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CG39BBPC-1 CONTENTS

TABLE OF CONTENTS
SECTION AND TITLE PAGE

1.0 INTRODUCTION.....................................................................................................................1-1
1.1 PRODUCT DESCRIPTION .................................................................................................1-2
1.2 PRODUCT SUPPORT .........................................................................................................1-2
1.3 RELATED LITERATURE ..................................................................................................1-4

2.0 PROCESS_CELL AND PROCESS_CELL_DK .....................................................................2-1

3.0 UNIT AND UNIT DK ...............................................................................................................3-1


3.1 APACS+ INBATCH.............................................................................................................3-1
3.2 APACS+ DIREKTOR ..........................................................................................................3-2

4.0 PHASE, PHASE_NOSFC, PHASE_DK, AND PHASE_NOSFC_DK ....................................4-1

5.0 CONNECTION AND CONNECTION_DK.............................................................................5-1

6.0 SEGMENT AND SEGMENT_DK ...........................................................................................6-1

7.0 DISCRETE DEVICE EQUIPMENT MODULES ...................................................................7-1


7.1 MOTOR_A AND VALVE_A...............................................................................................7-1
7.2 MOTOR_START_PH ..........................................................................................................7-1
7.3 MOTOR_STOP_PH .............................................................................................................7-2
7.4 MOTOR_TIMER_PH ..........................................................................................................7-2

8.0 TOTALIZER EQUIPMENT MODULES................................................................................8-1


8.1 FLOW_TOTAL ..................................................................................................................8-1
8.2 CHARGE_PH .....................................................................................................................8-2
8.3 FLOW_TOTAL_EAM ........................................................................................................8-2
8.4 WT_LVL_TOTAL .............................................................................................................8-3
8.5 FLOW_TOT_LOOP ............................................................................................................8-4
8.6 CHARGE_LOOP_PH..........................................................................................................8-5
8.7 FLOW_TOT_LP_TR ..........................................................................................................8-6

LIST OF TABLES
TABLE PAGE

TABLE 1-1 TIC Contact Information .................................................................................................1-3

April 1998 i
CONTENTS CG39BBPC-1

Moore Products Co. assumes no liability for errors or omissions in this document or for the application and use of information included in this
document. The information herein is subject to change without notice.

The Moore logo, ProcessSuite, APACS, and 4-mation are trademarks of Moore Products Co. All other trademarks are the property of the
respective owners.

8 Copyright1998 Moore Products Co. All rights reserved

ii April 1998
CG39BBPC-1 INTRODUCTION

1.0 INTRODUCTION
This document describes the Batch Basic Process Cell Application Library (version 4.00 or
higher), which contains a set of preconfigured derived function blocks (DFBs) for performing
common batch control functions. Also included in the library are DFBs that enable you to
implement a batch application equipment hierarchy in APACS+ process automation systems
4-mation. This is consistent with the recommendations of the ISA S88.01 Batch Control
Standard Part 1: Models and Terminology.

NOTE

Function blocks from the APACS InBatch and APACS Direktor


Communication and APACS Motor and Valve Function Block Libraries
used in this application library must be installed together with this
application library.

The library is in the form of a stand-alone, off-line Advanced Control Module (ACM)
configuration that is part of a system named BATCH. The configuration can be opened like any
other off-line database, and the blocks selectively copied from the library configuration and
pasted into a user-developed configuration. The library can be used directly from the floppy or
from a hard disk after first copying the entire library floppy contents onto the hard disk (keeping
all sub-directories intact).

The graphical presentation of each block in the Batch Basic Process Cell Application Library is
available in the APACS+ process automation systems 4-mation software. This configuration
guide is organized into the following sections:

Section 1, Introduction

Section 2, PROCESS_CELL and


PROCESS_CELL_DK

Section 3, UNIT and UNIT_DK

Section 4, PHASE, PHASE_NOSFC,


PHASE_DK, and PHASE_NOSFC_DK

Section 5, CONNECTION and


CONNECTION_DK

Section 6, SEGMENT and


SEGMENT_DK

Section 7, Equipment Modules

Section 8, Totalizer Equipment Modules

April 1998 1-1


INTRODUCTION CG39BBPC-1

1.1 PRODUCT DESCRIPTION

The Instrument Society of America (ISA) Batch Control Standard (S88.01) recommends a set of
batch terminology and models that control system users can implement to define the control
requirements of their batch manufacturing processes. The APACS+ controller was designed
according to the International Electrotechnical Commission (IEC) Programmable Controllers
Standard for Programming Languages (1131-3). The controllers hierarchical configuration
design allows perfect implementation of the S88.01 models.

This application library provides the derived and standard function blocks that enable you to
implement a batch application that is based on the S88.01 physical and equipment control models.
This library will enable you to define S88 Process Cells, Units, Equipment Modules, Control
Modules, and Phases. Two identical hierarchies are provided: one for the APACS InBatch batch
management utility and one for the APACS Direktor batch management utility. Each utility
requires a different set of interfacing variables and function blocks, all of which are provided in
the library.

Also provided in the library are derived and standard function blocks that perform common batch
control functions, such as discrete device control and flow totalization, and equipment modules
consisting of control modules and equipment phases.

NOTE

Function blocks from the Motor and Valve Function Block Library are
also used in conjunction with this application library and must be
installed together with the application library.

A graphical representation of the resource sheet of the configuration (the area level of the batch
model) is available in the APACS+ 4-mation software . The PROCESS_CELL block contains
the basic S88-based APACS InBatch equipment hierarchy. The PROCESS_CELL_DK block
contains the basic S88-based APACS Direktor equipment hierarchy. The EQUIP_MOD_LIB
block contains a set of factory-configured equipment phases and the equipment modules that
work with these phases. The contents of the DISC_DEVICE_EM block contains the discrete
device equipment modules. The contents of the TOTALIZER_EM block includes the totalizer
equipment modules. All of the other function blocks of the Batch Basic Process Cell Application
Library are described in sections 2.0 through 7.0 of this configuration guide.

1.2 PRODUCT SUPPORT

Product support can be obtained from a Technical Information Center (TIC). Each regional TIC
is a customer service center that provides direct telephone support on technical issues related to
the functionality, application, and integration of all products supplied by Moore. Regional TIC
contact information is provided in Table 1-1. Your regional TIC is the first place you should call
when seeking product support information. When calling, it is helpful to have the following
information ready:

Caller ID number, or name and company name - When someone calls for support for the first
time, a personal caller number is assigned. Having the number available when calling for

1-2 April 1998


CG39BBPC-1 INTRODUCTION

support will allow the TIC representative taking the call to use the central customer database
to quickly identify the caller=s location and past support needs.

$ Product part number or model number and version

$ If there is a problem with the product=s operation:


- Whether or not the problem is intermittent
- The steps performed before the problem occurred
- Any error messages or LED indications displayed
- Installation environment
Customers that have a service agreement (ServiceSuite or Field Service Agreement) are granted
access to the secure area of our Web site (www.mooreproducts.com/techservices). This area
contains a variety of product support information. To log on, you will be prompted to enter your
username and password.

TIC North America also offers a free faxback service called FaxRequest. You can dial-in to this
service to access documents such as press releases, product information sheets, and training
schedules. The service is completely automated and available 24 hours a day. To access this
service, call the FaxRequest number listed in Table 1-1. The first document you should request is
the directory (document number 9999). This document is constantly updated as new documents
are added. Each document has a number code assigned to it that you enter along with your fax
number (area code entry is always required). Upon completing your entry, the FaxRequest
computer automatically calls your fax machine and sends the requested documents.

TABLE 1-1 TIC Contact Information

Tel: +1 215 646 7400, extension 4842, option 1

Fax: +1 215 283 6343

TIC E-mail: ticgroup@mpco.com


NORTH AMERICA
FaxRequest: +1 215 646 7400, extension 4842, option 2

Bulletin Board Service: +1 215 283 4968

Hours of Operation: 8 am to 8 pm eastern time

Secure Web Site: www.mooreproducts.com/techservices

April 1998 1-3


INTRODUCTION CG39BBPC-1

TABLE 1-1 TIC Contact Information

Tel: +65 299 6454

Fax: +65 299 6053


TIC
ASIA E-mail: lohho@mpco.com

Hours of Operation: 9 am to 6 pm Singapore time

Secure Web Site: www.mooreproducts.com/techservices

Tel: +44 1935 470172

Fax: +44 1935 706969


TIC
EUROPE E-mail: uktic@mpco.com

Hours of Operation: 8:30 am to 5:15 pm GMT/BST

Secure Web Site: www.mooreproducts.com/techservices

1.3 RELATED LITERATURE

The following Moore Products Co. literature is available for reference:

4-mation 3.x:

4-mation Users Manual, Installation and Operation (located in binder UM39-6)


4-mation Users Manual, Function Block Languages (located in binder UM39-7)

4-mation 4.x:

4-mation Installation and Operation (located in binder UM39-11)


4-mation Function Block Language (located in binder UM39-12)

The following vendor literature should be available as needed:

Microsoft MS-DOS Operating System Reference


Microsoft Windows 3.1 (or later) Operating System Reference

1-4 April 1998


CG39BBPC-1 PROCESS_CELL

2.0 PROCESS_CELL AND PROCESS_CELL_DK


The derived function blocks PROCESS_CELL and PROCESS_CELL_DK are organizational
elements of the configuration hierarchy that is based on the ISA S88.01 physical model definition
of a process cell. In the physical model, a process cell is a logical grouping of equipment that
includes the equipment required for production of one or more batches.

PROCESS_CELL is used when interfacing to the APACS InBatch batch management software;
PROCESS_CELL_DK, when interfacing to the APACS Direktor batch management software.

On either sheet, the units (and the connections and segments that reside between the units) can be
arranged to form a graphical representation of the process; the elements, grouped into classes. If
there is insufficient space on a sheet to accommodate the required blocks, the sheet can be
extended after all function blocks on the sheet have been executed.

The contents of each function block are shown graphically in the APACS+ 4-mation software.

These blocks have no inputs or outputs.

April 1998 2-1


PROCESS_CELL CG39BBPC-1

2-2 April 1998


CG39BBPC-1 UNIT

3.0 UNIT AND UNIT_DK


The derived function blocks UNIT and UNIT_DK are organizational elements of the
configuration hierarchy that is based on the ISA S88.01 physical model definition of a unit.

In the batch model, a unit is "a collection of associated control modules and/or equipment
modules and other process equipment in which one or more major processing activities can be
conducted." Units are presumed to operate on only one batch at a time, relatively independently
of one another. An example of a unit is a reactor.

The UNIT function block is used when interfacing to APACS InBatch batch management
software; the UNIT_DK function block, when interfacing to APACS Direktor batch management
software.

Frequently used batch equipment modules and phases are included in the EQUIP_MOD_LIB
section of the Batch Basic Process Cell Application Library. Also provided are two sample
phases: the PHASE function block, a normal phase that uses an SFC, and the PHASE_NOSFC, a
simple non-SFC phase.

The contents of each function block are shown graphically in the APACS + 4-mation software.

These blocks have no inputs or outputs, but several local variables that are read and changed by
APACS InBatch or APACS Direktor are provided. In order to employ these variables, it is
necessary that additional logic be added.

3.1 APACS INBATCH

The Human Machine Interface (HMI) comment in cell A1 of the UNIT function block is used by
the APACS Database Bridge Utility HMI software to automatically generate the tags used by the
APACS InTouch HMI software and the APACS InBatch batch management software.

The APACS InBatch Unit system string variables (16 characters maximum) are the following:

CAMPN = campaign ID
LOTID = lot ID
RECID = recipe ID
RECNM = recipe name
BATSZ = batch size
BATST = batch status
BATMD = batch mode

Some of the InBatch system string variables (16 characters maximum) implemented as the
outputs of the block (for visual indication) are as follows:

BATCH = batch ID
USTAT = unit status
ALLOC = unit allocation
LASTR = last recipe ID

April 1998 3-1


UNIT CG39BBPC-1

The APACS InBatch Unit control Boolean variables are as follows: (APACS InBatch can write a
TRUE to each, while the logic on the right side of the Unit sheet resets them.)

UHOLD = unit hold


URSTR = unit restart
UABRT = unit abort

3.2 APACS DIREKTOR

The HMI comment in cell A1 of the UNIT_DK function block is used by the APS Point
Generator utility to automatically generate the tags used by the APACS Process Supervisor (APS)
HMI software. APACS Direktor can then use the APS tags.

The APACS Direktor Unit system string variables are the following:

Campaign_ID = campaign ID
Lot_ID = lot ID
Batch_ID = batch ID
Recipe_ID = recipe ID
Recipe_Name = recipe name
Batch_Size = batch size
Batch_Status = batch status
Batch_Mode = batch mode
Status = unit status
Allocation = unit allocation
Last_Recipe_ID= last recipe ID

Some of the Direktor system string variables are copied to the outputs of the block (for visual
indication) are as follows:

BATCH = batch ID (Batch_ID)


USTAT = unit status (Status)
ALLOC = unit allocation (Allocation)
LASTR = last recipe ID (Last_Recipe_ID)

The APACS Direktor Unit control Boolean variables are as follows: (APACS Direktor can write
a TRUE to each, while the logic on the right side of the Unit sheet resets them):

Unit_Hold = unit hold


Unit_Restart= unit restart
Unit_Abort = unit abort

3-2 April 1998


CG39BBPC-1 PHASE

4.0 PHASE, PHASE_NOSFC, PHASE_DK, AND PHASE_NOSFC_DK


The derived function blocks PHASE, PHASE_NOSFC, PHASE_DK, and PHASE_NOSFC_DK
are elements of the configuration hierarchy that is based on the ISA S88.01 procedural control
model definition of an equipment phase. The PHASE and PHASE_NOSFC blocks are used
when interfacing to the APACS InBatch batch management software. The PHASE_DK and
PHASE_NOSFC_DK are used when interfacing to the APACS Direktor batch management
software.

An equipment phase is a series of steps that cause actions, such as changing a controller mode or
setpoint that is a part of equipment control. InBatch and Direktor communicate with the
equipment phase through a recipe phase, writing the parameters to the phase (e.g. a new
controller setpoint value) and setting the phase mode (e.g. telling the phase to run, thereby
changing the controller setpoint to the desired value).

The PHASE and PHASE_DK function blocks are intended for a complex or multiple step phase,
while the PHASE_NOSFC and PHASE_NOSFC_DK blocks are intended for a simple phase,
with one step and no abort logic.

The phase sheets contain InBatch and Direktor interface blocks, SFC control blocks, and an
action (SFC_ACTION) containing the phase SFC.

The contents of all four function blocks are shown graphically in the APACS+ 4-mation software.

The InBatch interface blocks (INBATCOM, INREAL, INBOOL, INSTRING, INPIN, and
INPOUT) comprise the InBatch Communication Function Block Library. These blocks enable
InBatch to read and write the phase status variables and the phase parameters. Additionally, the
INBATCOM block performs some logic to determine the status of the phase.

The Direktor interface blocks (PHASECOM, PPREAL, PPBOOL, PPSTRING, PROCIN, and
PROCOUT) comprise the Direktor Communication Function Block Library. These blocks enable
Direktor to read and write the phase status variables and the phase parameters. Additionally, the
PHASECOM block performs some logic to determine the status of the phase.

The MOVE blocks and the CHRTMOD block place the SFC (inside the SFC_ACTION action) in
the correct operating mode. The SET_VAL_ERROR_OR block determines if any of the
SET_VAL blocks in the SFC are misconfigured; the ERROR outputs of the SET_VAL blocks
are to be connected to the ERROR variables (e.g. ERROR1).

The HMI comments on the PHASE sheet are used by the APACS Database Bridge Utility HMI
software to automatically generate the tags used by the InTouch HMI software and the InBatch
batch management software.

The HMI comments on the PHASE_DK sheet are used by the APS Point Generator utility to
automatically generate the tags used by the APACS Process Supervisor (APS) HMI software.
Direktor can then use the APS tags.

April 1998 4-1


PHASE CG39BBPC-1

The INT_OK input to the INBATCOM block prevents the phase from starting (if it is FALSE),
while the DFAIL input to the INBATCOM block holds the phase after it has started (if it is
TRUE). This represents a different interlock philosophy from the equipment modules (e.g.
MOTOR_A), where a PERMIT input will prevent a motor from starting (if it is FALSE) and an
INTRLK input will stop a motor at any point (if it is FALSE).

For a phase, it is likely that many of the same conditions that are intended to prevent a phase from
starting also have the purpose of holding the phase after it starts. Therefore, both the INT_OK
and DFAIL inputs to the INBATCOM block often require the same logic (but inverted). The
logic provided (see cells B8 thru C9) accommodates the case where the equipment modules
INT_OK output is connected to the INT_OK input of the phase; the equipment modules FAIL
output is connected to the DFAIL input of the phase.

The SFC_ACTION sheet contains the SFC that performs the phase functions. Contents are
shown graphically in the APACS 4-mation software.

InTouch HMI software has default batch phase structures (in addition to those indicated by the
HMI comments) that can display important information about the phase, such as the current step
and the conditions that must be met before continuing to the next step (stored as local variables).

In addition to communicating with the PHASECOM block, the APS HMI point type called
PHASE_3D_43C displays important information about the phase, such as the current step and the
conditions that must be met before continuing to the next step (stored as local variables).

The INIT action (and the other actions) sets the value of each of these variables, which are
identified in the following list. The ACTION1 action has a SET_VAL block to perform the data
write that will execute the phase. The PCOMP Boolean action pulses the PCOMP variable,
indicating to the INBATCOM block that the phase is completed.

The phase variables used by the InTouch batch structures and the APS PHASE_3D_43C point
type are as follows:

DEVICE1 = device 1 controlled by the phase (28-character string)


DEVICE2 = device 2 controlled by the phase (28-character string)
DEVICE3 = device 3 controlled by the phase (28-character string)
CURRENT_STEP = current step (28-character string)
NEXT_STEP = next step (28-character string)
COND1 = condition 1 for completing the current step (Boolean)
COND1_DESC = condition 1 description (28-character string)
COND2 = condition 2 for completing the current step (Boolean)
COND2_DESC = condition 2 description (28-character string)
COND3 = condition 3 for completing the current step (Boolean)
COND3_DESC = condition 3 description (28-character string)
COND4 = condition 4 for completing the current step (Boolean)
COND4_DESC = condition 4 description (28-character string)
COND5 = condition 5 for completing the current step (Boolean)
COND5_DESC = condition 5 description (28-character string)
COND6 = condition 6 for completing the current step (Boolean)

4-2 April 1998


CG39BBPC-1 PHASE

COND6_DESC = condition 6 description (28-character string)


COND7 = condition 7 for completing the current step (Boolean)
COND7_DESC = condition 7 description (28-character string)
COND_LOGIC1 = logic operation 1 (28-character string); most likely 'AND'
COND_LOGIC2 = logic operation 2 (28-character string); most likely 'AND'
COND_LOGIC3 = logic operation 3 (28-character string); most likely 'AND'

NOTE

The COND_LOGIC1 operation is to be performed on COND1 through


COND4, the COND_LOGIC2 operation on COND5 through COND7,
and the COND_LOGIC3 operation on the result of the first two
operations.

The inputs to the blocks are:

INT_OK = interlock ok status from equipment module(s)


DFAIL = device fail status from equipment module(s)

The outputs are used for visual indication of the phase status at the Unit level. These Boolean
status outputs are:

READY = ready
RUN = run
HELD = held
DONE = done
ABORTD = aborted
INTRLK = interlocked (TRUE=prevented from starting)

April 1998 4-3


PHASE CG39BBPC-1

4-4 April 1998


CG39BBPC-1 CONNECTION

5.0 CONNECTION AND CONNECTION_DK


The derived function blocks CONNECTION and CONNECTION_DK, elements of the
configuration hierarchy that is based on the ISA S88.01 physical model definition of an
equipment module, are used when interfacing to APACS InBatch and APACS Direktor batch
management software, respectively.

A connection is an equipment module that controls the transfer of material between units.
Connections contain equipment phases that govern the actions of the connections. Connections
may contain segments. Segments represent portions of a connection that are shared with other
connections, but they can be used by only one connection at a time (see section 6.0).

Frequently-used batch equipment modules and equipment phases can be found in the
EQUIP_MOD_LIB section of the Batch Basic Process Cell Application Library. APACS
InBatch and APACS Direktor communicate with the equipment phases within the connection
through a recipe phase, writing the parameters to the phase (e.g. a total flow setpoint value) and
setting the phase mode (e.g. tells the phase to run, thereby changing the total flow setpoint to the
desired value and starting the charge).

The contents of both function blocks are shown graphically in the APACS+ 4-mation software.

The CONNECTION block has no inputs, but several outputs that it provides are read and
changed by APACS InBatch or APACS Direktor(in addition to the phase variables). To employ
these variables, the addition of logic may be necessary.

The HMI comment in cell A1 of the CONNECTION function block is used by APACS Database
Bridge Utility HMI software to automatically generate the tags used by InTouch HMI software
and the APACS InBatch batch management software.

The HMI comment in cell A1 of the CONNECTION_DK function block is used by the APS
Point Generator utility to automatically generate the tags used by the APS HMI software.
APACS Direktor can then use the APS tags.

The 16-character string status outputs, used for visual indication of the connection variables at the
unit level, are as follows:

AVAIL = connection availability


ALLOC = connection allocation
LASTR = last recipe ID

Several local variables that are read and changed by APACS Direktor (in addition to the phase
variables) are provided. It may be necessary that logic be added to the connection to employ
these variables. These string variables are the following:

April 1998 5-1


CONNECTION CG39BBPC-1

Availability = connection availability


Allocation = connection allocation
Last_Recipe_ID = last recipe ID
The CONNECTION and CONNECTION_DK blocks have no inputs.

5-2 April 1998


CG39BBPC-1 SEGMENT

6.0 SEGMENT AND SEGMENT_DK


The derived function block SEGMENT and SEGMENT_DK, elements of the configuration
hierarchy that is based on the ISA S88.01 physical model definition of an exclusive-use common
equipment module, are used when interfacing to APACS InBatch and APACS Direktor batch
management software, respectively.

Connections contain equipment phases that act upon segments (see section 5.0). A library of
frequently used batch equipment modules and phases is in the EQUIP_MOD_LIB section of the
Batch Basic Process Cell Application Library.

The contents of these function blocks are shown graphically in the APACS+ 4-mation software.

The HMI comment in cell A1 is used by APACS Database Bridge Utility HMI software to
automatically generate the tags used by the APACS InTouch HMI software and the APACS
InBatch batch management software.

The HMI comment in cell A1 of the SEGMENT_DK function block is used by the APS Point
Generator utility to automatically generate the tags used by the APS HMI software. APACS
Direktor can then use the APS tags.

These blocks have no inputs, but several outputs that the SEGMENT function block provides are
read and changed by APACS InBatch . To employ these variables, the addition of logic to the
segment may be necessary. These 16-character string outputs are:

USTAT = segment status


ALLOC = segment allocation
LASTR = last recipe ID

Several local variables that are read and changed by APACS Direktor are provided. It may be
necessary that logic be added to the segment to employ these variables. These string variables are
as follows:

Status = segment status


Allocation = segment allocation
Last_Recipe_ID= last recipe ID

April 1998 6-1


SEGMENT CG39BBPC-1

6-2 April 1998


CG39BBPC-1 DISCRETE DEVICE EQUIPMENTMODULES

7.0 DISCRETE DEVICE EQUIPMENT MODULES


The MOTOR_A and VALVE_A function blocks are compiled standard blocks that comprise the
Motor and Valve Function Block Library. These blocks are utilized for the Discrete Device
Equipment Module section of the Batch Basic Process Cell Application Library, and as such
require less memory.

The APACS Motor and Valve Function Block Library Configuration Guide (CG39MOTVAL-1)
provides more detailed information.

7.1 MOTOR_A AND VALVE_A

These blocks provide standard motor start/stop and valve open/close equipment module functions
(similar to the MOTOR_1OUT and BLK_VLV_1OUT blocks in the Basic Application Library
provided with 4-mation).

Note that the FAIL outputs of the MOTOR_A and VALVE_A blocks are latched when a failure
occurs. They must be manually unlatched (by writing a FALSE to the FAIL output nub).

For APACS InTouch or APS HMI software, where the discrete alarms are typically calculated by
the HMI instead of using APACS alarm blocks, the operator faceplate has a button that resets
FAIL. When using an HMI that has been optimized to use the alarm blocks (e.g. HLLDA1),
acknowledging the alarm block also resets the FAIL output.

7.2 MOTOR_START_PH

The derived function block MOTOR_START_PH, part of the Discrete Device Equipment
Module section, is an example of a simple non-SFC phase (for APACS InBatch) designed to start
a motor controlled with a MOTOR_A block.

Block contents are shown graphically in the APACS+ 4-mation software.

See section 4.0 for information on simple non-SFC phases.

For this phase, the interlock and device fail statuses are implemented as block inputs, and the
motor speed setting is the only parameter to be set by APACS InBatch.

For interfacing to APACS Direktor, the INBATCOM and INREAL blocks should be replaced
with PHASECOM and PPREAL blocks (see section 4.0). This block contains the INIT and RUN
actions that are also presented and described in section 4.0.

The Boolean inputs are:

INT_OK = interlock ok status from the motor control module


DFAIL = device fail status from the motor control module

April 1998 7-1


DISCRETE DEVICE EQUIPMENT MODULES CG39BBPC-1

The Boolean status outputs used for visual indication of the phase status at the unit level are as
follows:

READY = ready
RUN = run
HELD = held
DONE = done
ABORTD = aborted
INTRLK = interlocked (TRUE = prevented from starting)

7.3 MOTOR_STOP_PH

The derived function block MOTOR_STOP_PH, part of the Discrete Device Equipment Module
section, is an example of a simple non-SFC phase designed to stop a motor controlled with a
MOTOR_A block.

Block contents are shown graphically in the APACS+ 4-mation software.

See section 4.0 for information on simple non-SFC phases.

This block has no parameters to be set by the batch management software. For interfacing to
APACS Direktor, the INBATCOM block should be replaced with a PHASECOM block (see
section 4.0).

The block contains the INIT and RUN actions that are also presented and discussed in sections
4.0.

This block has no inputs.

The Boolean status outputs used for visual indication of the phase status at the unit level are as
follows:

READY = ready
RUN = run
HELD = held
DONE = done
ABORTD = aborted
INTRLK = interlocked (TRUE = prevented from starting)

7.4 MOTOR_TIMER_PH

The derived function block MOTOR_TIMER_PH, part of the Discrete Device Equipment
Module section, is an example of a phase (for APACS InBatch) designed to run a motor
controlled with a MOTOR_A block.

The phase starts the motor, waits a prescribed amount of time to expire, then stops the motor.

7-2 April 1998


CG39BBPC-1 DISCRETE DEVICE EQUIPMENTMODULES

Block contents are shown graphically in the APACS+ 4-mation software. Information on phases
utilizing SFCs is provided in section 4.0. For this phase, the interlock and device fail statuses are
implemented as block inputs, and the motor speed and run time are parameters to be set by
APACS InBatch.

For interfacing to APACS Direktor, the INBATCOM and INREAL blocks should be replaced
with PHASECOM and PPREAL blocks (see section 4.0).

This block is slightly different than the PHASE block described in section 4.0. The
RUN_TIMER block has been added to determine how long the MOTOR_RUN action of the SFC
has been active (i.e. how long the motor has been running). The MOTOR_RUN action includes
SET_VAL blocks for both starting and stopping the motor.

The Boolean inputs are:

INT_OK = interlock ok status from the motor control module


DFAIL = device fail status from the motor control module

The Boolean status outputs used for visual indication of the phase status at the unit level are as
follows:

READY = ready
RUN = run
HELD = held
DONE = done
ABORTD = aborted
INTRLK = interlocked (TRUE = prevented from starting)
RUNTIM = elapsed time since motor was started
RT_SP = run time setpoint

April 1998 7-3


DISCRETE DEVICE EQUIPMENT MODULES CG39BBPC-1

7-4 April 1998


CG39BBPC-1 TOTALIZER EQUIPMENT MODULES

8.0 TOTALIZER EQUIPMENT MODULES

8.1 FLOW_TOTAL

The derived function block FLOW_TOTAL (Flow Totalizer), part of the Flow Totalizer
Equipment Module section, performs the function of a simple flow totalizer equipment module.
This block requires a non-pulsing flow signal, and the final control element should be a block
valve.

The block totalizes the input flow signal, compares it to a total setpoint, and determines if the
block valve should be open or closed. A preact setting allows the valve to be shut before the total
is reached, permitting perfect charging when the preact is set at the amount of material that
continues to flow after the valve is commanded to close.

The VALVE_A block functions well as a complementary block valve control module. A
separate charge phase (see section 8.2) resets the totalizer, sets the total setpoint, and starts the
charge.

Block contents are shown graphically in the APACS 4-mation software.

The TOT_SETPOINT block holds the total setpoint.

The PREACT_SUB block subtracts the PREACT input from the total setpoint to determine the
trip point for the FLOW_TOTAL block.

A TRUE written to the RESET local variable resets the FLOW_TOTAL block; RESET is then
reset FALSE by the circuit.

The OPEN output is the open command to the block valve control module; writing a TRUE to
this output starts a charge.

The END_R_TRIG and END_MOVE blocks reset the output to end the charge.

The ENG_UNITS and DESC blocks each have a soft list value for holding the engineering units
and descriptor.

The input to the block is:

PV= process variable (flow signal)

The outputs to the block are:

ALARM = alarm status


TOT_SP = total setpoint
TOTAL = actual total (used by the charge phase)
OPEN = open command to block valve control module
DONE = charge done status (used by the charge phase)

April 1998 8-1


TOTALIZER EQUIPMENT MODULES CG39BBPC-1

8.2 CHARGE_PH

The derived function block CHARGE_PH (Charge Phase for Flow Totalizer), part of the Flow
Totalizer Equipment Module section, is an example of a phase (for APACS InBatch) designed to
charge material using the FLOW_TOTAL equipment module block (see section 8.1).

The phase resets the total, sets the total setpoint, starts the charge, then waits until the charge is
completed.

Block contents are shown graphically in the APACS+ 4-mation software.

See section 4.0 for information on phases utilizing SFCs. For this phase, the interlock and device
fail statuses are implemented as block inputs, as are the actual total and the done status. The total
to be charged is a parameter to be set by APACS InBatch.

For interfacing to APACS Direktor, the INBATCOM and INREAL blocks should be replaced
with PHASECOM and PPREAL blocks (see section 4.0).
This block is slightly different than the PHASE block of section 4.0. The RESET_TOTAL,
SET_TOTAL_SP, and CHARGE actions each include a SET_VAL block for writing commands
and values to the FLOW_TOTAL block.

The inputs to the block are:

DFAIL = device fail status from the block valve control module
INT_OK = interlock ok status from the block valve control module
TOTAL = actual total from the FLOW_TOTAL block
DONE_T = charge done status from the FLOW_TOTAL block

The status outputs used for visual indication of the phase status at the unit level are as follows:

READY = ready
RUN = run
HELD = held
DONE = done
ABORTD = aborted
INTRLK = interlocked (TRUE=prevented from starting)
TOT_SP = total setpoint

8.3 FLOW_TOTAL_EAM

The derived block FLOW_TOTAL_EAM (Flow Totalizer for EAM Pulse Input), part of the Flow
Totalizer Equipment Module section, performs the function of a simple flow totalizer equipment
module. This block requires an EAM (Enhanced Analog Module) pulse flow signal, and the final
control element should be a block valve.

The block totalizes the pulsing input flow signal, compares it to a total setpoint, and determines if
the block valve should be open or closed. A preact setting allows the valve to be shut before the

8-2 April 1998


CG39BBPC-1 TOTALIZER EQUIPMENT MODULES

total is reached, permitting perfect charging when the preact is set at the amount of material that
continues to flow after the valve is commanded to close.

The VALVE_A block functions well as a complementary block valve control module. A
separate charge phase (see section 8.2) resets the totalizer, sets the total setpoint, and starts the
charge.

Block contents are shown graphically in the APACS+ 4-mation software.

The TOT_SETPOINT block holds the total setpoint.

The PREACT_SUB block subtracts the PREACT input from the total setpoint to determine the
trip point for the FLOW_TOTAL block.

A TRUE written to the RESET local variable resets the FLOW_TOTAL block; RESET is then
reset FALSE by the circuit.

The OPEN output is the open command to the block valve control module; writing a TRUE to
this output starts a charge. The END_R_TRIG and END_MOVE blocks reset the output to end
the charge.

The FLOW_RATE_CALC and FLOW_RATE_LIMIT blocks calculate the flow rate from the
changes to the TOTAL output signal.

The ENG_UNITS and DESC blocks each have a soft list value for holding the engineering units
and descriptor.

The input to the block is:

PLS_IN = pulse-type flow signal from an EAM

The outputs of the block are:

PV = process variable (flow signal)


ALARM = alarm status
TOT_SP = total setpoint
TOTAL = actual total (used by the charge phase)
OPEN = open command to block valve control module
DONE = charge done status (used by the charge phase)

8.4 WT_LVL_TOTAL

The derived block WT_LVL_TOTAL (Weight or Level Totalizer), part of the Flow Totalizer
Equipment Module section, performs the function of a simple flow totalizer equipment module.
This block requires a weight or level signal, and the final control element should be a block valve.

The block totalizes the flow by comparing the actual weight (or level) to the starting weight (or
level), compares it to a total setpoint, and determines if the block valve should be open or closed.

April 1998 8-3


TOTALIZER EQUIPMENT MODULES CG39BBPC-1

A preact setting allows the valve to be shut before the total is reached, permitting perfect charging
when the preact is set at the amount of material that continues to flow after the valve is
commanded to close.

The VALVE_A block functions well as a complementary block valve control module. A
separate charge phase (see section 8.2) resets the totalizer, sets the total setpoint, and starts the
charge.

Block contents are shown graphically in the APACS+ 4-mation software.

The RESET_MOVE block stores the current amount (PV) as the initial amount (AMOUNT0)
when a TRUE is written to the RESET local variable; RESET is then reset FALSE by the circuit.

The AMOUNT_SUB block calculates the total amount charged. The TOT_SETPOINT block
holds the total setpoint. The PREACT_SUB block subtracts the PREACT input from the total
setpoint to determine the trip point for the TOTAL_GE block.

The OPEN output is the open command to the block valve control module; writing a TRUE to
this output starts a charge. The END_R_TRIG and END_MOVE blocks reset the output to end
the charge.
The ENG_UNITS and DESC blocks each have a soft list value for holding the engineering units
and descriptor.

The input to the block is

WT_LVL = weight or level.

The outputs of the block are:

PV = process variable (flow rate)


ALARM = alarm status
TOT_SP = total setpoint
TOTAL = actual total (used by the charge phase)
OPEN = open command to block valve control module
DONE = charge done status (used by the charge phase)

8.5 FLOW_TOT_LOOP

The derived block FLOW_TOT_LOOP (Flow Totalizer with Flow Control Loop), part of the
Flow Totalizer Equipment Module section, performs the function of a flow control/totalizer
equipment module. This block requires a non-pulsing flow signal, and the final control element
should be a modulating valve.

The block totalizes the input flow signal, compares it to a total setpoint, and determines if the
modulating valve should be open or closed. During the charge, a single loop controller positions
the valve to keep the flow rate equal to a flow setpoint. A preact setting allows the valve to be
shut before the total is reached, permitting perfect charging when the preact is set at the amount
of material that continues to flow after the valve is commanded to close. A separate charge phase

8-4 April 1998


CG39BBPC-1 TOTALIZER EQUIPMENT MODULES

(see section 7.2.6) resets the totalizer, sets the total setpoint, sets the flow setpoint, and starts the
charge.

Block contents are shown graphically in the APACS+ 4-mation software.

The TOT_SETPOINT block holds the total setpoint. The PREACT_SUB block subtracts the
PREACT input from the total setpoint to determine the trip point for the FLOW_TOTAL block.
A TRUE written to the RESET local variable resets the FLOW_TOTAL block; RESET is then
reset FALSE by the circuit. The OPEN output is the open permissive for the modulating valve;
writing a TRUE to this output starts a charge. The END_R_TRIG and END_MOVE blocks reset
OPEN to end the charge.

The SETPOINT block provides the flow setpoint to the control loop section of the block; the
CONTROLLER block is the PID flow controller. The AUTO_MANUAL block enables manual
control of the valve and switches a -3.3 percent value as the output when not charging. The
ALARM block provides alarms on the flow value.

NOTE

Alarm 2 (low alarm) and alarm 3 (setpoint deviation alarm) are disabled
when not charging. The ALARM_STATUS block determines the
ALARM status output. The ENG_UNITS and DESC blocks each have a
softlist value for holding the engineering units and descriptor.

The input to the block is:

PV = process variable (flow signal).

The outputs of the block are:

SP = flow setpoint
OUT = output to modulating valve
ALARM = flow alarm status
AUTO = auto mode status variable
TOT_SP = total setpoint
TOTAL = actual total (used by the charge phase)
OPEN = open command to enable the flow control loop
DONE = charge done status (used by the charge phase)

8.6 CHARGE_LOOP_PH

The derived function block CHARGE_LOOP_PH (Charge Phase for Flow Totalizer with Flow
Control Loop), part of the Flow Totalizer Equipment Module section, is an example of a phase
(for APACS InBatch) designed to charge material using the FLOW_TOT_LOOP equipment
module block (see section 8.5).

The phase resets the total, sets the total setpoint, sets the flow setpoint, starts the charge, then
waits until the charge is completed.

April 1998 8-5


TOTALIZER EQUIPMENT MODULES CG39BBPC-1

Block contents are shown graphically in the APACS+ 4-mation software.

See section 4.0 for information on phases utilizing SFCs. For this phase, the actual flow, the
actual total, and the done status are implemented as block inputs. The flow setpoint and the total
to be charged are parameters to be set by APACS InBatch.

For interfacing to APACS Direktor, the INBATCOM and INREAL blocks should be replaced
with PHASECOM and PPREAL blocks (see section 4.0).

This block is slightly different than the PHASE block described in section 4.0. The
RESET_TOTAL, SET_TOTAL_SP, SET_FLOW_SP, and CHARGE actions each include a
SET_VAL block for writing commands and values to the FLOW_TOT_LOOP block.

The inputs to the block are:

PV = actual flow
TOTAL = actual total (from the FLOW_TOT_LOOP block)
DONE_T = charge done status (from the FLOW_TOT_LOOP block)

The status outputs used for visual indication of the phase status at the unit level are as follows:

READY = ready
RUN = run
HELD = held
DONE = done
ABORTD = aborted
INTRLK = interlocked (TRUE=prevented from starting)
FLO_SP = flow setpoint
TOT_SP = total setpoint

8.7 FLOW_TOT_LP_TR

The derived block FLOW_TOT_LOOP (Flow Totalizer with Flow Control Loop and Trickle
Action), part of the Flow Totalizer Equipment Module section, performs the function of a flow
control/totalizer equipment module. This block requires a non-pulsing flow signal, and the final
control element should be a modulating valve.

The block totalizes the input flow signal, compares it to a total setpoint, and determines if the
modulating valve should be open or closed. During the charge, a single loop controller positions
the valve to keep the flow rate equal to a flow setpoint. A preact setting allows the valve to be
shut before the total is reached, permitting perfect charging when the preact is set at the amount
of material that continues to flow after the valve is commanded to close. A separate preact setting
enables the loop to reduce the flow rate near the end of a charge; this trickle action reduces the
chance of a mismatch between the desired charge and the actual charge amounts. A separate
charge phase (see section 8.6) resets the totalizer, sets the total setpoint, sets the flow setpoint,
and starts the charge.

Block contents are shown graphically in the APACS+ 4-mation software.

8-6 April 1998


CG39BBPC-1 TOTALIZER EQUIPMENT MODULES

The TOT_SETPOINT block holds the total setpoint.

The PREACT_SUB block subtracts the PREACT input from the total setpoint to determine the
end-of-charge trip point for the FLOW_TOTAL block; the TRICK_PREACT_SUB block
subtracts the TR_PRE trickle preact input from the total setpoint to determine the trickle mode
trip point for the FLOW_TOTAL block.

A TRUE written to the RESET local variable will reset the FLOW_TOTAL block; RESET is
then reset FALSE by the circuit.

The OPEN output is the open permissive for the modulating valve; writing a TRUE to this output
starts a charge. The END_R_TRIG and END_MOVE blocks reset OPEN to end the charge.

When the trickle trip point has been reached, the TRICKLE_SEL block changes the
TRICKLE_FACTOR variable from 1.0 to 0.25, reducing the effective flow setpoint to a quarter
of its full value.

The SETPOINT block provides the flow setpoint to the control loop section of the block, which is
multiplied by the TRICKLE_FACTOR variable to determine the effective setpoint.

The CONTROLLER block is the PID flow controller.

The AUTO_MANUAL block enables manual control of the valve and switches a -3.3% value as
the output when not charging.

The ALARM block provides alarms on the flow value.

NOTE

Alarm 2 (low alarm) and alarm 3 (setpoint deviation alarm) are disabled
when not charging.

The ALARM_STATUS block determines the ALARM status output.

The ENG_UNITS and DESC blocks each have a softlist value for holding the engineering units
and descriptor.

The input to the block is:

PV = process variable (flow signal)

The outputs of the block are:

SP = flow setpoint
OUT = output to modulating valve
ALARM = flow alarm status
AUTO = auto mode status variable
TOT_SP = total setpoint
TOTAL = actual total (used by the charge phase)

April 1998 8-7


TOTALIZER EQUIPMENT MODULES CG39BBPC-1

OPEN = open command to enable the flow control loop


DONE = charge done status (used by the charge phase)
TRICKL = trickle mode status

8-8 April 1998