combined with several WFC_Prop Control Module Instances (between 2 to 8).

The WFC proportioning function is normally also used in combination with: • Drive Group (GRBAS05, GRPEXP) • Loop objects (PID) • Consumer objects (PID) • Preselection Binary (PREBIN) • Start Warning (STW)

For further details, see the Reference Manual for Dosing Objects.


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11.2.4 Learn the different object types

To do:

• You need to study the different Reference Manuals for the different object categories: • Basic Objects • Group Objects • Consumer Objects • Loop Objects • Dosing Objects • Report Objects • Communication Objects

• Concentrate basicly on the CONTROL part of the objects !

What are the different object types that exist ?

When and where do you use them ?


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11.3 Lesson 2 – Application and Variable Structure of BMI Applications

11.3.1 Description

This lesson describes the application and variable structure of BMI Applications.

11.3.2 Objectives


• Understand the application and variable structure of BMI Applications.

• Understand how variable names are constructed.

• Navigate in the application structure.

• Know where the “glue” logic or interlock logic for Groups needs to be programmed.

11.3.3 Application and Variable Structure

For each Process Section one Application is created in the corresponding project. The general rule is that one application is assigned to one specific Controller.

Some examples of Process Sections that can exist in a BMI application: • Cement Mill • Kiln • Cooler • Raw Mill • Bunker Transport • . . .


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An Application consists of two major items: • Data Types : variable structure • Control Modules : application structure

11.3.3.1 Variable Structure

11.3.3.1.1 Data Types

The Data Types are used for the following purpose: • To set-up the variable structure (via structured data types) • To define all the variables that are going to be needed in the application

Every application consists of exactly one, global, structured variable. The name of this variable must be IO and the data type is IO_Type.

IMPORTANT: The attribute must be hidden.


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In the Data Type IO_Type, all signal types are defined that are going to be needed in the application.

Reference Table, I/O-signal types Name Functionailty DIS Digital Input Signals, that are going to be presented on the operator station

(as alarm and/or dynamic point in a graphic display) DIX Digital Input Signals, that are NOT presented on the operator station

(only used in the application in the Control Builder). The signal is in general connected to an input of an object, like an availability signal for a motor.

DIC Digital Input Calculated. Signals that are going to be presented on the operator station (as alarm and/or dynamic point in a graphic display) and that are the result of a calculation or a control logic in the application.

The principle is the same for the following type of signals: • AIS/AIX/AIC : Analog input signals • DOS/DOX/DOC : Digital output signals • AOS/AOX/AOC : Analog output signals

I/O-signal types

I/O-signal types

Other signal types


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. . .

Reference Table, other signal types Name Functionailty STW Start Warning Signals. _NNN_GRn Signals for one specific Group within a process section

The actual signals for each Signal Type are defined in separate tables, which are the so called Data Types.

Example 1: All the variables for the digital input signals of the type DIS are defined in the Data Type DIS_Type, in the corresponding application.

Each digital input signal itself contains a set of pre-defined sub variables, that are defined in the Data Type DISData.

The Data Type DISData is defined in the library BMIStandard.


Variable names


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Example 2: All the variables for the objects and general signals (general variables) for the Group _211_GR1 are defined in the table _211_GR1 _Type.

Each Preselection contains a set of pre-defined sub variables, that are defined in the Data Type PreBinData.

The Data Type PreBinData is defined in the library BMIStandard.

The principle is the same for all other objects that can be part of a group: • MOT1, MOT2, MOTP, MOT1_VVF : Motor objects • PIDCtrl : PID Controllers • VLV1 : Valve objects

IMPORTANT: Each object type (MOT1, MOT2,…) has its corresponding set of pre-defined sub variables that are defined in its object type specific Data Type, in the library BMIStandard, which is password protected. E.g. MOT1 -> MOT1Data MOT2 -> MOT2Data … VLV1 -> VLV1Data

Variable names for the Preselections

General variables for the Group

Variable names for the Consumer Objects


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The example below illustrates the required variable structure for a typical BMI application:

IO_Type

AICData <AIC Tag 1>

AICData <AIC Tag 2>

AICData <AIC Tag 3>

AOSData <AO Tag 1>

AOSData <AO Tag 2>

AOSData <AO Tag 3>

bool <DI Tag 1>

bool <DI Tag 2>

bool <DI Tag 3>

GrpInput In

GrpOutput Out

GrpDrvCon GrpDrvCon

PreBinData <P1>

PreBinData <P2>

MOT1Data <Cons 1>

MOT2Data <Cons 2>

VLV1Data <Cons 3>

bool <My Var 1>

real <My Var 2>

dint <Board1>

dint <Board2>

bool <MCC1>_AV

AIC_Type AIS

DOC_Type DOC

AIX_Type AIX

AOC_Type AOC

AOS_Type AOS

AOX_Type AOX

DIC_Type DIC

DIS_Type DIS

DIX_Type DIX

AIS_Type AIC

DOS_Type DOS

DOX_Type DOX

<Grp1>_Type <Grp1>

<Grp1>_Type <Grp2>

<Grp1>_Type <Grp3>

<Grp1>_Type <Grp4>

System_Type System

MMS_Type MMSCom

STW_Type STW STWData <STW 1>

STWData <STW 2>

bool <Cons1>_RUN

bool <Cons1>_RFS

real <Signal1> N1_N2_Type N1_N2

N1_N2_Type N2_N1

Global variable IO of Data Type IO_Type

Signal types

In, Out and GrpDrvCon are always required for a Group

Optional Group specific variables, if needed

Variable names for Pre-selections

Variable names for consumer objects

Variable names for AIC signals

Variable names

Pre-defined sub variable sets defined in library BMIStandard


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The example below illustrates the required variable structure for the application _20, from the BMI_Training project; presented with Control Builder screen shots:

Signal types Data Types where the signal / object names are defined


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Variable names for Digital Input Signals of the type DIS

Variable names for the pre-selections, consumer objects and general signals (general variables) for the Group _211_GR1.

For more detailed information concerning the variable structure of each object type refer to the reference manual: BMI Library - Overview

Pre-defined sub variable set for DIS, defined in library BMIStandard

Pre-defined sub variable sets for the corresponding object types, defined in library BMIStandard


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11.3.3.1.2 Variable and tag naming

To be able to connect variables in the application, e.g. for interlock logic; the variable structure and also the variable naming must be very well known.

? Question 1:

• You need to programm some interlocks for a motor object of the type MOT1

• The tag name of the motor is 211-HC1.M1

• The motor object belongs to Group _211_GR1 in application _20

• The interlocks that need to be programmed are of the type IB2, IB3 and IB4

What are the complete variable names of the signals that you will connect to the output of the functions / function blocks from your interlock logic:

Refer to the reference manual: BMI Library – Consumer Objects

? Question 2:

• You need to connect a digital input signal (DIS) to an input of an AND-gate in your interlock logic for the motor 211-HC1.M1 (see question 1)

• The tag name of the signal is 211-HX1.T1.L

• The signal belongs to application _20

What is the complete variable name of the signal that you will connect to the input of the AND-gate in your interlock logic:

Refer to the reference manual: BMI Library – Basic Objects

⌦ The same principle is valid for all I/O-signals, Consumer Objects, etc…

Tag name: corresponds to the object name that is indicated on the operator station.

Variable name: corresponds to the variable name of the object in the Control Builder.


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11.3.3.2 Application Structure

11.3.3.2.1 Control Modules

The Control Modules are used for the following purpose: • To set-up the application structure (via single control modules) • To create and configure the objects (basic objects, consumer objects, etc…) that

belong to the corresponding application.

Remember the following from what we learned before: - For each Process Section one Application is created in the corresponding project - The general rule is that one application is assigned to one specific Controller

Single Control Modules (SCM), can be compared with a program, where several objects (basic objects, consumer objects, etc…) are grouped together and where additional control and/or interlock logic can be programmed for these objects, if needed.

SCMs for process I/O-signals and calculated I/O-signals. For each type of I/O-signal there is one SCM

SCMs for Group Objects. For each Group there is one SCM.


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11.3.3.2.2 Single Control Modules for I/O-signals

1. For each type of I/O-signal one Single Control Module (SCM) is created, as shown below:

2. Under the corresponding SCM, instances of the corresponding Object Type are created.

Example 1: All instances for the digital input signals of the type DIS are created under the SCM, which is called DIS.

. . .

Example 2: All instances for the analog input signals of the type AIS are created under the SCM, which is called AIS.

. . .

For each DIS-Signal there is one instance of the Object Type DIS

RULE: The instance name must be the same as the variable name, that was created in the Data Type DIS

For each AIS-Signal there is one instance of the Object Type AIS

RULE: The instance name must be the same as the variable name, that was created in the Data Type AIS


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3. Each instance under the corresponding Single Control Module has to be configured via the Parameter List, of that instance.

We also say, the parameters of the instance need to be connected.

Example 1: Configuration of the digital input signal of the type DIS, which has the tagname _211_2W1_G1_A

Refer to the reference manual: BMI Library – Basic Objects => DIS – Parameter Description

⌦ Parameters that have no Initial Value must be connected, otherwise an error indication will be shown, in the Project Explorer. Parameters that have an Initial Value can remain unconnected. If unconnected, the Initial Value is used as the default connection instead. The connection with the parameter IO, must be done. In this example the variable IO.DIS._211_2W1_G1_A (structured variable) is connected to the parameter IO.


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Example 2: Configuration of the analog input signal of the type AIS which has the tagname _211_HC1_J1_Z

Refer to the reference manual: BMI Library – Basic Objects => AIS – Parameter Description

⌦ Parameters that have no Initial Value must be connected, otherwise an error indication will be shown, in the Project Explorer.

The connection with the parameter IO, must be done. In this example the variable IO.AIS._211_HC1_J1_Z (structured variable) is connected to the parameter IO.


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11.3.3.2.3 Single Control Modules for Group Objects

1. For each Group that belongs to a process section, one Single Control Module (SCM) is created, as shown below:

Remember the following from what we learned before: - For each Process Section one Application is created in the corresponding project - The general rule is that one application is assigned to one specific Controller

2. Under the corresponding SCM for a Group, instances of the Consumer Objects that are member of that Group, are created.

Example 1: Under the SCM _291_GR1, all the instances for all Consumer Objects , that belong to the Group _291_GR1, are created.

Example 2: Under the SCM _291_GR2, all the instances for all Consumer Objects , that belong to the Group _291_GR2, are created.

This Group has the following instances: - 1 instance for the GROUP object - 2 preselection instances; PREBIN - 2 motor instances, motors of the type MOT1

RULE: The instance name must be the same as the variable name, that was created in the corresponding Data Type

RULE: The instance name must be the same as the variable name, that was created in the corresponding Data Type

This Group has the following instances: - 1 instance for the GROUP object - 6 motor instances, motors of the type MOT1


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3. Each instance under the corresponding Single Control Module for a Group has to be configured via the Parameter List, of that instance.

We also say, the parameters of the instance need to be connected.

Example 1: Configuration of the GROUP object, which has the tagname _291_GR1

Refer to the reference manual: BMI Library – Group Objects => GROUP – Parameter Description

Number of steps within the Group


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Example 2: Configuration of theMOT1 object, which has the tagname _291_BC3_M1

Refer to the reference manual: BMI Library – Consumer Objects => MOT1 – Parameter Description

? What do you remember from what we learned about Initial Value ? _______________________________________________________

Motor is started first (1) and stopped last (1001) within the Group


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11.3.3.2.4 Interlock (glue) logic for Group Objects

1. Basic sequential control (automatic sequential start-up and shut-down) of the different consumer objects that belong to a group is performed by the GROUP object.

No specific application programming is required for this, only the configuration of the GROUP object and the CONSUMER objects, is required: - For the GROUP object you need to configure the number of steps via the parameter NoOfSteps - For the CONSUMER objects you need to configure the start step and the stop step via the parameters GrpStartStep and GrpStopStep

2. Interlocks between the different consumer objects are not handled by the GROUP object, because they can be different from plant to plant.

The interlock logic is programmed on the Single Control Module level:


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Different Code Blocks contain the necessary Glue or Interlock Logic.

Naming convention of the Code Blocks:

• Pre-Selection : PreSel_Control

• Group interlocks : Intrl_<GROUP NAME>, e.g. Intrl_291_GR1

• Consumer interlocks : Intrl_<OBJECT NAME>, e.g. Intrl_291_BC3_M1

• One Code Block contains the Pre-Selection Logic (only if preselection is available in the Group; PREBIN objects)

• One Code Block contains the Interlock Logic for the GROUP itself.

• For each COMSUMER object one Code Block contains the corresponding Interlock Logic


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11.3.4 Learn to understand the application and variable structure

To do:

• You need to study the application _30 from the project BMI_Training:

How many GROUPs does this application have ?

What is the tag name and description of each GROUP ?

• Now, You need to investigate all GROUPs in application _30, in detail:

How many OBJECTs does each application have ?

What is the object type, tag name and description of each OBJECT ?

• Now, You need to investigate all I/O-signals in application _30, in detail:

How many Analog Inputs Signals are used in this application ?

How many Digital Input & Digital Output Signals are used in this application ?

• Now, You need to investigate the interlock (glue) logic from the Group _361_GR2 in application _30, in detail:

What do You observe ?

Try to explain the interlocks between the different objects.


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11.4 Lesson 3 – Add I/O-signals and connect them in the application

11.4.1 Description

This lesson describes how to add and connect I/O-signals in an existing application.

11.4.2 Objectives


• Add different type of I/O-signals in an existing application:

• Connect the I/O-signals to I/O-modules

• Connect the I/O-signals to existing control module instances or to interlock logic.

11.4.3 Type and categories of I/O-signals

Remember the following from what we learned before:

Reference Table, I/O-signal types: Name Functionailty DIS Digital Input Signals, that are going to be presented on the operator station

(as alarm and/or dynamic point in a graphic display) DIX Digital Input Signals, that are NOT presented on the operator station

(only used in the application in the Control Builder). The signal is in general connected to an input of an object, like an availability signal for a motor.

DIC Digital Input Calculated. Signals that are going to be presented on the operator station (as alarm and/or dynamic point in a graphic display) and that are the result of a calculation or a control logic in the application.


⌦ Summarised we can say, that there are two major categories of I/O-signals, nl: • I/O-signals that are integrated with the operator station:

- DIS, AIS, DOS, AOS (process signals) - DIC, AIC, DOC,AOC (calculated signals)

• I/O-signals that are not integrated with the operator station: - DIX, AIX, DOX, AOX (process signals)


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11.4.3.1 Add I/O-signals that are not integrated with the operator station

1. Found out what type of signal needs to be added (AIX, DIX, DOX, AOX):

. . .

2. Open the corresponding Data Type under the corresponding Application (remember what we learned before: one application for each process section) and add a new component.

Example: Adding a DIX-signal with the variable name _211_SX1_M1_OL in application _20. (the signal indicates OverLoad of the motor _211_SX1_M1).


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The variable for new signal will be inserted after the signal _211_SX1_M1_R as follows:

Don’t forget to press , to confirm and accept the modification.

? Why is the Data Type = bool ?

Variable names


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3. Now, connect the new signal to the corresponding Parameter of the corresponding Control Module Instance.

Example: Connect the new DIX-signal with the variable name _211_SX1_M1_OL to the Parameter M2 (MCC interface signal 2, default “Overload”) of the motor instance _211_SX1_M1, in application _20


? What is the most efficient way to connect the new signal ?


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4. At last, the new signal must be connected, to the corresponding I/O-channel of the corresponding I/O-module. The I/O-channel must be free, of course.

Example: Connect the new DIX-signal with the variable name _211_SX1_M1_OL to a free I/O-channel

? In which controller do you need to search for a free Digital Input Channel ?


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Go to a free channel and complete the fields Variable and I/O Description


Free Digital Input Channels (no variable connected)



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11.4.3.2 Add I/O-signals that are integrated with the operator station

1. Found out what type of signal needs to be added (AIS, AOS, DIS, DOS):

2. Open the corresponding Data Type under the corresponding Application

(remember what we learned before: one application for each process section) and add a new component.

Example: Adding a DIS-signal with the tag name 211-HX2.T1.LL in application _20. (this signal indicates Oil Temperature of the heater very low).


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The variable for new signal will be inserted after the variable _211_HX2_T1_L as follows:


? Why is the Data Type = DISData ?

? The variable name is _211_HX2_T1_LL and the corresponding tag name is 211-HX2.T1.LL ? Why is that ?

Variable names


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3. Now, a Control Module Instance of the type DIS has to be created.

Example: Creation of a DIS Control Module Instance with the instance name _211_HX2_T1_LL in application _20.

• Select the Library BMIStandard and the Control module type DIS from the window which is appearing now:

• Type the Instance name: RULE: The instance name must be the same as the variable name, that was created in the Data Type DIS

? Uncheck the box Connect parameters. WHY ?


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After pressing OK, the Control Module Instance for the DIS-signal 211-HX2.T1.LL, has been created.

The red indication indicates that the Parameters that needs a connection (those that have no Initial Value) are not connected, yet.

4. Now, the Control Module Instance has to be configured, via the Parameter List (Connections).

Example: Configuration of the Control Module Instance with the instance name _211_HX2_T1_LL in application _20.

Refer to the reference manual: BMI Library – Basic Objects => DIS – Parameter Description

What do you remember from what we learned about Initial Value ? _________________________ _________________________

Tag name of the DIS-signal


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5. Now, the new signal must be connected, to the corresponding Interlock Logic of

the corresponding Consumer Object.

Example: Connect the new DIS-signal with the tag name 211-HX2.T1.LL to the interlock logic of the Consumer Object 211-HC1.M2 in Group _211_GR1 in application _20.

? Do you remember how to go to the interlock logic ? _______________________________________________________

! Add an input to the AND-Gate and connect the DIS-Signal


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⌦ First add an input to the AND-Gate (Select the AND-Gate and press right-mouse key)

⌦ Then increase the number of inputs to three

=> Input has been added:

⌦ Now connect the new DIS signal to the new input of the AND-Gate:

Note the difference between the signal connections: - Signal.Normal : ________________________ - Signal.Value : ________________________



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6. At last, the new signal must be connected, to the corresponding I/O-channel of the corresponding I/O-module. The I/O-channel must be free, of course.

Example: Connect the new DIS-signal with the tag name _211_HX2_T1_LL to a free I/O-channel

? In which controller do you need to search for a free Digital Input Channel ?


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Go to a free channel and complete the fields Variable and I/O Description

Other Question: How must the connection be made for the signal types AIS, DOS, AOS ?

Signal T

Component to be connected

AIS

DOS

AOS

Free Digital Input Channels (no variable connected)


! Connection to be done with component .SigHW => Any idea why ?


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11.5 Lesson 4 – Insert a motor in an existing group

11.5.1 Description

This lesson describes how to insert a new motor in an existing group, via a practical exercise, that is done as team work and that is guided by the teacher.

11.5.2 Objectives


• Insert a new motor in an existing group

• Create the I/O-signals for the motor and connect them to the motor object.

• Program the interlock logic for the motor.

11.5.3 Procedure

The basic steps to be taken when inserting a new motor in an existing group are:

1. Creation of all variables that are going to be needed for the motor object and for its corresponding I/O-signals.

2. Creation and configuration of the control module instances for the motor and for the I/O-signals that are integrated with the operator station (e.g. Rope Switch).

3. Programmation of the interlock logic for the new motor.

4. Connection of the I/O-signal variables to the corresponding I/O-channels.


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11.5.4 Practical exercise

• A new motor must be inserted in the group 291_GR2 in application _20.

• The tag name of the new motor is 291-BC4.M1

• The new motor must start after the motor 291-BC1.M1 and before the motor 291-SC1.M1

• The new motor has the following Digital Input signals: Name Functionailty Remarks 291_BC4_M1_K Availability Availability 291_BC4_M1_R Feedback Run Feedback Run 291-BC4.AU Emergency stop Signal to be shown individually on the operator

station, as a square and as an alarm. 291-BC4.X1 General alarm Signal to be shown individually on the operator

station, as a square and as an alarm. 291-BC4.D1 Drift switch Signal to be shown individually on the operator

station, as a square and as an alarm.

• The new motor has the following Digital Output signal: Name Functionailty Remarks 291_BC4_M1_D Start order Output to contactor


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11.5.4.1 Creation of variables

Create all the variables that are going to be needed for the motor object and for its corresponding I/O-signals: - for the motor object - for the digital input signals - for the digital output signal

⌦ Refer to what you learned in Lesson 2.

11.5.4.2 Creation and configuration of Control Module Instances

First, create the control module instances for the following objects: - for the motor object - for the digital input signals of type DIS

Then, configure the control module instances:

Take attention to the following: - Tag name and Description of the motor object and the DIS-signals - Start and stop step of the motor object - Start and stop step of the other motor objects in the same Group.

⌦ Refer to what you learned in Lesson 2 and 3.

11.5.4.3 Programmation of interlock logic

To programm the interlock logic, you will need to insert a new code block in the corresponding Group.

The following interlocks need to be programmed: Tag name of DI-signal Functionailty Type of interlock 291-BC4.AU Emergency stop IC: Safety Interlock (process safety) 291-BC4.X1 General alarm IB1-Interlock 291-BC4.D1 Drift switch IB4-Interlock

To be able to do this you must very well understand the variable naming concept.

⌦ Refer to what you learned in Lesson 2 and 3.


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11.5.4.4 Connection of I/O-variables to I/O-channels

To connect the variables of the I/O-signals to I/O-channels, you will first have to search for free I/O-channels. If there are no free channels, you need to add a extra I/O-module.

⌦ Refer to what you learned in Lesson 3.

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