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August 2, 2011
B0700EE
Rev A
August 2, 2011
Invensys, Foxboro, I/A Series, the Invensys logo, FoxView, and FoxAPI are trademarks of Invensys plc, its
subsidiaries, and affiliates.
All other brand names may be trademarks of their respective owners.
Preliminary
2. All software issued by Invensys Systems, Inc. and copies of the software that you are
specifically permitted to make, are protected in accordance with Federal copyright
laws. It is illegal to make copies of any software media provided to you by
August 2, 2011
Invensys Systems, Inc. for any purpose other than those purposes mentioned in the
software license.
Contents
Figures.................................................................................................................................... xi
Tables.................................................................................................................................. xiii
Preface................................................................................................................................... xv
Audience ................................................................................................................................. xv
Revision Information .............................................................................................................. xv
Referenced Documents ........................................................................................................... xv
Terms and Definitions ............................................................................................................ xv
1. Overview ........................................................................................................................... 1
Preliminary
Features ..................................................................................................................................... 1
Platforms Supported ................................................................................................................. 1
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FoxBridge Software Architecture ............................................................................................... 2
Operation ................................................................................................................................. 4
Implementing the FoxBridge Software ...................................................................................... 5
Summary .................................................................................................................................. 6
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B0700EE – Rev A Contents
4. FoxBridge Configuration................................................................................................. 21
Remote Controller .................................................................................................................. 21
AspenTech Software on Off-Platform Windows PC ............................................................... 21
AspenTech Configuration Files .......................................................................................... 21
Model and CCF ............................................................................................................ 21
Preliminary
Hosts File ...................................................................................................................... 22
CIM-IO Logical Devices ............................................................................................... 22
Services File ................................................................................................................... 22
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CIM-IO Test Utility ..................................................................................................... 23
FoxBridge Host AW70 ........................................................................................................... 25
dmcfg Configuration File ........................................................................................................ 25
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Contents B0700EE – Rev A
Preliminary
Startup .................................................................................................................................... 56
Mapping Application Objects ............................................................................................ 57
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Smart Data Types - AWSCOD and LOOPST ................................................................... 58
Summary Displays .................................................................................................................. 60
Common Features .............................................................................................................. 61
Title Box ....................................................................................................................... 61
Buttons .......................................................................................................................... 62
Controller Summary Display .............................................................................................. 63
Controlled Variables ...................................................................................................... 63
Manipulated Variables ................................................................................................... 64
Feed-Forward Variables ................................................................................................. 66
Summary Display with Descriptions .............................................................................. 68
Summary Display - Engineer Environment ................................................................... 69
Summary Display - Operator Environment ................................................................... 70
Controller Economics Display ............................................................................................ 71
Controlled Variables ...................................................................................................... 71
Manipulated Variables ................................................................................................... 72
Controller Tuning Display ................................................................................................. 73
...................................................................................................................................... 73
Controlled Variables ...................................................................................................... 73
Manipulated Variables ................................................................................................... 74
Summary of SubControllers Display .................................................................................. 75
SubController Information ............................................................................................ 75
External Target and Composite LP Display(s) .................................................................... 76
External Target Display ................................................................................................. 76
ALLDemo Display ........................................................................................................ 79
Composites Display ....................................................................................................... 80
External Target And Composite Display ....................................................................... 83
Detail Displays ........................................................................................................................ 84
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B0700EE – Rev A Contents
DMCOP ............................................................................................................................ 84
DMCplus Object Selection Menu ................................................................................. 85
Detail Display Specific Button Set ................................................................................. 86
DMCOP Faceplate ........................................................................................................ 87
DMCOP Summary Data .............................................................................................. 87
Standard Detail Display Button Set ............................................................................... 87
DMCOP All Attributes Overlay .................................................................................... 88
DMCplus Controller Message Overlay .......................................................................... 89
DMCplus Controller Execution Overlay ....................................................................... 90
DMCplus Go Closed Loop Overlay .............................................................................. 91
DMCplus Go Open Loop Overlay ................................................................................ 92
DMCSB ............................................................................................................................. 93
Detail Display Specific Button Set ................................................................................. 94
DMCSB Faceplate ......................................................................................................... 95
DMCSB Summary Data ............................................................................................... 95
Standard Detail Display Button Set ............................................................................... 95
DMCCV Detail Display .................................................................................................... 96
Trend Area .................................................................................................................... 97
Preliminary
Historical Trend Area .................................................................................................... 97
Faceplate Area ............................................................................................................... 98
Summary Data .............................................................................................................. 98
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Buttons .......................................................................................................................... 98
Controlled Variable Detail Overlay ............................................................................... 99
DMCFF Detail Display ................................................................................................... 100
Overview ..................................................................................................................... 100
Faceplate Area ............................................................................................................. 101
Summary Data ............................................................................................................ 101
Buttons ........................................................................................................................ 101
Feedforward Detail Displays ........................................................................................ 102
Feedforward Detail Overlay ......................................................................................... 103
DMCMV Detail Display ................................................................................................. 103
Overview ..................................................................................................................... 103
Trend Area .................................................................................................................. 104
Faceplate Area ............................................................................................................. 105
Summary Data ............................................................................................................ 105
Buttons ........................................................................................................................ 105
Manipulated Variable Detail Display ........................................................................... 106
Manipulated Variable Detail Overlay .......................................................................... 107
Shutdown ............................................................................................................................. 107
Alarming ............................................................................................................................... 108
Customizing .......................................................................................................................... 108
Starting Up Custom Scripts or Programs .......................................................................... 108
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Contents B0700EE – Rev A
9. Maintenance.................................................................................................................. 115
FoxBridge Software ............................................................................................................... 115
Uninstall .......................................................................................................................... 115
FoxBridge Upgrade Checklist ........................................................................................... 116
Preliminary
Application Object Templates .......................................................................................... 120
Revision of Templates ................................................................................................. 120
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Example Template – DMCMV ................................................................................... 120
Map Files ......................................................................................................................... 125
Definition .................................................................................................................... 125
Manual Changes to Map Files ..................................................................................... 127
Application Object Database ............................................................................................ 128
Mappings ......................................................................................................................... 129
Available Scripts ............................................................................................................... 130
AppObjSrv .................................................................................................................. 130
AOS File System Organization ......................................................................................... 134
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B0700EE – Rev A Contents
Preliminary
Import Table Sizing ..................................................................................................... 165
OM Object ................................................................................................................. 165
Resizing the OM ......................................................................................................... 166
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FoxAPI Sizing .................................................................................................................. 166
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Contents B0700EE – Rev A
Preliminary
AOS CIM_IO Server with Multiple DMCplus Controllers ............................................. 185
Collecting Data from Multiple AWs ................................................................................ 186
Increasing the Number of CIMIO Servers linking DMCplus Controller to the I/A Series System
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186
FoxAPI Software ................................................................................................................... 188
FoxAPI Software Settings ................................................................................................. 188
FoxAPI Version Number .................................................................................................. 188
Scripts .................................................................................................................................. 189
Common Problems ............................................................................................................... 189
PCWS Software .................................................................................................................... 191
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Preliminary
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Contents
B0700EE – Rev A
x
Figures
1-1. I/A Series FoxBridge Software Architecture ................................................................... 2
1-2. FoxBridge Implementation ........................................................................................... 5
5-1. Relationship of Programs and Files ............................................................................. 30
5-2. DMCplus Collect Operation ...................................................................................... 35
6-1. Application Object Services Menu .............................................................................. 51
7-1. Summary Display Definitions ..................................................................................... 61
7-2. Summary Display - I/A Series Software V4.2 and Later ............................................... 67
7-3. Summary Display with Descriptions ........................................................................... 68
7-4. Summary Display - Engineer Environment ................................................................. 69
7-5. Summary Display - Operator Environment ................................................................. 70
7-6. Controller Economics Display .................................................................................... 71
7-7. Controller Tuning Display .......................................................................................... 73
7-8. Summary of SubControllers Display ........................................................................... 75
7-9. ALLDEMO Controller Display .................................................................................. 79
Preliminary
7-10. Composites Display .................................................................................................... 80
7-11. External Target and Composite Display ...................................................................... 83
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7-12. DMCOP Detail Display ............................................................................................. 84
7-13. DMCOP Detail Display Layout ................................................................................. 85
7-14. DMCOP All Attributes Overlay ................................................................................. 88
7-15. DMCplus Controller Message Overlay ....................................................................... 89
7-16. DMCplus Controller Execution Overlay ..................................................................... 90
7-17. DMCPlus Go Closed Loop Overlay ............................................................................ 91
7-18. DMCplus Go Open Loop Overlay ............................................................................. 92
7-19. DMCSB Detail Display .............................................................................................. 93
7-20. DMCSB Detail Display Layout .................................................................................. 94
7-21. DMCCV Controlled Variable Detail Display ............................................................. 96
7-22. DMCCV Detail Display Layout ................................................................................. 97
7-23. Ramp DMCCV Attribute Overlay .............................................................................. 99
7-24. DMCFF Detail Display Layout ................................................................................ 100
7-25. DMCFF Feedforward Detail Display ........................................................................ 102
7-26. Feedforward Attribute Overlay .................................................................................. 103
7-27. DMCMV Detail Display Layout .............................................................................. 104
7-28. DMCMV Manipulated Variable Detail Display ....................................................... 106
7-29. DMCMV Manipulated Variable Detail Overlay ....................................................... 107
8-1. Main DEMO Display ............................................................................................... 111
8-2. Column Process Graphic ........................................................................................... 112
8-3. Simulation Overlay ................................................................................................... 113
A-1. AOS Overall Functionality ........................................................................................ 119
A-2. Application Object Services Menu ............................................................................ 131
A-3. AOS File Layout ....................................................................................................... 134
B-1. Operator-Set AOUT Block ....................................................................................... 135
B-2. Supervisory Control Application with DDC ............................................................. 136
B-3. Two-Level Cascade ................................................................................................... 137
C-1. Method of Choosing Supervisory Setpoint ................................................................ 142
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B0700EE – Rev A Figures
Preliminary
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xii
Tables
2-1. Possible I/A Series Stations ............................................................................................ 9
3-1. Installation Commands ............................................................................................... 18
4-1. CIM-IO to Foxboro I/A Series Interface Service Definitions ....................................... 22
5-1. Data Collection Procedure .......................................................................................... 28
5-2. Data Collection File Types .......................................................................................... 30
5-3. Header Parameter Definition ...................................................................................... 31
5-4. DMCplus Collect Columns ........................................................................................ 36
5-5. DMCplus Build Versions ............................................................................................ 38
6-1. Example of AOD File ................................................................................................. 42
7-1. Environments Supported by FoxBridge Software ........................................................ 55
7-2. Display Manager Access Classes .................................................................................. 55
7-3. Menu Bar Availability ................................................................................................. 56
7-4. Current Summary Display Labels ................................................................................ 63
7-5. Detail Display Specific Button Set and Configured Actions ........................................ 86
Preliminary
7-6. DMCSB Button Set and Configured Actions .............................................................. 94
A-1. Application Object Definition Files Field Names ...................................................... 119
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A-2. DMCMV Template Commands ............................................................................... 120
A-3. DMCMV Template of Arguments ............................................................................ 121
A-4. Type of Underlying Block ......................................................................................... 122
A-5. Mapped Parameters Based on Block Type ................................................................. 123
A-6. Underlying Block Attributes ..................................................................................... 124
A-7. Attributes Not Mapped ............................................................................................. 125
A-8. Map Files Attribute Definitions ................................................................................ 126
C-1. Manipulated Variable Block Mappings ..................................................................... 155
C-2. New Block Parameters .............................................................................................. 156
C-3. Station Block Parameters ........................................................................................... 156
C-4. Block Parameter Attributes ........................................................................................ 157
C-5. Block/Parameter Matrix For New SSC Parameters .................................................... 160
C-6. Value Status Comparison .......................................................................................... 161
C-7. Block Status Parameter Bit Values ............................................................................. 162
E-1. File System Directories .............................................................................................. 168
E-2. Data Directory Files .................................................................................................. 168
E-3. Elements for Building Summary, Economics, and Tuning Displays .......................... 169
E-4. Scripts Shipped with FoxBridge Software .................................................................. 170
E-5. Application Menus .................................................................................................... 173
E-6. Main Application Directory Files .............................................................................. 175
E-7. Data .......................................................................................................................... 175
F-1. Bit Map of Various Conditions ................................................................................. 179
F-2. AOUT Block Parameter Values ................................................................................ 183
F-3. Directory Structure for FoxBridge Files ..................................................................... 184
F-4. Configuration of Services File Required to Support CIMIOs on Multiple AWs ........ 186
F-5. Configuration of Services File Required to Support CIMIOs on Multiple AWs ........ 187
F-6. Configuration of an Example Multi-Source cimio_logical_devices.def file ................ 187
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Preliminary
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Tables
B0700EE – Rev A
xiv
Preface
This document provides guidelines for understanding and utilizing the FoxBridge software. The
FoxBridge software provides a close coupling of the Aspen DMCplus® Controller with the
I/A Series® System.
Audience
This document is intended for process engineers and system administrators responsible for the
installation and maintenance of Aspen Technology, Inc.® multivariable controllers in an
I/A Series open control system. Chapter 6 “Controller Configuration” and Chapter 7 “FoxBridge
Controller Operation” contain information about the FoxBridge user interface and two sample
controllers supplied with the software. These sections may also be used by process operators who
will be using the controllers.
Preliminary
Revision Information
This is the initial release of this document.
August 2, 2011
Referenced Documents
For further information on relevant topics, refer to the following I/A Series documents:
♦ Integrated Control Configurator (B0193AV)
♦ Integrated Control Software Concepts (B0193AW)
♦ Supervisory Setpoint Control (SSC) (B0193RY)
♦ Application Object Services User’s Guide (B0400BZ)
You should also refer to the Aspen Technology documentation for the Aspen DMCplus software.
aod/AOD file A standard file format used by the MkMapFile tool and a set of Object
Templates to generate a valid map file. Its basic contents are the names of
the objects to be created, the name of the Object Template to use for
creation, and any parameterization data required by the Object Template
or MkMapFile.
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B0700EE – Rev A Preface
services are used, the program can use the Application Object Attributes
to obtain process data and to move data into the process.
Application Object The AOS package provides a set of services to users of Application
Services (AOS) Objects. These services include creation, deletion, mapping,
checkpointing, and alarming.
Application Applications Objects is the generic term for a type of OM variable object.
Objects (AOs) The term is used to refer to:
Preliminary
All Application Object Attributes collectively.
The collection of Application Object Attributes belonging to a particular
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second level name.
Application Objects reside in an AW and are hierarchical like the objects
found in a Control Station. The hierarchy is: Application (A), Object
(A:O or AO), and Attribute (AOA or A:O.A).
Though their names resemble Control Block Names, AOs do not have the
support of a Block Processor.
Application Objects are often used to represent data structures that would
normally be internal to a program (application), but which are more
useful if they are globally accessible through the OM. The FoxBridge,
Connoisseur, and the I/A Series Off-sites Suite (BOSS/OMIS/TIS) use
the AOS product in this manner.
Compound Block The name of a value associated with an I/A Series Control Block.
Parameter (CBP or
C:B.P)
globally known The I/A Series IPC mechanism is based on communication by logical
(logical) name name. A name can be locally known or globally known.
Locally known names are known only to the IPC service in the AW
running the program. Globally known names are registered with the
I/A Series Object Manager. The station address of globally known
programs can be found using OM calls. Locally known programs cannot
be found in that manner.
Programs using I/A Series IPC to communicate with a locally known
program must either know the other program's station address or it must
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Preface B0700EE – Rev A
use the I/A Series broadcast message. The station address of the other
program can be obtained from its globally known name.
locally known The I/A Series IPC mechanism is based on communication by name. A
(logical) name name can be locally known or globally known.
Locally known names are known only to the IPC service in the AW
running the program. Globally known names are registered with the
I/A Series Object Manager. The station address of globally known
programs can be found using OM calls. Locally known programs cannot
be found in that manner.
Programs using I/A Series IPS to communicate with a locally known
program must either know its station address or must use the I/A Series
broadcast message.
Logical Name A logical name is an ASCII string used to represent an I/A Series object.
An I/A Series object may be a value, a program, device, or alias. The
I/A Series Object Manager knows globally known logical names like the
value of a control block parameter (CBP) and the name of a historian.
Preliminary
Locally known names are used only with programs. They are not regis-
tered with the OM, but they are registered with the Foxboro® IPC layer.
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map file An ASCII file used to define the Application Object Attributes to be
stored in the aos database used to hold Application definitions.
mapping The term used for the transfer of data between an Application Object and
another OM variable under the control of the AOS mapping service.
Object Manager The I/A Series Name Server. It provides services that allow programs to
locate and access I/A Series objects. The most common objects are values
and programs using Foxboro IPC.
Object Template A Bourne shell script that defines the attributes of an Application Object.
It is combined with the information found in an aod file by MkMapFile
to form a map file.
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B0700EE – Rev A Preface
Preliminary
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xviii
1. Overview
This section provides an overview of the FoxBridge software.The FoxBridge software is a
product of Invensys Systems, Inc. which provides a close coupling between Aspen Technology,
Inc. on-line DMCplus controller software and the Foxboro I/A Series System.
Features
The FoxBridge software consists of the following items:
1. A FoxBridge Configuration Utility that allows the use of a taking a Controller
Configuration File and building the corresponding FoxBridge software components
including the required Application Objects software and Controller Displays.
2. The Application Object Services Utility, AppObjSrv, allows the user to maintain the
Application Object Database as the model changes, create the Application Objects
and map the Application Objects to I/A Series blocks.
Preliminary
3. Three example DMCplus controller applications, based on the standard 7x7
distillation column example, consisting of I/A Series control blocks, graphics, and
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FoxBridge controller. The application, DMCPLUSD, uses the I/A Series Supervisory
Control (SSC) methodology. The third application, ALLDEMO, is similar to
DMCPLUSD, but has two subcontrollers to allow users to experiment with the
subcontroller displays.
4. A Foxboro Tag Wizard to be used with the Build utility to easily convert a Model file
to a Controller Configuration file.
5. DMCplus Connect software communicates between the DMCplus programs and the
I/A Series system. The Connect program contains two CIM-IO™ servers, one for
Data Collection that uses FoxAPI™ software, and one for control that uses a high
performance Application Object interface for all data transfer between the DMCplus
controller and the I/A Series Application Objects.
6. A display interface to use DMCplus Data collection and extraction programs for use
during step testing, i.e., collect and extract.
7. Microsoft® SQL Server® software.
With proper application of these tools, an operational DMCplus controller can be created in a
very short period of time.
Platforms Supported
The FoxBridge product supports 70 Series workstations using I/A Series software version 8.1.1
and greater.
The FoxBridge product supports FoxView format Operator and Engineering Displays.
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B0700EE – Rev A 1. Overview
DMCplus Summary
Controller Displays
on AW
Setpoints and
Supporting
Information
Object Manager
Preliminary
DMCOP
DMCplusCV#N DMCplusFF#N
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DMCplusCV#3 DMCplusFF#3
DMCplusCV#2 DMCplusFF#2
DMCCV DMCMV DMCSB DMCMV DMCFF
FoxAPI at the AW
2
1. Overview B0700EE – Rev A
The first layer is the regulatory control resident in I/A Series CPs and Integrators. This layer
provides data acquisition and high-speed, robust control. The values in this control database are
accessible to any station in the I/A Series system through the use of the value name, that is, the
Compound:Block.Parameter (C:B.P). The values are communicated between the
systems through several standard layers of I/A Series software: the I/A Series Object Manager, the
I/A Series Interprocess Communication (IPC) and FoxAPI software.
Above the communication layer and resident in an AW memory are the FoxBridges
Application Objects (AOs). These FoxBridge objects map one-to-one with the CVs, MVs, and
FFs associated with a particular DMCplus controller. Application Objects provide the following
services to the FoxBridge software:
1. Use the standard I/A Series data naming convention, i.e., C:B.P, renamed for
convenience to Application:Object.Attribute (A:O.A) to distinguish AOs from CP
control blocks, which permits the use of standard I/A Series display building
techniques to construct generic displays, e.g., Detail Displays and generic overlays.
2. Provide a single data interface for data sourced from different locations, e.g., a single
A:O may hold data from a CP, an Operator, and the DMCplus Controller.
3. Provide data persistence, i.e., the values of an AOA may be checkpointed to a database
Preliminary
and all A:O.As are recreated at reboot.
4. Relatively inexpensive in terms of memory, CPU cycles, and dollars when compared
to the cost of storing the data in a CP block.
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Five types of Application Objects support the FoxBridge: software.
1. DMCOP - which controls the operation of the controller,
2. DMCSB - which contains all data related to a single Subcontroller,
3. DMCCV - which contains all data related to a single Controlled Variable,
4. DMCMV - which contains all data related to a single Manipulated Variable, and
5. DMCFF - which contains all data related to a single Feed-Forward Variable.
Each of these object types has a standard Detail Display invoked through the I/A Series display
manager command stddisp.
Accessing the Application Object layer are two disjoint applications: The DMCplus Controller
and the FoxBridge Human Interface.
The DMCplus Controller consists of the DMCplus MVC engine and Foxboro CIM-IO Servers,
which includes custom transformations to handle the specific requirements of the I/A Series
control. A DMCplus standard Controller Configuration File (CCF) file is used to configure the
DMCplus Controller. All communication to and from the controller is through the Application
Objects built for the controller.
Likewise, the FoxBridge Human Interface is built automatically from data contained in the CCF
file and the values shown on these displays and manipulated through it are attributes of
Application Objects.
The FoxBridge software does not include any AspenTech executables, except for the FOXAOS
CIM-IO servers. The AspenTech license and control software gets loaded onto the I/A Series
workstation and the FoxBridge software then communicates seamless to the AspenTech software.
The I/A Series display interface on the I/A Series workstation is used to start and stop the
controller as well as go to open and closed loop states.
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B0700EE – Rev A 1. Overview
Operation
The operation of the FoxBridge software is described in detail in a later section. However, in an
overview it is appropriate to describe the high points.
The first step is the construction of a process model. To build the process model, one must gather
data on the process, convert it to a model compatible file format (vectors), and move it to the
machine running the Model utility. The FoxBridge software supports these operations with the
CollectStatus display that uses Watchdog timers to monitor the collect process and a tool to use
extract.
Once the data has been collected, a model is built using the Model utility on a non-I/A Series
workstation; typically a PC running a Windows operating system. The model file is then brought
into the Build utility on the same workstation and converted into an I/A Series
Compatible Controller Configuration file using the Foxboro Tag Wizard template.
The Controller Configuration file and model file are then transferred to the I/A Series station.
These files are read at startup by the DMCplus Controller so that it knows where to read its
inputs and where to write its outputs. In the FoxBridge software, all data is read from and written
to an Application Object.
Preliminary
The CCF file provides the basis for the generation of an Application Object Definition (AOD)
file. The AOD file is used to build the required Application Objects, to associate Application
Objects with control blocks, to build the standard FoxBridge Display Set (Summary Displays and
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Detail Displays), and to create the standard FoxBridge menu structure.
The FoxBridge menu provides access to all FoxBridge displays for each configured
DMCplus application. The FoxBridge environments are automatically copied to the
d:/opt/fox/env directory.
The last steps involves the addition of a compound for each Controller. The Controller
compound named <cntlrName>OP, e.g. DMCPLUSDOP, supervises the controller operation. In
particular it contains blocks that monitors status of the DMCplus controller. Among other things,
these blocks monitors the DMCplus controller handshake and triggers fallback to
regulatory control in some cases. It also provides data to several standard FoxBridge displays.
The AOUT, PID and RATIO blocks have supervisory setpoint control and fallback functionality.
The Appendices in this manual describe these required compounds and blocks in detail.
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1. Overview B0700EE – Rev A
Preliminary
August 2, 2011
In Figure 1-2, the boxes with thick lines are procedures directly supported by the FoxBridge
product. The next sections explain this diagram by dividing it into three portions:
Preparation, Configuration and Operation.
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B0700EE – Rev A 1. Overview
Typically, when building a DMCplus Controller using the FoxBridge software, the steps are:
1. Plant step testing using the DMCplus Collect software.
2. Model identification and building.
3. Controller Configuration file generation using Build.
4. Load the Model File and CCF on the FoxBridge Host AW in the
d:/opt/dmcplus/app/<APPNAME> directory.
5. Using the Configure tool, Build the AOD file.
6. Using the Configure tool, Build the MAP File using the Application Object
templates.
7. Using the Configure tool, Segment the AOD File.
8. Using the Configure tool, Build Object Menu Picks, Summary, Economics, Tuning,
External Target and SubController Summary Displays.
9. Using the Configure tool, Build CV, MV and FF Detail Displays.
10. Using the Configure tool, Add the FoxBridge object tags into the Historian.
11. Using the Configure tool, Create the required Shared Variables.
Preliminary
12. Copy the displays to all other workstations.
13. Copy the DMCPLUSDOP compound to a control configurator for Watchdog Timer
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and Alarming support.
14. Edit the compound parameters so that the CIN alarms for DMC Time-out or DMC
On/Off go to the appropriate printers and workstations.
15. Assign MVs to a Supervisory Group and set the Fallback Option to the Appropriate
State.
16. Using the AppObjSrv tool, create the Application Objects database and the
Application Objects.
17. Using the AppObjSrv tool, Map the Application Objects.
18. Using the LOAD CCF button on the DMCOP Detail Display, load the CCF values
into the Application Objects or manually enter the information on the Summary and
Detail Displays. If remote operation, load the CCF on DMCplus Computer.
19. Start the Controller from the DMCOP Detail Display.
Summary
The I/A Series FoxBridge software contains all of the functions and features to quickly and easily
implement a DMCplus Controller on an I/A Series System.
6
2. FoxBridge Installation Planning
This section describes factors to be consider when planning the implementation of a
DMCplus controller using I/A Series FoxBridge software.
Preliminary
in this section.
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The DMCplus Controllers built using the FoxBridge software require names. These names must
meet the following restrictions:
1. Controller names must be no longer than 10 characters,
2. Controller names must meet the constraints of the I/A Series System, i.e., only upper-
case alphabetic characters, numeric characters, and underscores (_) are allowed,
3. Controller names must be unique within the set of I/A Series object names, e.g., a
compound name cannot be the same name as a DMCplus Controller.
4. The controller name, when appended with OP, must be unique.
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B0700EE – Rev A 2. FoxBridge Installation Planning
Preliminary
Product Limitations
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Functions Available From Different Station Types
The following classes of functions are available from the FoxBridge:
1. Engineering functions
Engineering functions provide support for the control engineer. These functions
include:
♦ Configuration of the FoxBridge software, e.g., creating .map files and building
graphics.
♦ Collection of data to build a model.
♦ Saving .ccf files while the controller is running.
2. Operation functions
Operation functions are those services provided to support the operator. These func-
tions include:
♦ Viewing the Summary, Economics, and Tuning displays.
♦ Viewing the Object Detail Displays.
♦ Starting and stopping the controller.
♦ Taking the controller open and closed loop, a.k.a., turning the controller on and
off.
3. Demonstration functions
Demonstration functions are those services provided by the FoxBridge software to
facilitate starting, operating, and stopping the demonstration controller.
Not all functions are available from all possible I/A Series stations as shown in Table 2-1:
8
2. FoxBridge Installation Planning B0700EE – Rev A
NOTE
The required tools depend on access to the logical host of the WP. If this logical
host is not the machine running the FoxBridge software, they will fail.
DDC Control
The DDC mode can be used by setting the SUPOPT to a value of 2.
Preliminary
The I/A Series software ships with the ability to create 1,250 Shared Variables or OM Objects.
August 2, 2011
Application Objects use the same type of resources as Shared Variables and since most FoxBridge
applications require dozens of Application Objects each with a hundred or so attributes, the limit
must be raised. The normal maximum limit is 4,000, but is recommended that this number be
increased to at least 45,000 by the procedure that follows.
The FoxBridge uses Application Objects for data storage, holders for all DMCplus controller
related data. The DMCplus Controller reads and writes only to these Application Objects which
reside in Object Manager shared memory on the FoxBridge Host AW. A separate
application, Application Object Services mapping, handles the communication between the
Application Objects and the Blocks in the Control Processor. Application Objects have a
Compound:Block.Parameter format, known as Application:Object.Attribute.
For each Controller, an application (similar in function to a compound) is created with the
controller name. Each tag in the Controller (CV, MV, FF, SB) is an object (similar to a block). So,
as far as the Object Manager (OM) number of objects required for the Controller is one per tag
and subController, plus one for the Controller level operation. For example, a 20 x 40 Controller
with 2 SubControllers will have 63 objects associated with it.
Each object, however, has a number of attributes (similar to parameters) associated with it,
depending on the type of the object. For example, a CV has all of it’s tuning and future
predictions as attributes. The attribute names come from AspenTech's DMCplus Data Entry
Dictionary. While each attribute is not considered an OM object, it does consume OM resources
in shared memory.
A quick rule of thumb would be to add up all controller variables (CVs, MVs, FFs) and multiply
by 100. The number arrived should be the minimum number for OM_NUM_OBJECTS. It is
recommended that you set the OM_NUM_OBJECTS to at least 20,000.
9
B0700EE – Rev A 2. FoxBridge Installation Planning
NOTE
The performance of the AW can be impaired if it does not have enough RAM to
handle the increased number of objects and other demands placed on it. While it is
the user's responsibility to purchase enough RAM for the required applications, the
AOS package includes a tool to help size its requirements.
OM Object Sizing
This section discusses the procedure to increase the number of Object Manager (OM)
objects. Examples of preferred configuration files can be found in the
d:\opt\dmcplus\tmplts directory.
1. Run D:\usr\local\show_params and record the results.
2. Edit the file D:\usr\fox\exten\config\user_rules.cfg to change the top range on:
♦ OM_NUM_OBJECTS to at least 20,000.
♦ OM_NUM_IMPORT_VARS to a large number, like 400.
3. Edit the file D:\etc\fox\opsys_usr.cfg to change value of:
Preliminary
♦ OM_NUM_OBJECTS to the maximum number entered in user_rules.cfg.
4. Run D:\usr\local\reconfig_IA prep_reboot to change the parameters on the next
August 2, 2011
reboot.
5. Reboot the AW.
6. After the reboot, run D:\usr\local\show_params and compare to the pre-change
values.
FoxAPI Configuration
The FoxAPI program is used to simplify the Object Manager API and extends it over a variety of
networks to various client computers. In addition, it minimizes the consumption of various
resources used by the OM.
The FoxBridge software makes heavy use of the FoxAPI data during data collection. The
Application Object Services mapping operation opens four FoxAPI data sets for each Controller.
Therefore, the FoxAPI parameters may need configuration for a particular project. Configuration
of FoxAPI parameters is accomplished by changing the file d:\opt\fox\ais\bin\foxapi.cfg and
restarting the package.
The first configuration change is to raise the maximum number of objects that the FoxAPI
program may address (maxobj) from the default of 5000 to a more realistic number, such as
20000 or 40000. If large numbers of points are being opened in a short period of time, ensure
that ctdlay is set to 200 (2 seconds). To conserve resources, one should request updates as
infrequently as possible. The update rate is set by the fastest_rsr parameter. It is adjusted in
increments of 0.5 seconds. A fastest_rsr setting of 4 is 2 seconds.
maxobj = 40000
ctdlay = 200
fastest_rsr = 4
10
2. FoxBridge Installation Planning B0700EE – Rev A
Preliminary
trcbrw = 0
open_wait = y
uread_direct = 0
August 2, 2011
nocsaonread = 1
fastest_rsr = 4
use_omopen = 1
ia_badstat = 0
skip_omread = 0
protect_index = 0
A sample foxapi.cfg file can be found in the d:\opt\dmcplus\tmplts directory.
11
B0700EE – Rev A 2. FoxBridge Installation Planning
Preliminary
August 2, 2011
12
3. FoxBridge Installation
This section describes the installation process for the FoxBridge software on I/A Series
workstations.
Overview
The installation procedure consists of the following steps:
TIP
Be sure to install the software packages in the order provided below.
1. Load the latest available version of the FoxAPI software and correctly configure the
d:\opt\fox\ais\bin\foxapi.cfg file.
2. Install the AspenTech license manager, DMCplus, APC Online (formerly AC
Preliminary
Online), and CIM-IO software to the default I/A Series workstation.
3. Reconfigure the OM Objects.
August 2, 2011
4. Install the Microsoft SQL Server software provided with the FoxBridge media.
5. Install the Application Object Services (AOS) software from the FoxBridge media.
6. Install the FoxBridge software from the FoxBridge media.
7. Update the configuration file (d:/usr/fox/customer/hi/dmcfg).
8. Load the FoxBridge Demo Compounds into a CP on the system.
9. Initialize and run the FoxBridge Demo.
Running the Distillation Column simulator demo provides two significant benefits:
1. If the simulator is loaded and running, the FoxBridge software can be used to control
it; this allows the demonstration to prove FoxBridge software is installed properly and
operational.
2. If the simulator is loaded and running, the simulation's interface can be used to train
operators and engineers on the operation of the FoxBridge software without
interfering with plant production.
13
B0700EE – Rev A 3. FoxBridge Installation
Preliminary
a. Change the Startup Type from Automatic to Manual
b. Select OK.
August 2, 2011
c. Close the Services window.
3. Select Start, Programs, then AspenTech, then Common Utilities and then
License Manager Selector.
a. Select DMCplus Online 6.0 and change from Broadcast to
Connect to Named License Server.
b. Enter the AW’s Letterbug as the Server Name.
4. It might be necessary to edit the System PATH to change the d:\usr\aos\exe entry
to d:\opt\aos\exe.
14
3. FoxBridge Installation B0700EE – Rev A
NOTE
If Microsoft SQL Server 2005 software is already installed on the workstation,
installation of the Microsoft SQL Server Express Edition software is not necessary.
To start the Microsoft SQL Server Express Edition software installation process on an I/A Series
workstation:
1. For security-enhanced I/A Series workstations, install the Microsoft SQL Server
software as a Microsoft domain user that has software installation privileges (i.e.
iainstaller).
2. Insert the FoxBridge for Windows CD-ROM into the CD-ROM drive in the AW/WP.
3. Start the installation process by selecting My Computer, then the CD-ROM drive letter
Preliminary
(for example E:).
4. Select the E:\SQL folder.
August 2, 2011
5. Select the SQLEXPR.exe file.
6. At the Open File - Security Warning window select Run.
7. At the End User License Agreement window accept the license agreement and select
Next.
8. At the Installing Prerequisites window select Install.
9. When the required components are installed successfully, select Next.
10. At the Welcome to the MSSQL Server Installation Wizard window select Next.
11. At the System Configuration Check window select Next.
12. At the Registration Information window fill-in the site specific information and
select Next.
13. At the Feature Selection window:
♦Select Browse
♦ Change the installation directory to D:\Program Files\Microsoft SQL Server
♦ Select OK.
♦ Select Next.
14. At the Authentication Mode window select Next.
15. At the Error and Usage Report Settings window leave both boxes unchecked and
select Next.
16. At the Ready to Install window select Install.
17. At the Completing Microsoft SQL Server 2005 Setup window select Finish.
15
B0700EE – Rev A 3. FoxBridge Installation
To start the Microsoft SQL Server 2005 software installation process on a 70 Series workstation:
1. Insert the FoxBridge for Windows CD-ROM into the CD-ROM drive in the AW/WP.
2. Start the installation process by selecting My Computer, then the CD-ROM drive letter
(for example E:).
3. Select the E:\SQL folder.
4. Select the SQLServer2005_SSMSEE.msi file.
5. At the Open File - Security Warning window select Run.
6. At the Welcome to the Install Wizard for Microsoft SQL Server Management
Studio Express window select Next.
7. At the License Agreement window accept the license agreement and select Next.
8. At the Registration Information window select Next.
9. At the Feature Selection window select Next.
10. At the Ready to Install the Program window select Install.
11. At the Completing the Microsoft SQL Server Management Studio Express
window select Finish.
Preliminary
Installation of Microsoft SQL Express software is now complete.
August 2, 2011
Application Object Services (AOS) Software
This section describes the installation of the AOS software.
1. For security-enhanced I/A Series workstations, install the AOS software as a Microsoft
domain user that has software installation privileges (i.e. iainstaller).
2. Verify that the Microsoft SQL Server Express Edition software has been installed.
3. Insert the FoxBridge for Windows media into the CD-ROM drive in the AW/WP.
4. Start the installation process by selecting My Computer, then the CD-ROM drive letter
(for example E:).
5. Select the E:\AOS folder. and select the setup.exe file.
6. After the installation is complete proceed with installing the FoxBridge software.
16
3. FoxBridge Installation B0700EE – Rev A
FoxBridge Software
To install the FoxBridge software on a 70 Series workstation, do the following:
NOTE
The FoxBridge software installation requires that the AspenTech APC (AC) OnLine
software be installed to one of the following locations:
If the AspenTech APC (AC) Online software was installed to a different location,
the FoxBridge software installation will be aborted.
Preliminary
2. Verify that the AspenTech software has been installed and licensed.
3. Verify that the Microsoft SQL Server Express Edition software has been installed.
August 2, 2011
4. Verify that the AOS software has been installed.
5. Insert the FoxBridge for Windows media into the CD-ROM drive in the AW/WP.
6. Start the installation process by selecting My Computer, then the CD-ROM drive letter
(for example E:).
7. Select the E:\FoxBridge folder and select setup.exe file.
8. After the installation is complete, remove the installation media.
9. To create a Save All of the DMCPLUSD demo compounds, run
D:\opt\dmcplus\app\DMCPLUSD\scripts\MkLoadAll.bat
10. Modify the Operating System OM_NUM_OBJECTS according to the instruction in
“Object Manager Sizing” on page 165. (Examples of the various configuration files are
located in the d:/opt/dmcplus/tmplts directory.)
11. Modify the FoxAPI Configuration file, foxapi.cfg, according to the instructions in
“FoxAPI Sizing” on page 166. (Examples of the various configuration files are located
in the d:/opt/dmcplus/tmplts directory.)
Automatic Startup
During the installation of the FoxBridge software the lines CIMIO_FOXAOS, CIMIO_FOXAPI and
DMCPLUS have been added to the bottom of the d:\usr\fox\bin\fox_apps.dat file so the
following programs start automatically.
♦ CIMIO_FOXAPI - CIM-IO server for data from the FoxAPI (data collection support
mostly). Any additional startup instructions can be made to the file
D:\usr\fox\bin\go_CIMIO_FOXAPI.ksh.
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B0700EE – Rev A 3. FoxBridge Installation
♦ CIMIO_FOXAOS - CIM-IO server for data from the AOS (DMCplus controller data
mostly). Any additional startup instructions can be made to the file
D:\usr\fox\bingo_CIMIO_FOXAOS.ksh.
♦ DMCPLUS - Create and setup the DMCplus Controllers on the machine. The script
D:\usr\fox\bin\go_DMCplus.ksh must be edited to start the required controller.
Replace the DMCPLUSD (demo controller name) variable with the desired controller
name and change the $MY_DM variable from the default to a valid display name.
To stop the programs from starting automatically, just remove the CIMIO_FOXAPI, CIMIO_FOXAOS,
or DMCPLUS line(s) from the D:\usr\fox\bin\fox_apps.dat file.
TIP
The CIMIO and FoxBridge entries in the fox_apps.dat file must be located after the
FOXAPI entry.
The sleep time (120) specified in the “go” scripts is used to assure that the FoxAPI
service has time to start before the CIM-IO services and FoxBridge components.
Preliminary
Display (Client) Software on WPs and Non-host AWs
August 2, 2011
Once the software has been installed on the host AW and controllers have been built, the
Controller display and required software should be loaded onto the Operator WPs and non-
FoxBridge host AWs. Each WP or non-host AW station only looks for FoxBridge information
from one host AW.
18
3. FoxBridge Installation B0700EE – Rev A
Display Installation
On each WP and non-host AW operation station:
1. From a NutCracker shell window, and change to the opt directory.
cd d:/opt
2. Tar the contents in. For example:
tar xvf wpFileSet.tar
3. Remove the file.
rm wpFileSet.tar
4. Run the installation script as described in Table 3-1 to link the correct environments
and Detail Displays.
cd dmcplus/scripts
Install.nt
FoxBridge Demos
The FoxBridge software provides a set of demos. The script DMCPLUSD, will be used and the
Preliminary
Operational Compound, DMCPLUSDOP, can be copied for use with other controllers.
Demo Environment
August 2, 2011
From the FoxView menu bar select File, then Change_Env, and then SSCDemo_Eng.
The display will change to the DMCPDEMO Summary display which takes about a minute to
load. All display points will be cyan (OOS) until the DEMO is initialized.
TIP
The Column simulator contains a lot of blocks so make sure the compounds are
loaded into a Control Processor that has excess memory and is not heavily loaded.
Station Block
The DMCPLUSD demo controller uses Watchdog Group 5 for all manipulated variables. When
the controller is started, the time-out value of 150 seconds (2.5 times the controller cycle time of
60 seconds) will be written to the CP station block parameter <CPLBUG>_STA:STATION.RESVL5.
Because this parameter cannot be set, setpars requires that the ICC be closed. Optionally, the
values of the Reset Timers can be set manually in the station block to 150 seconds.
19
B0700EE – Rev A 3. FoxBridge Installation
Preliminary
August 2, 2011
20
4. FoxBridge Configuration
This chapter describes how to configure the FoxBridge software.
Remote Controller
To use the DMCplus Engine with a 70 Series workstation the FoxBridge software must be set to
support remote operation.
The FoxBridge software is installed and configured on a I/A Series AW station, but configuration
is slightly different as the control and manage executables run remotely.
The CCF and Model files still must be on the FoxBridge AW and all FoxBridge and Application
Object Services building utilities must be used when building a new Remote Controller. The
differences are operational only.
Preliminary
AspenTech Software on Off-Platform Windows PC
As on the AW70 workstation with a resident controller, the AspenTech software is normally
August 2, 2011
installed to the folder <LocalDrive>\Program Files\AspenTech.
On the off-platform Windows workstation or server the following folders and files are of
importance:
------APC
---------Online or
------AC online
----------------app
---------------------<Controller>
---------------------------<Controller>.ccf
----------------------------<Controller>.mdl
-------CIM-IO
----------------etc
-----------------------cimio_logical_devices.def
-------DMCplus Desktop
----------------Templates
-------------------------FoxAosWiz.tcc
21
B0700EE – Rev A 4. FoxBridge Configuration
Hosts File
The hosts file, normally found in c:\windows\system32\drivers\etc should be modified to add
the AW name and IP address. The ping utility can be used to verify communication.
Services File
The services file, normally found in c:\windows\system32\drivers\etc should be modified
Preliminary
to add the CIM-IO services. These can be copied from the file
d:\opt\dmcplus\data\CIMIO_SERVICES on the FoxBridge Host AW.
August 2, 2011
Add the following lines to the services file:
22
4. FoxBridge Configuration B0700EE – Rev A
Table 4-1. CIM-IO to Foxboro I/A Series Interface Service Definitions (Continued)
NOTE
The FOXAOS test can only be used to get Application Object Attributes and not
Compound Block Parameters and the FOXIA test can be used for either.
Start the Cimio Test API utility by invoking it from the Cimio Menu Programs and the selecting
AspenTech, AspenTech Manufacturing Suite, CIM-IO, and then Test API. Select option 9.
First test FOXIA and then test FOXAOS.
Preliminary
AspenTech CIM-IO Version 5.4.1 Test Utility
August 2, 2011
--------------------------------------------------------
1-Test CIM-IO time functions
2-Test Adding a Logical Device
3-Test Deleting a Logical Device
4-Test Logging an Error Block
5-Test Logging a Message
6-Test Retrieving an Error Message
7-Test Retrieving a Status Message
8-Test Shutting Down a device
9-Test CIM-IO GET
a-Test CIM-IO PUT
b-Test CIM-IO DECLARE
c-Test CIM-IO CANCEL
d-Test CIM-IO GET Historical Data
e-Test CIM-IO Stop GET
f-Test Disconnecting from a device
g-Test Performance
h-Enable scanner
i-Disable scanner
x-Exit
Press a key to make your selection: 9
Please enter logical device name [IOSIMUL]: FOXIA or FOXAOS
Please enter unit number [1]: 1
Please enter number of tags [1]: 1
Please enter priority (1=HIGHEST 9=LOWEST) [1]: 1
Please enter time-out in seconds (enter 0 or -1 for infinite time-out) [10]:
Access Type: 1)Synchronous 2)Asynchronous
Please select access type [CIMIO_AT_SYNC]:
Please enter frequency in tenths of a second [100]:
Please enter list id [1]: -1
23
B0700EE – Rev A 4. FoxBridge Configuration
Preliminary
4) 32-bit signed integer (long)
5) Character string (ASCII)
6) Time entity
August 2, 2011
7) Enumeration
8) Ordinal
9) Delta time
10) External Identifier
11) Control Block AntiWindup
12) Control Block Status
13) Engineering Units
14) Description
24
4. FoxBridge Configuration B0700EE – Rev A
Preliminary
August 2, 2011
25
B0700EE – Rev A 4. FoxBridge Configuration
Preliminary
August 2, 2011
26
5. FoxBridge Controller Preparation
This section describes how to prepare FoxBridge Controllers.
Preliminary
program. At regular intervals, it retrieves the current values from the I/A Series Global
Process Database for all of the user specified points. The collect program writes the
August 2, 2011
values to a binary file, a.k.a., the collection data base.
♦ extract - This program is run during and after the response test to prepare the vector
files required for analysis of the plant data in Model. The extract program reads data
from the collection data base file and writes a vector file for each requested point.
The FOXIA CIM-IO Interface programs are also used and are located in the directory
<LocalDrive>\Program Files\AspenTech\Cim-IO\io\cio_fox_api.
All Data Collection input and output files reside in the d:\opt\dmcplus\datacol directory.
27
B0700EE – Rev A 5. FoxBridge Controller Preparation
5. There is no limit to the number of data extraction files that can be created from one
data collection process.
Step Description
Install the software. This portion of the procedure was completed
when the FoxBridge software was installed.
Make sure that the FoxAPI process is running The FoxAPI process should automatically start
upon reboot.
Load the four Watchdog Timer Compounds in These compounds are on the DMCPLUSD or
a CP DMCPDEMO Load All and are loaded with
the Demo Compounds.
Create the collection files or generate lists of Using a text editor, a collection file must be
Preliminary
TagNames. created in the format given below. Optionally,
create a file with a list of tags and use the
MkColList script to create the data collection
August 2, 2011
file in the correct CimIO format.
Edit the assignments in the Data Collection file Edit the IDLINE, SAMPLEPER, MAXSAMP,
to be correct. OFFSET, and EOFCHOICE assignments in
the data collection file to be their desired values.
Do not edit any other assignments.
Start Collect
Method 1- from the User Displays
Invoke the DMCplus CollectStatus display Select Tools then DMCplusCollect and then
CollectStatus in the FoxBridge Engineer
environment.
Select a Watchdog Timer and the data This will start the collect program using the
collection file and start collection. selected data collection file.
Method 2 - On Reboot
28
5. FoxBridge Controller Preparation B0700EE – Rev A
Step Description
Create go_<col> These files start the data collectors. There
should be one for each collector instance. The
content of the go_<col> file should be:
sleep 120
D:/opt/dmcplus/scripts/StopCollect
<colfile> <AWLBUG)
sleep 60
D:/opt/dmcplus/scripts/StartCollect
<watchdog> <colfile> <AWLBUG)>
where:
<watchdog> is DMCPLUS_COL1,
DMCPLUS_COL2, DMCPLUS_COL3 or
DMCPLUS_COL4
<colfile> is the name of the data collection file
<AWLBUG> is the letterbug of the FoxBridge host
AW70.
Preliminary
Add lines like the following to the file Each line will start a single collection instance.
D:/usr/fox/bin/fox_apps.dat <col1>
August 2, 2011
...
<coln>
where:
<col1> is the name of the 1st collect file
<coln> is the name of the nth collect file
Test extract From the FoxBridge Engineer environment run
Select Extract from under the DMCplusCollect extract on a particular collection group. After
selection under the Tools menu collect has been running for a few minutes, run
extract to verify that data is being properly
retrieved for each point. Select Tools, then
DMCplusCollect, and then runExtract.
If a fixed collection size has not been selected in Select the data collection filename and
the EOFCHOICE, stop the Data Collect Stop Collection to stop a collection.
program when complete.
At this point, the collection software is ready for the step tests to be executed.
29
B0700EE – Rev A 5. FoxBridge Controller Preparation
Preliminary
Secondary Extract File .clc Contains the data from extract.
Extract Tag File .ext Customer tag names for which data should be
extracted.
August 2, 2011
The relationships between the programs and their file types is summarized Figure 5-1.
extract
30
5. FoxBridge Controller Preparation B0700EE – Rev A
number of header parameters (Table 5-3) in the data collection input file that must be correctly
defined for proper operation.
Preliminary
CIMIOINFO Cim-IO general information: device unit number and
format. For the FoxBridge Data Collection this must always
be set to FOXIA, 1, NN.
August 2, 2011
CIMIOLIST Cim-IO list: maximum number of tags, maximum
description length and the maximum engineering units
length. A value of -1 indicates default. For the FoxBridge
Data Collection this must always be set to -1, 32, 6.
OFFSET The number of seconds after the top of the minute to
collect the first sample. It is recommended that four data
collection groups be created, each associated with a
different watchdog and each with a different offset, such a
0, 15, 30, and 45.
EOFCHOICE -1 = MAXSAMP is ignored and there is no limit to the
number of samples collected by collect. It is not
recommended that this option be used.
0 = The binary file is a fixed size file, so newer data may be
thrown away.
1 = The binary file is circular, so older data is overwritten.
NOMSGS This allows messaging to be turned off if NOMSGS is set
to 1. In the case of the FoxBridge application, the data
collection is monitored through the Collect Status
display, therefore messaging is not required.
WATCHDOGTAG Contains the Watchdog Tagname in Cim-IO format and is
updated every sample period as a health check for the Data
Collection.
NUMSAMPTAG This is the tag to contain the number of samples collected.
It is incremented each sample period.
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B0700EE – Rev A 5. FoxBridge Controller Preparation
For a FoxBridge Data Collection File, the following example shows a valid header. The only
values that should be modified are the IDLINE, SAMPLEPER, MAXSAMP, and
EOFCHOICE. All others should remain set at these values.
VERSIONNUM=1.1
IDLINE=TOWER Data Collection
SAMPLEPER=1m
MAXSAMP=10000
CIMIOINFO=FOXIA, 1, NN
CIMIOLIST=-1, 32, 6
OFFSET=5
EOFCHOICE=0
NOMSGS=1
WATCHDOGTAG="FOXIA":1:"DMCPLUS_COL:WATCHDOG.RI0001":DBVL:
NUMSAMPTAG="FOXIA":1:"DMCPLUS_COL:WATCHDOG.RI0003":DBVL:
Preliminary
STATUSTAG="FOXIA":1:"DMCPLUS_COL:WATCHDOG.RI0005":DBVL:
=================
August 2, 2011
After the header information, there is a delimiter of five or more "=", such as "===========". On
the line following the delimiter, the tag names begin.
Collection Tags are in a format to be interpreted by the CIMIO server and are always in the
following format, CMP:BLK.PRM; where CMP represents the Compound, BLK represents the
block and PRM represents the block name.
Real Variable:
""::"CMP:BLK.PRM":DBVL:
Integer Variable
""::"CMP:BLK.PRM":DBDV:
To make it easier to create this input file, the d:\opt\dmcplus\scripts\MkColList script builds a
list of points in the Compound:Block.Parameter format and converts the list into the format
required for collect. Type MkColList to display help information regarding this script; the output
is as follows:
MkColList
This is a utility for making a properly formatted Data Collection File
To run, type:
MkColList <NAME>
the script looks for an input file containing
a list of point to collect. The input file must
in the /opt/dmcplus/datacol directory and be named:
<NAME>.pts
The input file will be converted into the proper
collect / connect format and called <NAME>. The
file name should be edited per the documentation.
To assign proper SAMPLPER, MAXSAMP, OFFSET and EOFCHOICE.
Do not modify any of the other assignments.
The defaults are:
32
5. FoxBridge Controller Preparation B0700EE – Rev A
SAMPLEPER=1m
MAXSAMP=10000
OFFSET=5
EOFCHOICE=0
For example:
1. Create a list of points called TOWER.pts in C:B.P Format
in the /opt/dmcplus/datacol directory
2. Run "MkColList TOWER"
3. A file called TOWER will be created in the /opt/dmcplus/datacol
directory and used by the collect program.
4. Edit TOWER to verify the values per the documentation
To build a valid DMCplus Collect Input file, start with a file that contains the list of points
desired. This file must be placed in the d:\opt\dmcplus\datacol directory and have the name of
the collection group with an extension of .pts. For example, here is a file of
Compound:Block.Parameter names called TOWER.pts.
d:\opt\dmcplus\datacol\TOWER.pts
DMCPLUS30A:DPI104.PNT
DMCPLUS30A:DPI103.PNT
Preliminary
DMCPLUS30A:TI105.PNT
DMCPLUS30A:LI103.PNT
August 2, 2011
DMCPLUS30A:VPI103.PNT
DMCPLUS30A:TI106.PNT
DMCPLUS30A:AI210.PNT
DMCPLUS30A:FI101.SPT
DMCPLUS30A:TI103.SPT
DMCPLUS10A:PIC103.SPT
DMCPLUS30A:FIC107.SPT
After running d:\opt\dmcplus\scripts\MkColList TOWER, a file called TOWER will exist in the
d:\opt\dmcplus\scripts directory and look like this:
VERSIONNUM=2.0
IDLINE=TOWER Data Collection
SAMPLEPER=1m
MAXSAMP=10000
CIMIOINFO=FOXIA, 1, NN
CIMIOLIST=-1, 32, 6
OFFSET=5
EOFCHOICE=0
NOMSGS=1
WATCHDOGTAG="FOXIA":1:"DMCPLUS_COL:WATCHDOG.RI0001":DBVL:
NUMSAMPTAG="FOXIA":1:"DMCPLUS_COL:WATCHDOG.RI0003":DBVL:
STATUSTAG="FOXIA":1:"DMCPLUS_COL:WATCHDOG.RI0005":DBVL:
=================
""::"DMCPLUS30A:DPI104.PNT":DBVL:
""::"DMCPLUS30A:DPI103.PNT":DBVL:
""::"DMCPLUS30A:TI105.PNT":DBVL:
""::"DMCPLUS30A:LI103.PNT":DBVL:
""::"DMCPLUS30A:VPI103.PNT":DBVL:
""::"DMCPLUS30A:TI106.PNT":DBVL:
""::"DMCPLUS30A:AI210.PNT":DBVL:
33
B0700EE – Rev A 5. FoxBridge Controller Preparation
""::"DMCPLUS30A:FI101.SPT":DBVL:
""::"DMCPLUS30A:TI103.SPT":DBVL:
""::"DMCPLUS10A:PIC103.SPT":DBVL:
""::"DMCPLUS30A:FIC107.SPT":DBVL:
Now edit the IDLINE, SAMPLEPER, MAXSAMP and EOFCHOICE to be
appropriate for the data collection.
Preliminary
RRATE 2
WRATE 3
August 2, 2011
The deltas and scan rates can be increased if network loading is a problem, or if a large number of
points is being collected. The delta values must be greater than 0. The RRATE parameter is
measured in 1/2 second increments (2 = 1 second).
34
5. FoxBridge Controller Preparation B0700EE – Rev A
Preliminary
August 2, 2011
Figure 5-2. DMCplus Collect Operation
To begin data collection, one must prepare a COL file in the format previously described and
placed in the d:\opt\dmcplus\datacol Data Collection directory. It is recommended that the
desired tags be split into four groups, each with a different OFFSET and that these four groups be
associated with a different Watchdog Timer.
Once the file is in the directory, the Tools menu within the FoxBridge Engineer environment
offers the DMCplusCollect and CollectStatus pick which raises the process graphic used to
control the DMCplus collect program.
To start data collection, select an unused Watchdog timer, i.e., one which does not have a COL
file listed in its ColFile column, and select a data collection file from the Collection Files list. The
selected names will appear next to the Selected Watchdog: and Selected ColFile prompts. Once
the names are selected, click on the Start Collection button to start data collection.
To stop data collection, select the name of the COL file that you wish to stop and click on the
Stop Collection button.
Whether stopping or starting the data collection, the message bar will provide a series of messages
describing the operation and its success or failure. Monitor the Bad Smpls column on the display.
35
B0700EE – Rev A 5. FoxBridge Controller Preparation
NOTE
If there is a problem with the COL file, the collect program will quit running
without notification, other than the WDT timing out. If this occurs, examine the
log file in the d:\opt\dmcplus\logs directory. The log file will contain the error
printout.
Column Meaning
Name Name of a particular WDT compound. New compounds can be
created by duplicating one of the existing ones. Be sure to update
the display to add support for it.
Time-out If OK, the program is loaded and updating the Watchdog timer. If
TimedOut, the program is not updating the Watchdog timer and is
probably no longer in memory.
Preliminary
MaxSmpl Maximum number of samples that can be recorded in the data base,
i.e., the .bin file
August 2, 2011
SmplCnt Number of samples recorded in the database, i.e., the .bin file.
Bad Smpls Number of bad samples recorded by the collect program.
LastRun Time of the last execution in hh.mm format.
ColFile Name of the data collection file in use by the collection program
using the Watchdog.
Type This describes the type of Data Collection File as indicated by the
EOFCHOICE.
Options are:
Inf - (EOFCHOICE is set to 1) Not recommended, collection file
will grow infinitely.
Fix - (EOFCHOICE is set to 0) Data Collection will stop when
SmplCnt reaches MaxSmpl.
Cir - (EOFCHOICE is set to 1) Data Collection file will be a circu-
lar file. The extract program must be run periodically before data is
overwritten.
36
5. FoxBridge Controller Preparation B0700EE – Rev A
DMCPLUSD
Enter the Name of the File to Run Extract: [DMCPLUSD]
Do you wish to Run Extract for Collection DMCPLUSD? y
Enter extraction sample period in minutes [1] >>
Extract beginning with time: May 19, 1998 09:04:05? [Y] >>
Extract ending with time: May 19, 1998 09:32:05? [Y] >>
Use default filename (DMCPLUSD) for .ext file? [Y] >>
Use default filename (DMCPLUSD) for .clc file? [Y] >>
Creating DMCPLUSD.clc
Extract with another .ext file? [N] >>
When the Extract portion of Data Collection is started, a file called <colfile>.cle is used as
input. This file contains AspenTech-generated vector tag names which are generated using the
compound name and part of the block name. This file should be edited to make more user
friendly vector tag names prior to running Extract. Once it is created, keep a backup of this edited
<colfile>.cle files as it is created every time the Collect portion of Data Collection is started or
changed.
When adding points to an existing Data Collection file (<colfile>.col), remove the file
<colfile>.ext prior to running data extraction or the new tags will not be extracted.
Preliminary
DMCplus Collect Troubleshooting
It is possible to get the Data Collection Files (which get edited during Data Collection) or the
August 2, 2011
Watchdog Timers (which have parameters set up during Data Collection) in an invalid state. If a
Data Collection is unable to start, use the following procedure to initialize the Data Collection
system.
1. Select each Data Collection file and select Stop Collect. Even if the Data Collection
is not running, the Data Collection .col file will be edited to its original state.
2. Initialize the Watchdog Timer parameters. From a NutCracker shell window, type:
cd /opt/dmcplus/scripts
init_collect ALL
Data Transfer
Once the data files are complete, they must be transferred to a PC running the AspenTech Data
Modeling program, MODEL.
37
B0700EE – Rev A 5. FoxBridge Controller Preparation
Modeling
Data Modeling is performed on the PC using the AspenTech’s Model package. This work is not
covered here. However, the final output of this effort is a Model File (MDL) which is required for
the later steps.
The previous data transfer topics discusses the issues involved in moving the Model File back to
the I/A Series station. Both the Model file and the Controller Configuration file are generated on
using the PC based tools and are required for Controller operation on the I/A Series system.
The Model file and Controller Configuration file base names must be the same name as the
Controller name. Therefore, if the Controller is to be named FCCU then the model file must be
fccu.mdl and the Controller Configuration file must be fccu.ccf.
Preliminary
Table 5-5. DMCplus Build Versions
August 2, 2011
DMCplus Build Version I/A Series FoxBridge Software Version
1.11 2.x
2.0 3.x
3.1 4.x
5.x 4.1 and later
6.x 5.x and 6.x
All CCFs created with a prior version of the Build program must be updated. The FoxAosWiz.tcc
Tag Wizard that is supplied with the current version I/A Series FoxBridge software must be used.
! CAUTION
Do not use the FoxAosWiz.tcc, Tag wizard or the foxaos.tcc template used with
a prior FoxBridge software version.
Preparing Build
1. If upgrading from a prior version of the FoxBridge software, remove the
foxaos.tcc template from the DMCplus Templates folder.
2. After loading the current DMCplus software on your PC, load the updated
FoxAosWiz.tcc template provided with the current FoxBridge software or from
AspenTech. Overwrite the FoxAosWiz.tcc template that was provided with the older
DMCplus software. The FoxAosWiz.tcc template can be found in the
d:\opt\dmcplus\tmplts directory.
38
5. FoxBridge Controller Preparation B0700EE – Rev A
Preliminary
Subcontroller Names and specify the Minimum Number of Good Subcontrollers.
g. Close the Options screen. When prompted to run the Tag Wizard, select No.
August 2, 2011
h. Review the CCF configuration to check the checkboxes for Feedforward MVs,
MVs or CVs with External Targets or CVs with Intermittent Signals. Custom
Calculations or Rankings can be defined or assigned at this time.
i. Once the Controller Configuration has been verified, run the Tag Wizard by
selecting Tools and then Tag Wizard.
j. Select Next, Next, Next, Next, and then Finish in the Tag Wizard.
3. Save the CCF.
File Transfer
Once the Model and Controller Configuration files have been generated and the FoxBridge
software has been loaded onto the I/A Series workstation, then the files must be put in the correct
directory on the I/A Series workstation.
The Model and Controller Configuration files must have the same base name and that name
must be the Controller name. Copy the mode and controller configuration files to the
d:\opt\dmcplus\app\<CONTROLLER> directory. Where <CONTROLLER> is the Controller name in
uppercase letters. As mentioned before the Controller name must be ten characters or less.
For example, if the Controller name is MYTOWER and the Model and Controller Configuration
Files are on a diskette, then type the following:
mkdir d:/opt/dmcplus/app/MYTOWER (make the directory)
cd d:/opt/dmcplus/app/MYTOWER (go to the directory)
cp a:/mytower.mdl MYTOWER.mdl (copy the Model file)
cp a:/mytower.ccf MYTOWER.ccf (copy the CCF)
39
B0700EE – Rev A 5. FoxBridge Controller Preparation
Preliminary
August 2, 2011
40
6. Controller Configuration
This section describes how to configure FoxBridge Controllers.
Configure Utility
Configuration of the FoxBridge software is performed using the FoxBridge Configuration utility.
The FoxBridge Configuration utility is invoked by running the batch file
d:\opt\dmcplus\scripts\Configure.bat. Once the program is started, the following will be
displayed in the window:
Enter the name of the Application: [DMCPLUSD]
where the name of the last controller configured was DMCPLUSD. Enter your Controller Name or
simply press the Enter key to accept the proposed default. Once the application has been
specified, the utility will change its working directory to the default location for all files related to
the Controller (with the exception of the CCF and Model files) and it will display:
Preliminary
Changing to: /opt/dmcplus/app/DMCPLUSD/data
Hit Return to continue:
August 2, 2011
At this point, the screen will clear and the following menu will be displayed on the station:
Select the options that you would like to perform on DMCPLUSD:
---FILE BUILDING AND MAINTENANCE:
1 - RECONCILE CCF and AOD Files
2 - BUILD the Application Object MAP File from DMCPLUSD.aod
3 - Edit the Controller Configuration File [DMCPLUSD.ccf]
4 - Edit the Application Object Definition file [DMCPLUSD.aod]
5 - Edit the MAP file [DMCPLUSD.map]
---FILE SEGMENTING FOR DISPLAY PURPOSES:
10 - SEGMENT the AOD file automatically
The original file is not altered. New files are created
11 - Remove the segment files
---SUMMARY DISPLAY BUILDING:
20 - Build the AppObj Menus for the AppObjs in DMCPLUSD.aod
21 - Build the Summary Display for the AppObjs in DMCPLUSD.aod
22 - Build the Economics Display for the AppObjs in DMCPLUSD.aod
23 - Build the Tuning Display(s) for the AppObjs in DMCPLUSD.aod
24 - Build the SubController Summary Displays for AppObjs in DMCPLUSD.aod
25 - BUILD ALL Menus and Summary Type Displays [20-24]
--- HISTORIAN AND VARIABLES:
34 - Build the Historian for trend support from DMCPLUSD.aod
35 - Build the SVs required for trend and D button support
36 - BUILD ALL Detail Displays, Historian and SVs [30-35]
---OTHER ACTIVITIES:
90 - Change Application
91 - Specify suffixes for the SSC [_SSC] and FALLBACK [_FALL] CALC blocks
(Version 4.1 or NONSSC Implementations Only!)
Q - Exit and save logs.
Enter Selection ->
If this is a new application (DMCplus Controller), the directory structure is created, however, the
resulting structure is empty. Before work can be done, the user must place the model file built by
41
B0700EE – Rev A 6. Controller Configuration
Model and Controller Configuration File in the controller directory, e.g., place the
files DMCPLUSD.mdl and DMCPLUSD.ccf in the directory d:\opt\dmcplus\app\DMCPLUSD.
Preliminary
SubController information. For SubControllers (type DMCSB) only the type and SubController
Name are entered in the AOD file. If a different mapping is desired, as in the case of FEEDT
August 2, 2011
below, then the parameter can be appended to the block type and the mapping and range will be
modified as required.
Here is an example AOD file (Table 6-1) for a 7x7 Controller with 2 SubControllers:
#This file is used for definition of an Applications Objects
#Delimit each element by white space.
#Only valid object types are processed.
#Shell comments are discarded.
#Only first element of line is used.
42
Table 6-1. Example of AOD File (Continued)
The AOD file is located in d:\opt\dmcplus\app\<APPNAME>\data and is used for the creation
of the MAP file and generation of all Summary displays. Therefore, it is important that the AOD
file is correct. The complete file is called <APPNAME>.aod. Since it is a manually created file, it
is a good idea to keep a backup copy of the file.
To minimize the work involved during reconfiguration, e.g., when a new CV is added or an old
one is deleted, the procedure for generating an AOD file preserves as much information as
possible from the previous one.
The algorithm that is implemented is:
1. Identify the objects defined by the CCF file,
2. For each object in the original AOD file (not in the new CCF file), ask the user if the
object should be renamed, deleted, or kept.
3. For each object in the CCF that is not in the AOD, ask the user for the mapping
Preliminary
information or allow it to be skipped since it can be added manually later. In an
ACCP system, the Compound and Block will correspond with the Application and
August 2, 2011
Object.
The Rename, Delete, or Keep options are the most complex.
♦ Rename is useful if the name in the AOD is misspelled or the name in the Model file
has been changed for clarity.
♦ The Delete option simply removes the object from the AOD file and the I/A Series
system.
♦ The Keep option leaves the object in the AOD file even though it will not be used by
the controller. This option can be useful as one experiments with the best
combination of objects since it allows data values like alarm limits to be preserved.
The Map or Skip options are straightforward.
♦ The Map option requires the entry of a Compound Name, a Block Name, and,
optionally, a Block Type.
♦ The Skip option places the record in the file without any mapping information. The
file should not be used in this state.
Once an AOD file has been modified, then a new map file must be generated. If the Application
Object associated with the Controller have been created, then the Application Objects must be
deleted and recreated using Option 20 of the AppObjSrv menu. Refer to Appendix A “Applica-
tion Object Services” for more information.
For ACCP systems, the Block Types will be ACPID, ACAIN, ACAOUT, and ACAMB. If the
ACCP scanner configuration and been built and the ACCP objects have been created, then the
AOD file will correctly reflect these values.
The following is a sample run of a new CCF against an AOD with a misspelled Object Name.
Enter Selection -> 1
43
B0700EE – Rev A 6. Controller Configuration
+ ReconcileAOD DMCPLUSD
DMCCV CONDOP SPLITTER DPI103 AIN is no long needed.
Rename, Delete, or Keep CONDOP? [r|D|k]:
r
Enter the new name:
CONDDP
470 (These numbers will vary with the size of the controller)
470
The new AOD is:
# This file is used for definition of an Applications' Objects
# Delimit each element by white space.
# Only valid object types are processed.
# Shell comments are discarded.
# Only first element of line is used.
# Type Object Cmpd Block Type ModeSubctl
DMCCV COLDP SPLITTER DPI104 AIN SSC
DMCCV CONDDP SPLITTER DPI103 AIN SSC
DMCCV DRAWT SPLITTER TI105 AIN SSC
DMCCV OHLEVEL SPLITTER LI103 AIN SSC
DMCCV OHPVALV SPLITTER PIC105 PIDA.OUT SSC
Preliminary
DMCCV OHTEMP SPLITTER TI106 AIN SSC
DMCCV SSCOMP SPLITTER AI210 AIN SSC
DMCFF FEED SPLITTER FI101 PID SSC
August 2, 2011
DMCFF FEEDT SPLITTER TI103 PID SSC
DMCMV OHPRESS SPLITTER PIC103 PID SSC
DMCMV OHPROD SPLITTER FIC107 PID SSC
DMCMV REBBTUS SPLITTER QIC701 PID SSC
DMCMV REFLUXS SPLITTER FIC201 PID SSC
DMCMV SSFLOW SPLITTER FIC210 PID SSC
+ exec
+ exec
Hit Return to continue
44
6. Controller Configuration B0700EE – Rev A
The form of automatic segmentation provided groups objects by type (DMCCV, DMCMV, and
DMCFF in that order) with two types on a given page if and only if all of the objects of the next
type will fit on the last page of the current type. The algorithm used is as follows:
1. The existing AOD file is scanned and objects of each type are extracted into separate
files.
2. The internal order for these objects is preserved.
3. The CVs are assigned to a segment until the maximum number of CVs on the page
has been reached. The maximum number is calculated based on the number of lines
of the display less the number of lines required for fixed display items, e.g., the title.
4. If there is room in the last CV segment for all of the MVs, the MVs are added to it.
5. If the MVs were not stored in the last CV segment, they are allocated to new MV only
segments in the same manner as the CVs.
6. If there is room in the last MV segment for all of the FFs, the FFs are added to it.
7. If the FFs were not stored in the last MV segment, they are allocated to new FF only
segments.
To segment an existing AOD file, select item 10 from the menu as shown below:
Preliminary
Enter Selection -> 10
When the new segment files have been created, they will be listed as follows:
August 2, 2011
The segmented aod files produced from DMCPLUSD.aod are:
DMCPLUSD.aod.SUM.0
...
DMCPLUSD.aod.SUM.n
Hit Return to continue
where DMCPLUSD.aod.SUM.0 is the first AOD file segment and DMCPLUSD.aod.SUM.n is the nth
and final segment for the Summary displays. The initial AOD file is never altered due to
segmentation. Segments will be created for the Summary, Economics, Tuning (including the
External Target and CLP Display) and Subcontrollers (if used). Each of these displays has a
different density and therefore requires different types of segmenting.
45
B0700EE – Rev A 6. Controller Configuration
Preliminary
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCCV/OHTEMP]
Building Menu Pick for SSCOMP
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCCV/SSCOMP]
August 2, 2011
Building Menu Pick for FEED
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCFF/FEED]
Building Menu Pick for FEEDT
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCFF/FEEDT]
Building Menu Pick for OHPRESS
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCMV/OHPRESS]
Building Menu Pick for OHPROD
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCMV/OHPROD]
Building Menu Pick for REBBTUS
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCMV/REBBTUS]
Building Menu Pick for SSFLOW
[/opt/dmcplus/app/AppMenus/DMCPLUSD/DMCMV/SSFLOW]
Hit Return to continue
46
6. Controller Configuration B0700EE – Rev A
The Summary Display set is the Operator's primary source of information on the Controller and
its current behaviors. The Economics Display set shows the performance of the controller in
terms of dollars. The Tuning Display allows the user to adjust the controller's tuning parameters.
When all of Summary and Detail Displays have been generated, the procedure on page 37 can be
used to copy the displays to non-host AWs and WPs. This procedure will copy all displays and
scripts required for the FoxBridge Host and will repack the displays. If displays generated on the
FoxBridge Host are manually copied to other workstations, the displays should be repacked. Use
the REPACK DISPS button on the DMCOP page for each Controller to repack all related
FoxBridge displays if they have been manually copied.
Summary Display
After the AOD file has been segmented, the Summary Displays should be built. The resulting
file(s) will have an extension of _sumx. The following shows how this is accomplished and the
results of the operation.
Enter Selection -> 21
The default files are:
DMCPLUSD.aod.SUM.0
...
Preliminary
DMCPLUSD.aod.SUM.n
Do you want to use the default files? [Y|n]
August 2, 2011
At this point, one may use the proposed set of segmented files or an alternate set of names.
Pressing the Enter key causes the default files to be used. Entering a space delimited list of names
allows an alternate set of names to be used. For example, one might wish to enter the files named
xaa, xbb, and xcc (the results of a split(1) command). The following lines show how to do this:
The default files are:
DMCPLUSD.aod.SUM.0
Do you want to use the default files? [Y|n]
xaa xbb xcc
When the generation of the displays has completed, the utility shows a list of the new files:
The new Display files are:
DMCPLUSD.SUM0
...
DMCPLUSD.SUMn
Hit Return to continue
where DMCPLUSD.SUM0 is the first summary graphic (based on the first AOD file segment) and
DMCPLUSD.SUMn is the nth and final graphic based on the nth and final segment.
Economics Displays
The Economics Display(s) are created by selecting Option 22 from the Configure menu. As with
the Summary display, the use the entire AOD file is optional, provide AOD file segments
manually, or use AOD segments created specifically for the Economics display(s). The resulting
file(s) will have an extension of _ecox.
Tuning Displays
The Tuning Display(s) are created by selecting Option 23 from the Configure menu. As with the
Summary display, the use the entire AOD file is optional, provide AOD file segments manually,
47
B0700EE – Rev A 6. Controller Configuration
or use AOD segments created specifically for the Tuning display(s). The resulting file(s) will have
an extension of _tunx.
If External Targets or Composite LP is enabled for the Controller, then a separate set of displays
will be created to show the parameters associated with these. The resulting displays will have an
extension of _etcx.
Preliminary
I/A Series Historian Configuration
The Configuration Utility allows the user to configure an I/A Series Historian to support the
August 2, 2011
FoxBridge Detail Display trend areas by selecting item 34.
Enter Selection -> 34
This selection causes the following question and answer session to begin:
Enter Scan Rate in seconds: 2 4 10 20 30 60 120 300 600 [20]
This question asks how often the data in the Historian should be updated since most controllers
run with a frequency of 1 minute or longer. The default seems appropriate.
Enter DeadBand [0.01]
Points in the I/A Series Historian are updated on a change driven basis. The amount of change
required to generate a transmission to the Historian is set by this prompt. The value is in
engineering units.
Enter the Maximum number of sample records in the (extended) sample file.
Each record contains 100 samples. [10]
The Historian needs to know how many values to record for each Attribute being added.
Entering this value says that 1000 samples must be preserved. With the default rate of 20 seconds,
1000 samples represents at least 20,000 seconds (almost 6 hours).
If the Historian should be configured, answer y to the next prompt. If not, enter n and the
Configuration Utility will save the Historian configuration file and print its name so that the file
may be edited and used later.
Automatically update the historian? [y|N] y
Valid historians are:
hist01
hist02
hist03
Enter the name of the historian
48
6. Controller Configuration B0700EE – Rev A
Preliminary
characteristics of all display managers on this AW or WP. As it reads and processes display
manager names, it lists them on the screen.
Adding 1AW51A...
August 2, 2011
Adding 1WP51A...
NOTE
This file, if properly maintained, will actually contain the names and configurations of
all display managers in the system.
Once all of the display manager names have been processed, a script file exists that contains the
omcrt commands required to create the Shared Variables. This script,
D:/opt/dmcplus/scripts/CreateSVs, can be executed by answering the following question
affirmatively.
Create the Shared Variables? [Y|n]:
Type Y or simply enter to choose the default of creating the shared variables and Application
Objects. This option is also run by the /opt/dmcplus/scripts/go_DMCplus script that runs on
bootup to create and map Application Object for a specified controller.
49
B0700EE – Rev A 6. Controller Configuration
Application Objects
Configuration of the Application Objects required for a particular DMCplus Controller is
performed using the Application Object Services Configuration utility. This utility can be run
directly by entering the following command:
d:/opt/aos/scripts/AppObjSrv
or by running the batch file d:\opt\dmcplus\scripts\AppObjSrv.bat. Refer to Appendix A
“Application Object Services” for a complete description of this utility
Once the program is started, it will check if the FoxAPI/AIS process is running. If so, it will issue
the following note:
AIS is running.
If the FoxAPI process is not running, the utility asks if it should start it:
AIS(FoxAPI) does not seem to be running.
If it is not running, this script does not work correctly.
Do you want me to try and restart it? [Y|n]
Preliminary
Accepting the default, causes the utility to switch to the home directory for the FoxAPI program,
i.e., d:/opt/fox/ais/bin, and run the startup script, aisstart.
Once, the FoxAPI process is running, the following four questions will be asked in the window:
August 2, 2011
Enter the name of the Application: [DMCPLUSD]
Enter the location of the Application's Log Files:
[/opt/dmcplus/app/DMCPLUSD/logs]
Enter the location of the Application's Map File:
[/opt/dmcplus/app/DMCPLUSD/data]
Enter the name of the Application's map File: [DMCPLUSD.map]
where the name of the last controller configured was DMCPLUSD. If the same controller is to be
configured, simply press the Enter key to accept the proposed defaults. For the FoxBridge
software, the log directory is always /opt/dmcplus/app/<APPNAME>/logs and the map file
directory is always /opt/dmcplus/app/<APPNAME>/data and the map file is always
<APPNAME>.map where <APPNAME> is the name of the Controller.
If the Controller name is incorrect for the Map File prompt, the AppObjSrv process will exit.
Once the application has been specified, the utility will change its working directory to the default
location for all files related to the Controller being configured and it will display:
Hit Return to continue:
At this point, the screen will clear and the menu in Figure 6-1 will be displayed:
50
6. Controller Configuration B0700EE – Rev A
Preliminary
August 2, 2011
Figure 6-1. Application Object Services Menu
This menu provides access to all available commands related to the Application Objects.
51
B0700EE – Rev A 6. Controller Configuration
The following information is shown. First, the database is created from the current map file and
the application is registered with CSA, then the Application Objects are created and
registered with the Object Manager. If there are any I type (ICC) mappings, then the connection
is made to the CPs. By default, I type mappings are not used in FoxBridge Applications, therefore
connect, disconnect and verify operations are not used.
Building AppObj database...
AppObj database built.
Creating AOAs...
AOAs created.
Performing connect...
Connect completed.
The current process state will change from UNDEFINED to AOS_CREATE. Before DMCplus
Controller operation can take place the Application Objects must be mapped to Control Objects
using the Option 10 Start Mapping Application Objects. This operation is described on page 57.
If changes are made to the AOD file, such as the number or types of DMCplus tags, then a new
map file must be created and the database must be regenerated as described above. If changes to
mappings are made, such as using a custom Object Template to send a DMCplus
software attribute to an I/A Series block, then the database must also be regenerated.
Preliminary
Option 2 in the AppObjSrv menu will create the Application Objects and register them with the
Object Manager using the currently loaded database for the application rather than the map file.
August 2, 2011
The database contains the current checkpointed value. This is the option typically used after
rebooting as called from the go_DMCplus script. Option 1 in the AppObjSrv menu must be
chosen if any map file changes are made.
Control Loops
Instructions on the configuration of I/A Series control loops is beyond the scope of this
document. However, each CV, FF, and MV in the controller must be associated with an
underlying control block. The Application Objects used for the DMCplus Controller will be
mapped to parameters in Control Blocks.
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6. Controller Configuration B0700EE – Rev A
Watchdog Timers
The FoxBridge software includes a demonstration controller, DMCPLUSD. Since it is
operational, it requires the support of a Watchdog Timer in the CP. All of the blocks required for
the DMCPLUSDOP compound are located in the SAVEALL folder
d:\opt\dmcplus\app\DMCPLUSD\ntcompounds\DMCPLUSDOP.
This compound is entirely self-contained. To use it for other controllers,
1. In the Integrated Control Configurator (ICC), copy the demo compound
DMCPLUSDOP to the Paste Buffer and name it <APPNAME>OP where
<APPNAME> is the name of the Controller.
2. Paste the compound into the appropriate Control Station.
No other configuration is required.
Watchdog Timer and Controller Fallback support is provided within the Station Block. There are
eight (8) Supervisory Groups in each Control Processor Station Block. The following are
requirements of control block configuration:
1. All Blocks (AOUT, PID, RATIO family) associated with Manipulated Variables must
be assigned to one of the eight groups in the Control Processor.
Preliminary
2. All Manipulated Variable blocks within a controller must be assigned to the same
group.
August 2, 2011
3. If Manipulated Variables for a single controller are contained in multiple Control
Processors, the MASTERWDT block in the Operational Compound will handle
group level fallback for all Control Processors.
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B0700EE – Rev A 6. Controller Configuration
Preliminary
August 2, 2011
54
7. FoxBridge Controller Operation
This section describes the operation of FoxBridge Controllers.
Environments
Within the I/A Series system the term display manager environment, or simply environment,
refers to set of available menu bar options and a set of enabled access levels. Access to any
environment can be made subject to the entry of a password.
The FoxBridge software provides support for three environments as described in Table 7-1.
Name Description
Remote Provides minimal access to the I/A Series system. It disables all
Preliminary
pickpoints and creates a View Only environment for Remote user.
Operator Provides access to all operator functions, e.g., changing Operator High
August 2, 2011
and Low limits and starting/stopping the DMCplus Controller.
Engineer Provides access to engineering functions, e.g., the FoxBridge and
Application Object configurators and the High and Low
Engineering limits.
The restrictions on access are implemented by using the standard display manager Access Level
controls. Each pickable point on a FoxBridge graphic is assigned to one of the classes listed in
Table 7-2.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Just as pick points are controlled on an environment basis so are the displays and tools accessible
to the user. Table 7-3 describes what is available on each menu bar button in each environment.
Preliminary
5 DMCTools Provides access to the FoxBridge software x
and Application Object configurator.
August 2, 2011
These environments support the use of I/A Series passwords. Passwords may be added using the
display manager set password utility, dmsepass. Use the standard I/A Series documentation for
more information regarding the dmsepass command.
Startup
The summary startup procedure is as follows. The first two steps are performed by the
go_DMCplus script if setup to run upon an AW reboot.
1. Start the Application Object mapping services.
2. Start the DMCplus Controller, i.e., load it in memory and get it running. This is
accomplished from the DMCOP detail display.
3. After the controller has initialized (2 controller cycle times), check the status of the
CVs, MVs, and FFs. The controller will not run in closed loop mode until all of the
critical variables are RDY (TEST) or GOOD. In addition, enough variables must be
good. The term enough refers to the parameters in the model configuration process
for defining enough good values. The MVs will first display E then D.
4. If SubControllers are used, turn each SubController, to be used, on by selecting OFF in
the DMCSB SubController Detail Display and then selecting the Toggle button.
Optionally, use the Summary of SubControllers Display to turn the SubControllers
on. All SubControllers that are still off must be non-critical.
5. Close the DMCplus Controller loop. From the Summary Display, close the loop by
picking on the words OPEN LOOP next to Mode: or selecting OPEN LOOP on the
DMCOP Display. Confirm the selection on the overlay. This process will enable all
MVs with a SRVIND entry of ON, as long as, their SubController (if any) is ON.
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7. FoxBridge Controller Operation B0700EE – Rev A
6. At this point, if the DMCplus Controller is in a good state to run, it will acknowledge
the blocks as indicated by the yellow box on the MV Summary Display lines (not for
SMG or ACCP systems). This box will stay for one controller cycle.
7. When the loops are using their new setpoints, a green box will appear and stay as long
as the loop is being controlled by the DMCplus Controller.
8. To turn ON a non-critical SubController after the DMCplus Controller is already
running CLOSED LOOP, select the ENABLE MVS button on the DMCSB Detail
Display. This executes only in the top half of a Controller cycle and turns ON the
SubController and enables all of the SubController's MVs that have a SRVIND of
ON.
To get a Controller up and running in an open loop mode upon the I/A Series workstation
bootup, edit the d:/usr/fox/bin/go_DMC.ksh script with a line that runs the go_DMCplus for
each controller. For example:
d:/opt/dmcplus/scripts/go_DMCplus <CONTROLLER>
where <CONTROLLER> is the name of the Controller.
Optionally, the name of a display manager as a second argument can be provided for the message
line indications of the startup. The go_DMCplus script creates the Application Objects from an
Preliminary
existing database (the same as choosing Option 2 from the AppObjSrv menu) and maps the
Application Objects at a 2 second rate with a 600 minute checkpoint frequency. The script then
August 2, 2011
starts the Controller in open loop mode.
If multiple Controllers are to be started up, simply add a line for each Controller in the
d:/usr/fox/bin/go_DMCplus.ksh file. Do not run the lines in the background (with an "&" at
the end of the line) as this may overload the processor if trying to start all Controller
simultaneously.
NOTE
Leave the AppObjSrv menu open after mapping or the mapping process will exit
when the AppObjSrv menu exits.
At this point, the verification process is invoked if "I" (ICCAPI) type mappings are present. By
default, the FoxBridge Application Object templates do not use "I" type mappings. Therefore, the
Connect, Disconnect and Verify options do not apply.
The mapping services need to know how often to run (the period) and how often to checkpoint
(on demand or periodically) and whether or not to skip the initialization of Put mappings
(required for systems with Spectrum Interface Processors). Choose the defaults (what is in the
brackets or the capital letter in the brackets) or type in the desired answers. For example:
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B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
should be disregarded.
2. If periodic checkpointing is selected, then the checkpoint request may appear in the
August 2, 2011
error log.
3. If CP40s are used, then retry errors may occur on the G or g type mappings which use
the uread command. It is normal for CP40s to see one retry message for each variable.
If mapping errors occur because of incorrect mappings, these should be corrected before
attempting to run the controller. If the errors are due to errors in the AOD file, then follow these
steps:
1. From the DMCOP Display, perform a SAVE TO CCF to save the current tuning
parameters to the CCF.
2. UNMAP the Controller (Option 11 in AppObjSrv)
3. DELETE the Application Objects (Option 21 in AppObjSrv)
4. Correct the AOD file either using Option 1or manually editing the .aod file.
5. Rebuild the map file (Option 2 in AppObjSrv)
6. Initialize the Application Object database and create the objects (Option 0 in
AppObjSrv)
7. Map the Controller (Option 10 in AppObjSrv)
8. From the DMCOP display, perform a LOAD CCF and confirm to load the tuning
data from the CCF into the initialized Application Objects.
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7. FoxBridge Controller Operation B0700EE – Rev A
AWSCOD:
The values for the Manipulated Variable anti-windup code are:
0 OK Can move in either direction
1 LOW Can only move output in a positive direction
2 HIGH Can only move output in a negative direction
3 BLOCKED Cannot move output
The AWSCOD is based upon the LHI and LLO parameters which are mapped to:
♦ Boolean Outputs 1 and 2 in the SSC CALC Block for NONSSC MVs
♦ Status bits in the SUPBCO parameter of the downstream block for SSC MVs
♦ The SPI and SPD bits for SMG MVs
Logic:
Default AWSCOD to OK
If LHI and LLO are both set, MV is in SSC mode and in Supervisory Control
(SC is set)
Set AWSCOD to BLOCKED.
If LHI only is set
Set AWSCOD to HIGH
Preliminary
If LLO only is set
Set AWSCOD to LOW
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LOOPST:
The values for Loop Status are:
0 OFF DMCplus Controller cannot adjust this value
1 ON DMCplus Controller can adjust this value
Logic:
Default LOOPST to ON
If LLO and LHI are both set, MV is in Supervisory Control (SC is set) and the MV is
not an SMG DDC loop
Set LOOPST to OFF
If Supervisory Enable (SE) is not set
Set LOOPST to OFF
If Supervisory Control (SC) is not set and Last Cycle Supervisory Control (OLDSC)
is set (i.e. the MV went off control).
Set LOOPST to OFF
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B0700EE – Rev A 7. FoxBridge Controller Operation
Summary Displays
The FoxBridge Configuration utility supports the automatic generation of several types of
summary displays:
1. The Controller Summary Display which is used by the operator to control the
operation of the DMCplus Controller.
2. The Economics Summary Display which displays the most significant economic data
available from the DMCplus Controller.
3. The Tuning Display that allows the Engineer to tune the performance of the
DMCplus Controller.
4. External Target Display and Composite LP Display, or a combination of the two,
only if one or both of these is enabled for the Controller.
5. Subcontroller Summary Display(s) if Subcontrollers are configured for the
Controller.
6. Operator Displays for WP20s and WP30s with limited functionality.
The Summary Displays are tabular arrangements of the information of greatest importance with
in their specialized areas. The Summary Display layouts are based on information provided by the
Preliminary
AspenTech Inc. and on the experience of several engineers familiar with the operation of a
DMCplus Controller.
August 2, 2011
However, the most important feature of these displays is the fact that they are automatically
generated from a set of I/A Series display library elements by the FoxBridge Configuration utility.
The user may modify these display elements and the Configuration Utility to meet the needs of a
particular project.
The FoxBridge Configuration Utility builds the Summary Displays automatically from library
elements stored in the d:\opt\dmcplus\displibfv directory. The Configuration Utility will
build more than one page in the particular Summary Display format if there are too many
variables to display on a single page.
The Summary Displays consist of five major areas, Figure 7-1.
1. The Title Box,
2. The Controlled Variables Summary Area (all three summary types),
3. The Manipulated Variables Summary Area (all three summary types),
4. The Feed-Forward Variables Summary Area (Controller Summary and SubController
Summary only), and
5. The Buttons Area.
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7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
August 2, 2011
Figure 7-1. Summary Display Definitions
Common Features
This section discusses the common features of summary displays and their use.
Title Box
Positioned across the top of the display, the Title Box provides status and summary information
for the selected controller. (See Figure 7-1 for a Summary Display example.)
where
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B0700EE – Rev A 7. FoxBridge Controller Operation
<lastRunDate& Shows the time and date of the last execution of the DMCplus Controller.
Time>
If the controller is STOPPED, the <status> field is shown with a white background. Otherwise,
it is shown with an aqua (light cyan) background.
Preliminary
If the controller is OPEN LOOP, the <cntlrMode> field is shown with a white background.
Otherwise, it is shown with an aqua (light cyan) background. Picking on the OPEN LOOP field
invokes an overlay which allows putting the Controller in Closed Loop or Open Loop mode.
August 2, 2011
Picking on the aqua colored box that holds the <status> and <cntlrMode> fields causes the
Operation Object's (DMCOP) Detail Display to be raised. This Detail Display allows the user to
start and stop the controller, to checkpoint the controller database, and perform other controller
wide actions.
Buttons
The Summary Display buttons are arranged as follows:
where
Back Takes the user to the previous Summary Display. If invoked from the first
display, it does nothing.
Home Takes the user to the first Summary Display. Optionally a specific
Summary Display can be chosen by selecting the word Home and typing
in the page number. For example, if the summary displays are from 0 to 7,
and the information needed is on Summary Page 5, type in number 5 and
the next time the Home button is selected, Summary Page 5 will be
displayed.
Next Takes the user to the next Summary Display. If invoked from the last
display, it does nothing.
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7. FoxBridge Controller Operation B0700EE – Rev A
More Takes the user to the External Target and Composite LP Display from the
Tuning or Economics Display only if the Controller is configured for it.
Label 1 Takes the user to the home display on one of the two other
Summary Types.
Label 2 Takes the user to the home display of the remaining Summary Type.
The labels on the Label buttons change according to the type of display to which they are
attached. Table 7-4 is a list of the label assignments:
Table 7-4. Current Summary Display Labels
Preliminary
Current Sum. Disp Label 1 Label 2
Controller Economics Tuning
August 2, 2011
Economics Summary Tuning
Tuning Economics Summary
ET & CLP Economics Tuning
where
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B0700EE – Rev A 7. FoxBridge Controller Operation
status The current status of the CV from the DMCplus Controllers point of
view (S, BAD, GOOD, PRED, USE PR or MNT PR as specified by the
DEPSTA attribute of this object).
value The current value of the CV. The background is red if AOS mapping is off
or incorrect.
Ll The Low Limit on the target value for the CV. The background changes
to dark gray if the DMCplus Controller sets DEPACT to 2 (lower limit),
to orange if to 12 (gave up on the lower limit), and to blue/gray of to 22
(the LP had to move the CV below the external target but above the lower
limit). When picked, allows the operator to enter a new lower limit for the
target. Limited to the Engineering Limits.
tgt The Target Value for the CV. The background changes to dark gray if the
DMCplus Controller sets DEPACT to 7 (the CV is a setpoint) and to
white if to 8 (inactive). The background changes to blue/gray if DEPACT
is set to 20 indicating that an external target is being used.
Hl The High Limit on the Target Value for the CV. The background changes
Preliminary
to dark gray if the DMCplus Controller sets DEPACT to 1 (upper limit),
to orange if to 11(gave up on the upper limit) and to blue/gray if to 21
August 2, 2011
(the LP had to move the CV above the external target but below the upper
limit). When picked, allows the operator to enter a new lower limit for the
target. Limited to the Engineering Limits.
Manipulated Variables
The Manipulated Variable information is arranged as follows:
where
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7. FoxBridge Controller Operation B0700EE – Rev A
status The current status of the MV from the DMCplus Controllers point of
view (EOFF, BAD, GOOD, FFWD, or RDY as specified by the INDSTA
attribute of this object).
A series of fields that control the ability of the MV to accept a setpoint
from the DMCplus Controller and indicate its current state.
Y A Yellow Box which if visible means that the MV has been sent a valid
setpoint by the DMCplus Controller in response to a request for such.
Preliminary
E/D Enabled (E)/Disabled (D) for Supervisory Control (The underlying block
will not request a Supervisory Setpoint until this field is set.). C indicates
that the variable is in Supervisory (Computer) control and an F indicates
August 2, 2011
Fallback. This is consistent with the Detail Displays. When picked,
toggles the Supervisory switch between Enabled and Disabled.
L/R Local (L)/Remote (R) which indicates that the underlying control block is
in Remote or Local mode. When picked, toggles the Local/Remote switch
between Remote and Local.
M/A Manual (M)/Automatic (A) status of the underlying control block. When
picked, toggles the Manual/Automatic switch between Manual and Auto.
value The current value of the MV. The background is red if AOS mapping is
off or incorrect.
spt/out The Setpoint or Output being sent by the DMCplus Controller to the
process, i.e., the output of the DMCMV object which is used by the
underlying control block as an input signal, The background is red if AOS
mapping is off or incorrect. If the Controller is OFF (in Open Loop) this
field will display N/A indicating that the value is not being calculated.
ll The Low Limit on the Target Value for the MV. The background changes
from light gray to dark gray if the DMCplus Controller sets MANACT to
2 (lower limit) or to blue/gray if set to 22 (the LP has to allow the variable
to move below the External Target but above the Lower Limit). The back-
ground color changes to Hi Yellow when LLO is set (AWSCOD=1). If
both ll and hl are Hi Yellow, then the MV is invalid (AWSCOD=3).
When picked, allows the operator to enter a new lower limit for the target.
Limited to the Engineering Limits.
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B0700EE – Rev A 7. FoxBridge Controller Operation
tgt The Target Value for the MV. The background changes from light gray to
dark gray if the DMCplus Controller sets MANACT to 4 (LPSTEP in up
direction), 5 (LPSTEP in down direction), 6 (zero move due to zero cost
or minimum move criterion) or 7 (the MV is used as a setpoint). The
background changes to blue/gray if MANACT is set to 20 indicating that
an external target is being used.
hl The High Limit on the Target Value for the MV. The background changes
from light gray to dark gray if the DMCplus Controller sets MANACT to
1 (upper limit) or to blue/gray if to 21 (the LP has to allow the variable to
move above the External Target but below the Upper Limit) The back-
ground color changes to Hi Yellow when LHI is set (AWSCOD=2). When
picked, allows the operator to enter a new lower limit for the target.
Limited to the Engineering Limits.
Feed-Forward Variables
The Feed-Forward Variable information is arranged as follows:
Preliminary
August 2, 2011
ObjName srv status value
where
status The current status of the FF from the DMCplus Controllers point of view
(BAD, GOOD, FFWD, or RDY as specified by the DEPSTA attribute of
this object).
value The current value of the FF. The background is red if AOS mapping is off
or incorrect.
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7. FoxBridge Controller Operation B0700EE – Rev A
Figure 7-2 shows the Demo Controller, DMCPLUSD, running in a closed loop mode with 56
seconds left until the next Controller Execution. Only one Controlled Variable, OHLEVEL, is
critical, while all five MVs are critical. The CV CONDDP is at its Lower Limit and the CV
SSCOMP is at its upper limit, as shown by the dark gray background. All five MVs have a Good
Status and are in Computer Control mode (as indicated by the green box and the C in the Status
column). The MV OHPROD is setup to fallback into Remote mode, while the other four MVs
will fallback into local mode. All MVs are in Automatic, which is required for Computer Control.
Preliminary
August 2, 2011
Figure 7-2. Summary Display - I/A Series Software V4.2 and Later
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B0700EE – Rev A 7. FoxBridge Controller Operation
NOTE
Since this Controller is running Open Loop, the SP/OP field for the Manipulated
Variables shows N/A since the Controller is not currently writing Setpoints.
Preliminary
August 2, 2011
Figure 7-3. Summary Display with Descriptions
68
7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
August 2, 2011
Figure 7-4. Summary Display - Engineer Environment
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B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
August 2, 2011
Figure 7-5. Summary Display - Operator Environment
70
7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
August 2, 2011
Figure 7-6. Controller Economics Display
Controlled Variables
The Controlled Variable information is arranged as follows:
where
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B0700EE – Rev A 7. FoxBridge Controller Operation
Manipulated Variables
The Manipulated Variable information is arranged as follows:
ObjName description lp cost lp step max move tgt cur spt lost $
where
lp cost This field has two numbers shown separated by a slash (/). The first is the
cost of the MV. The second is engineering units of the MV. Entry of the
MV's cost.
Preliminary
lp step The current movement step per LP cycle. Entry of the value.
max move The maximum total movement that is allowed for the MV. Entry of the
August 2, 2011
value.
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7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
August 2, 2011
Figure 7-7. Controller Tuning Display
Controlled Variables
The Controlled Variable information is arranged as follows:
where
LP<LO LP lower equal concern error (DEP < Low Limit). Entry of value.
LP>HI LP lower upper concern error (DEP > high Limit). Entry of value.
CM<LO Control calculation lower equal concern error (DEP < Low Limit). Entry
of value.
CM MID Control calculation middle equal concern error (Low Limit < DEP <
High Limit). Entry of value.
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B0700EE – Rev A 7. FoxBridge Controller Operation
CM>HI Control calculation upper equal concern error (DEP > High Limit). Entry
of value.
TRANZL Transition zone size for CV equal concern error at the lower limit. In Eng
Units. Entry of value.
TRANZU Transition zone size for CV equal concern error at the upper limit. In Eng
Units. Entry of value.
ROTFAC Ramp Rotation Factor. Must be between 0 and 1.0. Only visible for Ramp
Variables. Entry of value.
Manipulated Variables
The Manipulated Variable information is arranged as follows:
where
Preliminary
ObjName Name of the DMC Manipulated Variable as defined in the Application
Object Definition file. This name is typically the name assigned during
August 2, 2011
the modeling process by the engineer using MODEL. When picked, raises
the Detail Display for the indicated MV.
lp cost This field has two numbers shown separated by a slash (/). The first is the
cost of the MV. The second is engineering units of the MV. Entry of the
MV's cost.
lp step The maximum steady-state target move (step) per LP cycle. Entry of the
value.
max move The largest total movement that is allowed for the MV in one cycle. Entry
of the value.
sup move Manipulated variable move suppression factor. Affects how aggressively
the Controller will move the manipulated variables to achieve control
objectives. A larger value means more suppression, i.e. less movement.
Entry of the value.
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7. FoxBridge Controller Operation B0700EE – Rev A
SubController Information
In the Operator or Engineer mode, SubControllers can be turned OFF and ON from this
display. In the Engineering mode, the SubController Criticality, Minimum Number of Good
CVs and Minimum Number of Good MVs can be modified.
Selecting the SubController Name will display the SubController Detail Display, Figure 7-8.
Preliminary
August 2, 2011
Figure 7-8. Summary of SubControllers Display
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B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
Display on page 79.
August 2, 2011
DMCplus Controller:<appName> ET Request:<ETreq> Status:<status>
ET Status:<ETstatus> Model:<cntlrMode> xxx
<lastRunDate&Time>
Page:<page>
where
<ETreq> Indicates that ET processing has been requested (ON) or not (OFF).
<lastRunDate& Shows the time and date of the last execution of the DMCplus Controller.
Time>
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7. FoxBridge Controller Operation B0700EE – Rev A
<xxx> The number of seconds until the DMCplus Controller runs again. This
value comes from the Station Block SSC Timer Controllers running in
Closed Loop mode and from the Pulse block for all other cases.
ObjName srv status swc ETvalue ETCLPL ETCLPU ETCECL ETCECU ETCTRK
where
ObjName Name of the DMCplus Controlled Variable. When picked, raises the
Detail Display for the indicated CV.
srv External Target service switch to enable or disable External Targets for this
dependent variable. Toggles the Service between ON and OOS.
Preliminary
swc External target dependent variable switch. Toggles between No (0), Tmr
(1) and IRV (2).
August 2, 2011
ETvalue External Target of this dependent variable.
ETCLPL Solution type for the lower external target for this dependent variable.
LP = linear
QP = quadratic or least squares
ETCLPU Solution type for the upper external target for this dependent variable.
ETCECL Lower equal concern error used to weight the amount of violation for
equally ranked external targets.
LP = linear
QP = quadratic or least squares
ETCECU Upper equal concern error used to weight the amount of violation for
equally ranked external targets.
ETCTRK External Target track switch. Toggles between OFF and ON.
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B0700EE – Rev A 7. FoxBridge Controller Operation
where
ObjName Name of the DMC Manipulated Variable. When picked, raises the Detail
Display for the indicated MV.
srv External Target service switch to enable or disable External Targets for this
manipulated variable. Toggles the Service between ON and OOS.
Preliminary
ETvalue External Target for this manipulated variable.
August 2, 2011
ETMECL Lower external target equal concern error used to weight the amount of
violation for equally ranked external targets.
ETMECU Upper external target equal concern error used to weight the amount of
violation for equally ranked external targets.
ETMTRK External target tracking switch. Toggles between OFF and ON.
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7. FoxBridge Controller Operation B0700EE – Rev A
ALLDemo Display
The ALLDEMO Display, Figure 7-9, shows the ALLDEMO controller, which has been built to
include external targets. The ALLDEMO display can be reached by selecting the More button
from either the Economic or Tuning displays.
Preliminary
August 2, 2011
Figure 7-9. ALLDEMO Controller Display
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B0700EE – Rev A 7. FoxBridge Controller Operation
Composites Display
Figure 7-10 is an example of a Composites Display.
Preliminary
August 2, 2011
Figure 7-10. Composites Display
where
<CLPstat> Indicates the status of this controller with respect to the Composite
steady-state optimizer: IGNORE,PASSIVE or ACTIVE.
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7. FoxBridge Controller Operation B0700EE – Rev A
<lastRunDate& Shows the time and date of the last execution of the DMCplus Controller.
Time>
<xxx> The number of seconds until the DMCplus Controller runs again. This
value comes from the Station Block SSC Timer Controllers running in
Closed Loop mode and from the Pulse block for all other cases.
Preliminary
ObjName srv status swc CLPvalue CLPRKL CLPRKU TRK
where
August 2, 2011
ObjName Name of the DMCplus Controlled Variable. When picked, raises the
Detail Display for the indicated CV.
srv External Target service switch to enable or disable External Targets for this
dependent variable. Toggles the Service between ON and OOS.
swc External target dependent variable switch. Toggles between No (0), Tmr
(1) and IRV (2).
CLPRKL Lower limit ranking value supplied to the CLP for this CV. Entry of value.
CLPRKU Upper limit ranking value supplied to the CLP for this CV. Entry of value.
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B0700EE – Rev A 7. FoxBridge Controller Operation
where
ObjName Name of the DMC Manipulated Variable. When picked, raises the Detail
Display for the indicated MV.
srv External Target service switch to enable or disable External Targets for this
manipulated variable. Toggles the Service between ON and OOS.
Preliminary
CLPCST Composite LP Cost. Entry of value.
August 2, 2011
CLPCRI The Composite objective for this manipulated variable. If CLPCRI is
COST, Composite tries to minimize the actual cost of this variable. If
CLPCRI is set to MOVE, then minimizing movement in either
direction is the objective for this MV.
COST = Minimum Cost
MOVE = Minimum Move
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7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
August 2, 2011
Figure 7-11. External Target and Composite Display
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B0700EE – Rev A 7. FoxBridge Controller Operation
Detail Displays
The following sections explain the five standard Detail Displays: DMCOP, DMCSB, DMCCV,
DMCMV and DMCFF.
DMCOP
This section pertains to the DMCOP Details Display, Figure 7-12.
Preliminary
August 2, 2011
Figure 7-12. DMCOP Detail Display
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7. FoxBridge Controller Operation B0700EE – Rev A
Summary Data
Preliminary
Buttons
August 2, 2011
Figure 7-13. DMCOP Detail Display Layout
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B0700EE – Rev A 7. FoxBridge Controller Operation
Table 7-5. Detail Display Specific Button Set and Configured Actions
Preliminary
NAME>/scripts directory to support custom CCF entries, it will
also be run (non-remote only).
August 2, 2011
SAVE TO CCF Writes the current operating data into the CCF so that it could be
taken to the Simulate program, using the save_ccf.sh script (non-
remote only).
CHKPT Causes the Checkpointable DMCplus Controller Application
Objects to be saved in the Application Object database so that the
values are preserved in case of processor reboot or system restart
using the checkpoint.sh script.
WTCHDG Raises the detail display for the Watchdog Timer block.
SUM Raises the Controller Summary Display
COST Raises the Economics Summary Display
TUNE Raises the Tuning Summary Display
NOTE
The only buttons that are supported on the WP30 DMCOP Detail Display are
MSG, DETAIL, SAVE TO CCF, CHKPT, and SUM.
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7. FoxBridge Controller Operation B0700EE – Rev A
DMCOP Faceplate
The Faceplate for a DMCOP object shows the following information:
1. The Controllers Name,
2. The DMCOP object type,
3. The execution status of the controller, i.e., Running (loaded into memory) or Stopped
(not loaded).
4. The controllers mode of operation (if the status is Running), i.e., Open Loop (no
setpoints being generated) and Closed Loop (setpoints being generated).
The Mode area is pickable and invokes an overlay to allow changing to Closed Loop or Open
Loop as described below. The execution status text or EXE button invoke the START/STOP
Controller Overlay.
Preliminary
3. An indicator that shows if Prediction Initialization is in progress,
4. A switch to initiate Prediction Initialization,
August 2, 2011
5. A field that shows the amount of time before a Watchdog time-out will occur or zero.
This field should alternate between these two values each controller cycle.
87
B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
August 2, 2011
Figure 7-14. DMCOP All Attributes Overlay
88
7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
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Figure 7-15. DMCplus Controller Message Overlay
89
B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
August 2, 2011
90
7. FoxBridge Controller Operation B0700EE – Rev A
NOTE
It can take up to two cycles before ONSTS shows the status change.
Preliminary
August 2, 2011
Figure 7-17. DMCPlus Go Closed Loop Overlay
91
B0700EE – Rev A 7. FoxBridge Controller Operation
NOTE
It can take up to 2 cycles before the ONSTS variable shows the status change.
Preliminary
August 2, 2011
Figure 7-18. DMCplus Go Open Loop Overlay
92
7. FoxBridge Controller Operation B0700EE – Rev A
DMCSB
This section discusses the DMCSB Detail Display, Figure 7-19.
Preliminary
August 2, 2011
Figure 7-19. DMCSB Detail Display
93
B0700EE – Rev A 7. FoxBridge Controller Operation
SUBS
LIST
Summary Data
Preliminary
Buttons
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Figure 7-20. DMCSB Detail Display Layout
94
7. FoxBridge Controller Operation B0700EE – Rev A
DMCSB Faceplate
The Faceplate for a DMCSB object shows the following information:
1. The Controllers Name,
2. The DMCSB object type,
3. The SubController's mode of operation - ON or OFF.
The Mode area is pickable and the TOGGLE button can be used to change the mode from OFF
to ON and vice versa.
Preliminary
All Pickable fields are Integers and can be modified in the Engineering Environment.
August 2, 2011
The Standard Detail Display Button Set includes the following items:
1. An ACK button for process alarms on this object,
2. A PREV DISP button to recall the previous process graphic,
3. A TOGGLE button to manipulate the switches on the graphic,
4. Ramp buttons and the associated data entry box, and
5. A SUB SMRY button calls the first SubController Summary Display for this subcon-
troller.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
August 2, 2011
Figure 7-21. DMCCV Controlled Variable Detail Display
96
7. FoxBridge Controller Operation B0700EE – Rev A
Summary
Data
Preliminary
Buttons
August 2, 2011
Figure 7-22. DMCCV Detail Display Layout
Trend Area
The Trend Area is divided into two portions: a Historical Trend of the CVs DEP parameter and a
plot of the predicted values for the CV. The Prediction plot shows two trends, i.e., the value of the
CV with and without the use of the DMCplus Controller. The Prediction Plot is not
supported on WP30 displays or the 70 Series workstations.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Faceplate Area
The upper right hand quadrant of the DMCCV Detail Display is occupied by two Faceplates.
One is the Faceplate developed of the DMCCV object. The other is a standard I/A Series
Faceplate for the underlying block which furnishes real-time data to the DMCCV object. The
Appendices contain a table showing which underlying block types that are supported for the
DMCCV object.
The DMCCV object's Faceplate displays the high and low scale, the engineering units, and the
reading of the DMCCV object. As with all I/A Series Faceplates, a bar graph is supplied. Beside
the bar are three sets of markers. These markers graphically illustrate the validity limits, the
engineering limits, and the operator limits applied to this variable.
Summary Data
The summary data area contains several groups of data. The first group provides numeric
representations of the three sets of limits, the current target, the current reading. The second
group gives numeric representations of the average predicted error, the Linear Prediction error,
and the current prediction error. The third group shows numeric representations of the Tuning
parameters: LP low, LP high, Low concern, Middle concern, High Concern, Low weight, and
High weight. The final group is spread across the display: the description, the compound and
Preliminary
block names of the underlying blocks, the controller's status, the weight in the LP algorithm of
the MV, the tracking status, and the LP shadow value.
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Buttons
The display has two sets of buttons: the DMC specific buttons and the standard detail buttons.
The DMC specific buttons are:
1. B which raises the Detail Display for the DMCOP object of this controller,
2. VAR. DETAIL which shows the overlay that contains an entry for each and every
attribute of the DMCCV object, and
3. CTL. DETAIL which shows the Detail Display of the underlying block.
The Standard Detail Display Button Set includes the following items:
1. An ACK button for process alarms on this object,
2. A PREV DISP button to recall the previous process graphic,
3. A TOGGLE button to manipulate the switches on the graphic,
4. Ramp buttons and the associated data entry box, and
5. An A/M button that puts the underlying block in the Automatic or Manual state, and
6. An R/L buttons that puts the underlying block in the Remote or Local state.
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7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
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Figure 7-23. Ramp DMCCV Attribute Overlay
Note that certain fields are invisible depending on the Variable and Controller Configuration. For
example, this variable is not an Integrating Variable, therefore all of the Ramp Attributes are
invisible. On an integrating variable, these attributes would appear. This Controller is configured
for External Targets and Composite LP, therefore the fields relating to these applications are
visible. If this variable were an Intermittent Signal, such as an Analyzer, then the NEWPV
attribute would appear just below the SSERR attribute. All other attributes are visible in this
example.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Overview
The DMCFF Detail Display consists of the following areas:
1. The DMC Object Trend Area,
2. The DMC Object Selection Menu,
3. The Detail Display Specific Button Set,
4. The DMCFF Faceplate,
5. The DMCFF Summary data, and
6. The Standard Detail Display Button Set.
The DMCFF Detail Display layout is shown in Figure 7-24.
Preliminary
Trend Faceplate Faceplate
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Summary
Data
Buttons
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7. FoxBridge Controller Operation B0700EE – Rev A
Faceplate Area
The upper right hand quadrant of the DMCFF Detail Display is occupied by two Faceplates.
One is the Faceplate developed of the DMCFF object. The other is a standard I/A Series
Faceplate for the underlying block which furnishes real-time data to the DMCFF object. The
Appendices contain a table showing which underlying block types are supported for the DMCFF
object.
The DMCFF object's Faceplate displays the high and low scale, the engineering units, and the
reading of the DMCFF object. As with all I/A Series Faceplates, a bar graph is supplied. Beside
the bar is a set of markers. These markers graphically illustrate the limits associated with a
DMCFF object.
Summary Data
The summary data area contains two groups of data. The first group provides numeric
representations of the validity limits and the current reading. The second group is spread across
the display: the description, the compound and block names of the underlying blocks, and the
controller's status.
Buttons
Preliminary
The display has two sets of buttons: the DMC specific buttons and the standard detail buttons.
The DMC specific buttons are:
August 2, 2011
1. DMCOP which raises the Detail Display for the DMCOP object of this controller,
2. VAR. DETAIL which shows the overlay that contains an entry for each and every
attribute of the DMCFF object, and
3. CTL. DETAIL which shows the Detail Display of the underlying block.
The Standard Detail Display Button Set includes the following items:
1. An ACK button for process alarms on this object,
2. A PREV DISP button to recall the previous process graphic,
3. A TOGGLE button to manipulate the switches on the graphic,
4. Ramp buttons and the associated data entry box, and
5. An A/M button that puts the underlying block in the Automatic or Manual state, and
6. An R/L buttons that puts the underlying block in the Remote or Local state.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
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Figure 7-25. DMCFF Feedforward Detail Display
102
7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
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Figure 7-26. Feedforward Attribute Overlay
Overview
The DMCMV Detail Display consists of the following areas:
1. The DMC Object Trend Area,
2. The Detail Display Specific Button Set,
3. The DMCMV Faceplate,
4. The DMCMV Summary data, and
5. The Standard Detail Display Button Set.
The DMCMV Detail Display layout is shown in Figure 7-27.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Summary
Data
Buttons
Preliminary
Figure 7-27. DMCMV Detail Display Layout
August 2, 2011
Trend Area
The Trend Area is divided into two portions: a Historical Trend of the MVs VIND parameter and
a plot of the predicted values for the MV. The Prediction plot shows two trends, i.e., the value of
the MV with and without the use of the DMCplus Controller.
Because the Historical Trend is a standard trend object, the user has the normal I/A Series Trend
Object capabilities, e.g., Scrolling back in time and determining the value at a particular time.
In particular, the Historical Trend Area has the following controls:
1. The time span for the trend shown as days:hours:minutes:seconds.
2. The current value of the trended point.
3. A pickable R or H which controls whether or not the trend updates with new data (R)
or shows only historical data (H).
4. A pair of back to back triangles (< >) which are used when in Historical mode to scroll
back and forth through the recorded data.
5. A gray box with or without a P (paused) which is used to pause the update of the real-
time trend.
6. A gray bar at the bottom of the area which can be picked on to determine the value
and time tag of the reading immediately above the pick point when the trend mode is
H (historical data) or P (paused).
As near as possible, this trend object provides functionality similar to the horizontal gray bar at
the bottom of the Historical Trend by providing small gray boxes at the bottom of the plot area.
When picked these boxes execute a script that updates the header area with the requested
information. There is a pickable box for each plotted point.
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7. FoxBridge Controller Operation B0700EE – Rev A
Faceplate Area
The upper right hand quadrant of the DMCMV Detail Display is occupied by two Faceplates.
One is the Faceplate developed of the DMCMV object. The other is a standard I/A Series
Faceplate for the underlying block which furnishes real-time data to the DMCMV object. The
Appendices contain a table showing which underlying block types are supported for the
DMCMV object.
The DMCMV object's Faceplate displays the high and low scale, the engineering units, and the
reading of the DMCMV object. As with all I/A Series Faceplates, a set of bar graphs is supplied.
These bars are arranged to match those of the PID block. The VIND parameter of a DMCMV
object is the measurement of the DMCMV object. Likewise, the VINDSP parameter is the
output of the DMCMV object and the SSMAN is the object's setpoint.
To the left of the bar are three sets of markers. These markers graphically illustrate the validity
limits, the engineering limits, and the operator limits applied to this variable.
Summary Data
The summary data area contains several groups of data.
The first group provides numeric representations of the three sets of limits, the current target, the
Preliminary
current reading, and the current movement.
The second group shows numeric representations of the LP parameters: Maximum Movement,
August 2, 2011
the LP Step, the LP Shadow, the Move Suppression, the LP cost, and cost criteria.
The final group is spread across the display: the description, the compound and block names of
the underlying blocks, the controller's status, and the tracking status.
Buttons
The display has two sets of buttons: the DMC specific buttons and the standard detail buttons.
The DMC specific buttons are:
1. DMCOP which raises the Detail Display for the DMCOP object of this controller,
2. VAR. DETAIL which shows the overlay that contains an entry for each and every
attribute of the DMCMV object, and
3. CTL. DETAIL which shows the Detail Display of the underlying block.
The Standard Detail Display Button Set includes the following items:
1. An ACK button for process alarms on this object,
2. A PREV DISP button to recall the previous process graphic,
3. A TOGGLE button to manipulate the switches on the graphic,
4. Ramp buttons and the associated data entry box, and
5. An A/M button that puts the underlying block in the Automatic or Manual state, and
6. An R/L button that puts the underlying block in the Remote or Local state.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Preliminary
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Figure 7-28. DMCMV Manipulated Variable Detail Display
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7. FoxBridge Controller Operation B0700EE – Rev A
Preliminary
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Figure 7-29. DMCMV Manipulated Variable Detail Overlay
NOTE
Certain fields are invisible depending on the Variable and Controller
Configuration. This Controller is configured for External Targets and Composite
LP, therefore the fields relating to these applications are visible.
Shutdown
The DMCplus Controller shutdown procedure is as follows:
1. Put the Controller in OPEN LOOP mode. This action will cause the cause the
controller to stop producing setpoints and drop the MVs out of their Supervisory
Mode. The controller needs 2 controller cycles to complete this action.
2. Select the EXE button on the DMCOP Detail Display or select the word
RUNNING to invoke the Controller Execution overlay. Select the word STOP
CONTROLLER and CONFIRM to Stop the Controller. This action sets the
DMCXIT flag which causes the program to leave memory. The controller will require
approximately 3 controller cycles to complete this action.
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B0700EE – Rev A 7. FoxBridge Controller Operation
Alarming
Two Contact Input Blocks are available for DMCplus Controller Alarming in the Standard OP
Compound, DMC_TIMEOUT and DMC_ONOFF. These blocks link to the other Blocks in
the Compound.
The DMC_TIMEOUT block will alarm if the DMCplus Controller is STOPPED, i.e. not
loading into memory and running.
The DMC_ONOFF block will alarm if the DMCplus Controller goes from an OPEN LOOP to
a CLOSED LOOP state.
To use these blocks, simply edit the Compound Parameters of the <APPNAME>OP Compound
where <APPNAME> is the name of the Controller. Include the Logical Names of Workstations,
Printers, System Monitor, Historian, or FoxAMI™ to send the Alarm to one of these devices.
Customizing
There are several ways a DMCplus Controller can be customized. The Object templates that
define the standard Controller mappings can be customized. Refer to page 42 for information on
Preliminary
the Object Template search path.
The Summary Display templates located in the d:\opt\dmcplus\displibfv folder can be
customized to change the look of the Summary displays. Custom scripts can be invoked for a
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Controller either upon startup or after a FoxBridge host reboot.
108
8. FoxBridge Software Demo
This section describes how to use the demo FoxBridge controllers.
The FoxBridge Demo consists of:
1. A completely implemented FoxBridge demonstration designed for the 7x7
Distillation Column commonly used with DMCplus Controllers as an example.
2. A set of compounds, DMCPLUS30A, DMCPLUS10A, and DMCPLUS10C are
used to simulate both the process of a distillation tower with a side draw and the
I/A Series blocks required to control the process.
3. A compound, DMCPLUSDOP, which implements the Watchdog timer and other
controller related functions per the FoxBridge convention.
4. A process graphic of the column with the supporting overlays and scripts required to
make the demonstration useful.
The FoxBridge Demo is a standard part of the FoxBridge product and serves the
Preliminary
following purposes:
1. The demo can be used in sales situations as a simple demonstration of the operation
August 2, 2011
and function of the FoxBridge product.
2. It can be used in startup situations to verify the installation and operation of the
FoxBridge product.
3. It provides a reference example useful to engineers interested in applying this product.
Demo Setup
Upon installation of the FoxBridge software, the FoxBridge Demo compounds must be loaded
and certain setup procedures followed. These setup procedures are only required on the initial
startup of the DMC Demo.
Perform the following actions to setup the 7x7 Distillation Column Example:
1. Load the demonstration compounds from the LOADALL folders found in the
d:\opt\dmcplus\app\DMCPLUSD\ntcompounds folder. These compounds are
DMCPLUSDOP, DMCPLUS10A, DMCPLUS10C, and DMCPLUS30A. The
DMCPLUS10A, DMCPLUS10C, or DMCPLUS30A compounds can be loaded in
the same or different CPs.
2. Switch to the SSCDemo_Eng environment. The DMC DEMO Summary display
will be called up. It will take a while to come up and all points will be cyan (OOS)
until the DMC DEMO controller has been Initialized as follows.
3. Select the Options menu and then selection InitRunDemo and RunDMCPLUSD.
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B0700EE – Rev A 8. FoxBridge Software Demo
NOTE
Prior to initializing the demo, the CIMIO servers must be started manually. Do this
by running the cimio_autostart.bat file located in the directory
<LocalDrive>:\Program Files\AspenTech\CIM-IO\commands. This should start
both the FOXAPI (%CIMIOROOTQ%\io\cio_fox_api) and the
FOXAOS ((%CIMIOROOTQ%\io\cio_fox_aos) CIM-IO servers.
Preliminary
3. Creates the Application Objects required to support the DMC demo.
4. Maps the Application Objects to the Compound Blocks Parameters in the
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Compounds loaded into the Control Processor.
5. Turns on the Compounds in the Control Processor.
6. Repacks the FoxBridge DEMO Displays.
7. Creates shared variables required for trending support.
8. Sets up the Tuning Parameters for the Application Objects.
9. Starts up the DMCplus DEMO Controller (only if not remote)
10. Initializes the FoxBridge DEMO CV and MV loops.
11. Closes the Loop of the DMCplus DEMO Controller.
Remote Controller operation only: If the FoxBridge software is set up for remote controller
operation on a separate computer, then the DMCPLUSD CCF and model files will need to be
copied to the FoxBridge workstation. The file should be placed in
d:\opt\dmcplus\app\<controllerName>. Run the demo as described in “FoxBridge Demos” on
page 19.
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8. FoxBridge Software Demo B0700EE – Rev A
Preliminary
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Figure 8-1. Main DEMO Display
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B0700EE – Rev A 8. FoxBridge Software Demo
Preliminary
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Figure 8-2. Column Process Graphic
112
8. FoxBridge Software Demo B0700EE – Rev A
Preliminary
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Figure 8-3. Simulation Overlay
The SETUP DEMO is selected only on the initial startup of the DMC Demo. It establishes
required tuning constants. These should be checkpointed to the Application Objects Database via
the DMCOP display.
The INITIALIZE SIMULATION button puts the simulation in a default state and makes it
ready for use.
The STEP FEED FLOW RATE toggles the feed flow between 45 and 38. These bumps allow
one to see how the controller responds to an upset.
The CHANGE AI LIMITS moves the high and low limits on the Analyzer CV, i.e., SSCOMP, so
that one can see how the controller responds to a change in setpoint.
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B0700EE – Rev A 8. FoxBridge Software Demo
Operation
The general operation of the DMCplus Controller is quite simple: Set the high and low limits on
the CVs that represent the upper and lower limits of their acceptable range, e.g., the high and low
acceptable percentage of a component in a product stream. The controller uses its model of the
process to put the MVs at a position that results in the desired CV values. These limits need
monitoring and may need adjusting. Refer to the MESSAGES for informative messages.
In the case of the simulation, the SUMMARY button of the process graphic raises the standard
FoxBridge Summary Display. This display allows the user to adjust the CV’s high and low limits.
Alternatively, the CHANGE AI LIMITS button of the SIMULATE overlay performs the same
action for a particular CV. Using this button, allows one to easily see the controller's response to
changing CV limits.
Process Upsets
One of the strengths of the DMCplus Controller is its ability to promptly respond to process
upsets, e.g., increases or decreases in Feed Flow to the tower. The demonstration allows the user to
see the effects of such changes in both an Open Loop situation and a Closed Loop situation.
Preliminary
Simply use the STEP FEED FLOW button to move the feed flow up or down while the
DMCplus Controller is first OPEN LOOP and, later, CLOSED LOOP. Use the OpenLoop and
ClosedLoop menu picks under the Operation menu pick under Option pulldown menu to Open
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and Close the Controller Loop.
Shutdown
To shutdown the controller:
1. Pick on the aqua box to raise the DMCOP Detail Display,
2. Pick on the EXE button to raise the Start/Stop overlay,
3. Pick on the STOP CONTROLLER button, and
4. Pick on the CONFIRM button.
The shutdown period requires about three Controller cycles for completion: 0.5 to 1.0 to notice
the request, a fraction to free the controller's resources, and 2.5 for the Watchdog to notice.
To completely delete all the Application Objects from Memory as well as shutdown the
controller, select StopDelDemo and StopDemo from the Option menu pick.
NOTE
This does not delete the files, only the objects.
114
9. Maintenance
This section pertains to the maintenance of the FoxBridge software and the DMCplus software
packages.
FoxBridge Software
Uninstall
If for some reason, the FoxBridge software must be completely uninstalled from its Host AW,
follow this procedure. This procedure removes FoxBridge, CimIO and Application Object
Services files and should be used with extreme caution. It is intended primary for Demo Systems
or testbeds.:
1. Stop all DMCplus Controllers, stop AOS mapping and delete all AOS objects.
2. Back up any Controller app directories to be saved:
Preliminary
d:\opt\dmcplus\app\<APPNAME>
3. Log into the FoxBridge Host.
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4. Use Windows Add or Remove Programs to uninstall the FoxBridge software and the
AOS software.
5. Save any map files.
6. If desired, remove the D:\opt\aos and D:\opt\dmcplus folders.
7. Remove any custom edits to the d:\usr\fox\bin\user_apps.dat file and delete any
go_<controllName> scripts.
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B0700EE – Rev A 9. Maintenance
Preliminary
August 2, 2011
Off-Line (once per Controller):
1. Upgrade CCF file to new version.
116
Appendix A. Application Object
Services
This appendix discusses the use of Application Object Services.
Application Object Services (AOS) is a product of Invensys Systems, Inc. which provides a close
coupling of user applications or third-party products with I/A Series products. The AOS product:
1. Allows data to be stored at locations with standard-length hierarchical names called
Application Objects (AOs).
2. Allows user to define specific attribute (parameter) names (up to six characters by the
I/A Series application convention) within the Application Object.
3. Allows automatic and high-speed creation and initialization of these AO attributes at
reboot.
4. Allows checkpointing of selected Application Object attributes (A:O.As) to a database
Preliminary
and restoration of those values at reboot.
5. Provides mapping services that move data from Application Object attributes
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(A:O.As) to the Control Block parameters and vice versa.
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B0700EE – Rev A Appendix A. Application Object Services
Preliminary
1. Standard-length hierarchical names (Application:Object).
2. User-specified attribute (parameter) names (limited to 6 characters by the I/A Series
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application convention).
3. Automatic and high speed creation at reboot with initial values.
4. Checkpointing of selected parameters to a database and restoration of those values at
reboot.
5. Mapping services that move data from an Application:Object attribute (A:O.A) to a
control block parameter and vice versa.
Because A:Os use a hierarchical naming structure, they allow the user to group data into
meaningful data structures and make those data structures visible through the I/A Series Detail
Display mechanism.
Implementation
The AOS product consists of the following items:
1. A configuration utility, named AppObjSrv, and associated scripts that allow the user
to establish and maintain an Application Object database.
2. An executable, named aos, which implements the creation, initialization, mapping
and checkpointing of Application Objects on an application basis.
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Appendix A. Application Object Services B0700EE – Rev A
aos
map
aod file
User aos aos
Manipulation map file buildDB database create
Template Memory
Preliminary
Figure A-1. AOS Overall Functionality
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This process is controlled through the Application Object Configuration Utility, AppObjSrv.
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B0700EE – Rev A Appendix A. Application Object Services
Revision of Templates
To add or delete attributes, to change the default mappings for given underlying blocks, or to add
support for new blocks, simply edit the appropriate template in the directory
d:\opt\aos\data\ObjTemplates in the SSC.
Preliminary
mechanism is implemented.
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Table A-2. DMCMV Template Commands
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Appendix A. Application Object Services B0700EE – Rev A
This section (Table A-3) of the template, checks for the proper number of arguments being passed
to the script. If the number is incorrect, messages describing the arguments and their use are
issued.
Preliminary
echo ' '\<block\> is the name of the block
to which this object is mapped
echo ' '\<block type\> is the type of the
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underlying block
echo ' 'If \<cmpd\> is present, \<block\>
must be present.
echo ' 'If \<block type\> is present,
\<cmpd\> \& \<block\> must be present
echo ' 'If \<block type is supplied it will
be used. If not supplied,
echo ' 'the script will try to \'omget\'
it
echo ' ' \<mode\> is either SSC or NONSSC,
exit 1
fi
CMPD= Setup a number of shell variables
BLK=
PN=
used throughout the script.
TYPE= Define shell variables
SSC_PN=
FBK_PN=
STATION=UNKNOWN
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B0700EE – Rev A Appendix A. Application Object Services
Now determine the type of the underlying block (Table A-4), if one is supplied.
Preliminary
AOUTR. Newly supported blocks
must have an entry in this case
statement.
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# AOUT, AOUTR
32 | 71)
TYPE=AOUT
;;
# PID, PIDE, PIDX, PIDXE, PIDA
7 | 121 | 9 | 122 | 123)
TYPE=PID
;;
21)
TYPE=RATIO
;;
*)
TYPE=
esac
fi
PN=$CMPD:$BLK Shell variable with C:B name.
SSC_PN=‘echo $PN_SSC | awk ‘ { print $1 $2 }’‘ Shell variable with SSC Block name.
FBK_PN=‘echo $PN_FALL | awk ‘ {print $1 $1}’‘ Shell variable with Fallback Block
name.
STATION=‘locate $3‘ Station holding the compound -
retrieved from CSA.
fi
if {$TYPE. = AOUT. -o $TYPE. = PID. -o $TYPE. = RATIO.} This line is used to specify the block
types that the script knows how to
handle.
Newly supported blocks must be
added here.
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Appendix A. Application Object Services B0700EE – Rev A
This section (Table A-5) of the template, handles the specific changes required for mapped
Preliminary
parameters based on their underlying block type. For example, the VINDSP parameter of a MV
mapped to a PID block goes to a parameter other than a VINDSP mapped to an AOUT block.
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Table A-5. Mapped Parameters Based on Block Type
if [$KNOWN_TYPE = 1] Newly supported block types must
then
be added to corresponding entries
echo $1:$2.DETAIL X C 4
\"/opt/dmcApps/$1/dd/dmcmv/DMCMV.$TYPE\" for each of the attributes shown for
50 existing block types.
case $TYPE in
AOUT)
echo $1:$2.MEAS $PN.MEAS R 3 0.0 0.001
echo $1:$2.SPT $PN.MEAS R 3 0.0 0.001
echo $1:$2.OUT $PN.OUT R 3 0.0 0.001
echo $1:$2.MA $PN.MA R 5 0 0.5
echo $1:$2.VINDSP $SSC_PN.RI01 P 3 0.0 0.001
echo $1:$2.ACK $SSC_PN.BI16 P 5 0 0.5
;;
PID | \
PIDE | \
PIDX | \
PIDXE)
echo $1:$2.MEAS $PN.MEAS R 3 0.0 0.001
echo $1:$2.SPT $PN.SPT R 3 0.0 0.001
echo $1:$2.OUT $PN.OUT R 3 0.0 0.001
echo $1:$2.MA $PN.MA R 5 0 0.5
echo $1:$2.LR $PN.LR R 5 0 0.5
echo $1:$2.VINDSP $SSC_PN.RI01 P 3 0.0 0.001
echo $1:$2.ACK $SSC_PN.BI16 P 5 0 0.5
;;
RATIO)
echo $1:$2.MEAS $PN.MEAS R 3 0.0 0.001
echo $1:$2.SPT $PN.RATIO R 3 0.0 0.001
echo $1:$2.OUT $PN.OUT R 3 0.0 0.001
echo $1:$2.MA $PN.MA R 5 0 0.5
echo $1:$2.VINDSP $SSC_PN.RI01 P 3 0.0 0.001
echo $1:$2.ACK $SSC_PN.BI16 P 5 0 0.5
;;
esac
else
123
B0700EE – Rev A Appendix A. Application Object Services
Preliminary
echo $1:$2.OUT UNKNOWN_SRC R 3 0.0 0.001
echo $1:$2.MA UNKNOWN_SRC R 5 0 0.5
echo $1:$2.VINDSP UNKNOWN_DST P 3 0.0 0.001
echo $1:$2.ACK UNKNOWN_DST P 5 0 0.5
August 2, 2011
echo $1:$2.IR UNKNOWN_SRC R 5 0 0.5
echo $1:$2.LHI UNKNOWN_SRC R 5 0 0.5
echo $1:$2.LLO UNKNOWN_SRC R 5 0 0.5
fi
fi
The attributes in this section (Table A-6) of the template, do not depend on block type, but
depend on the specification of an underlying block. If the name is provided, additional mappings
are defined. If the name is not provided, a set of defaults is used.
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Appendix A. Application Object Services B0700EE – Rev A
The remaining template attributes are not mapped, Table A-7. Most of them are constants, that
is, their values may be changed, but they are returned to their initial value at reboot. Some are
checkpointed attributes; on reboot, they are recreated with their most recently checkpointed
value.
Preliminary
echo $1:$2.CST X U 3 0.0 0.01
echo $1:$2.LPMAN X U 3 0.0 0.01
echo $1:$2.SHPMAN X C 3 0.0 0.01
echo $1:$2.SUPMOV X U 3 0.0 0.01
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echo $1:$2.CMOV X C 3 0.0 0.01
echo $1:$2.MANACT X C 2 0 0.5
echo $1:$2.INDSTA X C 2 0 0.5
echo $1:$2.INDFLG X C 2 0 0.5
echo $1:$2.FMOV00 X C 3 0.0 0.01
echo $1:$2.FMOV01 X C 3 0.0 0.01
echo $1:$2.FMOV02 X C 3 0.0 0.01
echo $1:$2.FMOV03 X C 3 0.0 0.01
echo $1:$2.FMOV04 X C 3 0.0 0.01
echo $1:$2.FMOV05 X C 3 0.0 0.01
echo $1:$2.FMOV06 X C 3 0.0 0.01
echo $1:$2.FMOV07 X C 3 0.0 0.01
echo $1:$2.FMOV08 X C 3 0.0 0.01
echo $1:$2.FMOV09 X C 3 0.0 0.01
echo $1:$2.FMOV10 X C 3 0.0 0.01
echo $1:$2.FMOV11 X C 3 0.0 0.01
echo $1:$2.FMOV12 X C 3 0.0 0.01
echo $1:$2.FMOV13 X C 3 0.0 0.01
All existing template files follow this pattern. Adding mapping support for new underlying block
types is fairly straightforward. However, these changes do not address any changes required in the
Detail Displays for these objects.
Map Files
Definition
The Application Object database accepts a map file as its input. The map file enumerates all the
objects and attributes for a given application and defines how each attribute is handled.
There are two types of lines in a map file:
1. Object definition lines which consist of the object name and type.
2. Attribute definition lines which define the attributes found in objects of this type.
125
B0700EE – Rev A Appendix A. Application Object Services
Preliminary
♦ I - ICC mapping: AOA -> CBP, supervised within the CP.
♦ U - updatable constant that is checkpointed.
August 2, 2011
♦ C - constant, not checkpointed.
Data Type The I/A Series data type for the attribute:
♦ 1 – CHARACTER
♦ 2 – INTEGER
♦ 3 – FLOAT
♦ 4 – STRING
♦ 5 – OM-BOOL
♦ 6 – OM_LNG_INT
♦ 8 – OM_SHORT_INT
♦ 9 – OM_S_PKBOL
♦ 10 – OM_L_PKBOL
Initial Value Initial value for the attribute during its creation. If the attribute is a
checkpointed attribute, the initial value is used for the first creation.
Thereafter, the checkpointed value is used during creation.
Change Delta/ I/A Series application change delta or the length of the string if the
String Length data type is STRING.
126
Appendix A. Application Object Services B0700EE – Rev A
Preliminary
line is ignored if supplied.
9. The TYPE attribute of an object is automatically created and initialized by AOS when
August 2, 2011
it processes an AO definition line in the mapping text file. Thus, there should be no
TYPE AOA definitions in the mapping text file.
10. Do not create attributes with the name R[I|O][number], e.g., RI1 or RO1. These
names are reserved and automatically created when an attribute whose name is
HSC[I|O][number] is encountered.
11. Do not create attributes with the name "ecode". This attribute created by AOS. The
"ecode" attributes are cleared during mapping initialization. An object's ecode is set to
a negative number representing an error condition if any of the object's attributes
receives an error during mapping initialization, the opening of AIS lists, or during a
read or write mapping event.
12. String data types can only have map operators of 'C', 'G', 'g' and 'U'. The length of a
string is specified in its deadband field. The minimum length of any string is 32. The
maximum length of any string is 254.
127
B0700EE – Rev A Appendix A. Application Object Services
Preliminary
attribute name
3. table map
August 2, 2011
map_appid
map application database id
map_objid
map object database id
map_attrid
map attribute database id
map_operator
map type
map_cbpname
map CBP name
map_value
map current value
map_deadband
map deadband
map_datatype
map data type of application object
4. table object
aappobj_appid
object application database id
appobj_id
object database id
appobj_name
0bject name
appobj_type
object type
128
Appendix A. Application Object Services B0700EE – Rev A
Mappings
Read (R) mappings are implemented using an AIS read list of C:B.Ps and the appobj_set call.
Both the value and status of a CBP are copied to its associated AOA when a change occurs in the
CBP.
Write (W) mappings are implemented using an AIS read list of AOAs and an AIS write list of
C:B.Ps. The value (but not the status) of an AOA is copied to its associated CBP when a change
occurs in the AOA.
Put (P) mappings are implemented using an AIS read list of AOAs. C:B.Ps are updated using one-
shot sets. P mappings are slower than W mappings, but put-mapped C:B.Ps do not have to be
secured.
ICC (I) mappings are supervised within a CP. When mapping is turned on, AOS optionally
informs the ICC to connect an AOA to a CBP. When mapping is turned off, AOS optionally
informs the ICC to disconnect the AOA from the CBP. This indicates that the connection is no
longer in use.
A Get (G or g) mapping initializes an AOA with its associated CBP value once when mapping is
turned on, and thereafter only by user request via the REREAD option on the AppObjSrv menu,
or the AOSREREAD script file.
Preliminary
For W, P, and I mappings, the AOA source value is initialized to its associated CBP sink value
when mapping is turned on. This "backwards" copy is done to reduce the possibility of process
August 2, 2011
upsets when mapping is turned on.
NOTE
Strings cannot be R, W, P, or I mapped.
129
B0700EE – Rev A Appendix A. Application Object Services
Available Scripts
The AOS scripts that are available can be located in the D:\opt\aos\scripts directory. The AOS
scrips are documented in the Application Object Services User’s Guide, B0400BZ. This document is
include as part of the FoxBridge for Windows CD-ROM.
The aos executable implements the Application Object Services, i.e.,
1. Building an Application Object Database,
2. Creating an application's objects in memory,
3. Mapping an application's objects to and from their appropriate locations, and
4. Recording specific attribute values into the Application Object Database.
Nine commands (AOSBUILDDB, AOSCREATE, AOSMAP, AOSMAPC, AOSCHKPT,
AOSUNMAP, AOSDELETE, AOSDELETED, AOSREREADG) exist to perform these
services.
One additional command (AOSDEBUG) exists to facilitate problem resolution. The
AOSREPORT and AOSMODIFY commands exist to allow user maintenance of the AOS
database contents.
AppObjSrv is the interactive configuration utility for Application Objects. Its operation is fully
Preliminary
interactive in that is prompts the user for needed information.
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AppObjSrv
AppObjSrv is the configuration utility for Application Objects. It’s operation is fully interactive,
i.e., it prompts the user for the needed information. With this information available to it, the util-
ity will build the Application Object database, allow the instantiation of the objects, and start and
stop the mapping operation.
AppObjSrv prompts the user for four inputs upon invocation. It stores the last entered value for
ease of use. If the value in brackets ([ ]) is the desired value, simply press Return. The four inputs
are as follows:
130
Appendix A. Application Object Services B0700EE – Rev A
Figure A-2 shows menu layout for the AppObjSrv configuration utility.
Preliminary
August 2, 2011
Figure A-2. Application Object Services Menu
131
B0700EE – Rev A Appendix A. Application Object Services
Preliminary
31), then Unmapped (option 11) and Deleted (Option 21). Once those steps, are
completed, option 20 will perform the follow:
♦ Generate a new map file under another name (Current Map File)
August 2, 2011
♦ Compare Current Map File with the New Map File
♦ Determine the Added or Deleted Objects or Variables and report them
♦ Add the New Objects to the Current Map File. Remove Deleted Object from the
Current Map File.
♦ Load the modified Current Map File into the database (AOSBUILDDB)
♦ Create the Application Objects from the Database.
♦ Established ICCAPI (I mappings) connections.
This allows you to make modifications to your controller without losing tuning and
checkpointed parameters.
21 - DELETE AOs for DMCPLUSD
This option deletes all Application Objects. Application Objects must be unmapped
before selecting this option. This option should be selected before any database
modification.
31 - CHECKPOINT DMCPLUSD data
This option sends a checkpoint request to the application. All objects with a U or g
mapping will be updated in the database if they have changed beyond their deadband.
32 - CONNECT the CBP/AOA mappings for DMCPLUSD
This option will establish the ICCAPI connections for all I mappings.
33 - DISCONNECT the CBP/AOA mappings for DMCPLUSD
This option will disconnect the ICCAPI connections for all I mappings.
34 - VERIFY agreement between CBP/AOA mappings for DMCPLUSD
This option checks the ICCAPI (I) mappings.
132
Appendix A. Application Object Services B0700EE – Rev A
Preliminary
cal.
40 - VIEW standard log for DMCPLUSD mapping
August 2, 2011
This option allows you to view the standard Mapping log, aos_map.log, in the standard
logs directory. It is important to View the Error Log before starting the Controller since
any errors could be critical.
41 - CHANGE Application
This allows you to change to another application or controller.
42 - CHECK AIS status
This allows you to check to make sure that AIS is running. AIS must be running in order
for mapping to function.
43 - MODIFY AOS Database
This option allows you to modify information in the database using a program called
MapViewer. MapViewer allows the database to be easily queried and updated in a form
type display. If modifications are made, it is a good idea to generate a current map file
(Option 37) to preserve the changes.
133
B0700EE – Rev A Appendix A. Application Object Services
/opt
aos
Preliminary
MapViewer
August 2, 2011
exe hdr obj src
134
Appendix B. Supervisory Setpoint
Control (SSC)
This appendix describes the fundamentals of Supervisory Setpoint Control.
This version of the I/A Series FoxBridge software can be used with two types of systems: those
that support Supervisor Setpoint Control (SSC) inherently and those that do not. All computer
based controllers required SSC to deal with the potential for computer or application failure. All
Supervisory Setpoint Control (SSC) implementation must have the following features at a
minimum:
1. A place to write the setpoint.
2. A method of switching from one setpoint to another.
3. A method of confirming that the supervisory setpoint is okay to use, i.e., that the
supervisory application has initialized.
Preliminary
4. Indicators that the cascade is working properly.
5. A value to track when the loop is unavailable.
August 2, 2011
6. A watchdog timer to monitor the health of the link to the supervisory application.
7. A mechanism to support switching from the supervisory setpoint to a fallback
configuration when the watchdog timer indicates that the failure occurred.
8. A mechanism to support switching from the supervisory setpoint to a fallback
configuration when a loop is no longer in use by the DMCplus controller
AOUT
Operator Entry MEAS
OUT
135
B0700EE – Rev A Appendix B. Supervisory Setpoint Control (SSC)
In this configuration, the operator simply enters the desired value into the MEAS parameter of
the block.
In DDC operation, a supervisory application would replace the operator during some portion of
the operation of the plant and prevent any operator entry from moving the output. Figure B-2
shows this type of operation.
Operator Selection of
Operating Mode (Local/DDC)
Operator Entry
AOUT
MEAS
Supervisory Value
OUT
Preliminary
Sometimes one refers to using DDC control on the output of a PID block. However, if the PID is
connected to the AOUT, the behavior is identical to the situation described in Figure B-1, and, if
the PID is in the middle of a cascade, the behavior is identical to that described in Figure B-2.
August 2, 2011
Supervisory Setpoint Control
Supervisor Setpoint Control (SSC) refers to the situation where a supervisory program provides
setpoints to a controller or set of controllers. The moment to moment control of the process is left
to the controller and the supervisory controller devotes its attention to overall process shifts rather
than high speed interaction with the process.
There are two cases to consider, providing a setpoint to a cascade of controllers and interrupting a
cascade while in SSC mode.
Figure B-3 shows a typical two level cascade as it might be implemented in an I/A Series
controller.
136
Appendix B. Supervisory Setpoint Control (SSC) B0700EE – Rev A
PID
LR
Operator Entries
SPT
MEAS PID
BCALCI BCALCO
INITI INITO
OUT RSP
FBK LR
SPT
MEAS AOUT
Operator Entries
BCALCI BCALCO
INITI INITO
Preliminary
OUT MEAS
FBK OUT
August 2, 2011
Figure B-3. Two-Level Cascade
To implement SSC, one must provide logic to validate the setpoint from the supervisory program
and to seamlessly switch modes.
NOTE
The INITO parameter of a block is set if it or another downstream block in set to
Local mode among other reasons. This is important to remember in the following
Appendices since this means that the INITO parameter can be used to determine if
the cascade is opened using the LR switch.
137
B0700EE – Rev A Appendix B. Supervisory Setpoint Control (SSC)
Preliminary
August 2, 2011
138
Appendix C. SSC Based I/A Series
System
This appendix describes implementing FoxBridge over SSC based I/A Series systems.
Newer versions of the I/A Series software incorporates new parameters and status bits in the PID,
AOUT and RATIO family of blocks to perform Supervisory Control. The I/A Series document
Supervisory Setpoint Control, B0193RY, describes these new parameters and their functionality.
Each block in the PID, AOUT, and RATIO family can be configured to support Supervisory
Setpoint Control by configuring a Supervisory Option parameter. Configuring this parameter
allows the block to go into SPC mode if the proper handshaking is performed. In future releases
of I/A Series software, another option will be added to allow the block to go into DDC mode
upon proper handshaking.
The Supervisory Setpoint is written into a new Supervisory Setpoint parameter. The block will
Preliminary
not accept the Supervisory Setpoint unless it is initially acknowledged with the acknowledge bit
set in the status bits of the Supervisory Setpoint variable. A Supervisory Back Calculation
parameter provides tracking information for the Supervisory application. New status bits in the
August 2, 2011
Block Status parameter indicate whether the block is enabled for Supervisory mode, in
Supervisory control, or in Fallback mode.
Each block to be enabled for Supervisory Control is assigned to one of eight groups. The Control
Processor Station block contains Watchdog Timers for each group as well as Group Enable and
Group Fallback capability. The DMCPLUSD Demo uses Group 5, SUPGRP=5.
Block Configuration
To use the I/A Series software 8.1.1 and later (SSC) FoxBridge, the Manipulated Variable loops
must be properly configured to allow Supervisory Setpoint Control and Fallback. The
following parameters should be configured for all Manipulated Variables:
1. Configure INITSE=0 for all PID, PIDA, PIDX, PIDXE, PIDE, AOUT, and RATIO
to prevent use of stale Supervisory Setpoints upon block initialization. Certain
applications may warrant configuring INITSE to be 1, but this is not considered
secure and should not be standard practice.
2. Configure SUPOPT=1 for all MV blocks to allow Supervisory Setpoint Control. In
I/A Series software V4.3/V6.1 or later, configuring SUPOPT=2 will allow the block
to use DDC mode rather than SPC mode.
3. Configure SUPGRP=<Ctrl No.> if multiple controllers used. Default=1.
Manipulated Variables within a Controller must all have the same SUPGRP even if
they are in different CPs. Likewise, if multiple Controllers have Manipulated
Variables in the same CP, then each Controller must use a different SUPGRP.
4. Configure FLBOPT to appropriate Fallback Option (1=Auto, 2=Manual, 3=Remote,
4=Local) for all MV blocks.
139
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Preliminary
Configure SUPOPT to be 1
August 2, 2011
SSC Enabled if:
1. At Block Level, setting SE --> 1
2. At Group Level, setting SUPENA bit --> 1
When SSC Enabled:
1. BLKSTA.SE --> 1
2. BLKSTA.FLB --> 1
3. If TIMENA bit = 1 then
TIMVLn reset to RESVLn and Timer Activated
4. If FLBRQn = 0 then
FLBSTA --> 0
If SSC Enabled at Group Level, all blocks in the group are enabled, unless FLBREQ=2, then
those blocks must be enabled by setting SE --> 1 individually for each block.
SSC is Disabled by one of the following:
1. At Block Level, setting SE --> 0
2. At Group Level, by clearing SUPENA bit --> 0
3. At Group Level, by setting SDn momentary input --> 1
When SSC Disabled:
1. BLKSTA.SE -> 0
2. BLKSTA.SC -> 0
3. BLKSTA.FLB -> 0
4. TIMVLn -> 0
5. Timer deactivated, but still enabled
140
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Fallback Logic
In I/A Series software V4.2 and later, automatic Fallback of Supervisory Control can be generated
by any one of the following:
1. By the expiration of the Fallback Timers
2. By an explicit group input Fallback Request.
3. By an explicit block input Fallback Request. This will cause only the target block to
fallback and will not affect any other blocks or loops in the group.
Most of the Fallback Logic is handled in the FOXAOS Cim-IO Custom Transformations. The
FALLBK parameter for I/A Series software V4.2 and later MVs is a Put Map to the FLBREQ
parameter of the Block. Since all mapping requests are exception driven, FALLBK must be reset
except when a specific condition occurs that should cause a Fallback. Conditions which will cause
an MV Fallback to occur by setting FALLBK to 1 are:
1. The Controller is trying to write a Computer Setpoint, but the block is not in a valid
state to accept it (such as in Track or Hold).
2. The MV is in FFW or OOS mode and the Controller is not writing a setpoint to the
block, yet the ACK has been set for two cycles and the downstream block is trying to
Preliminary
Initialize.
3. The MV is in a SubController and the SubController is turned OFF.
August 2, 2011
4. The downstream block is Enabled for Supervisory Control or in Supervisory Control
and no Setpoint is being written to it.
5. The Controller has switched from Closed Loop to Open Loop in the last cycle.
In all other cases, FALLBK is set to 0 so that a 0 to 1 transition can occur if required. These reset
conditions include:
1. Trying to Acknowledge Downstream Block and Block is Enabled for Supervisory
Control and has the Initialization Request Set. Reset FALLBK to allow initialization
to occur.
2. No setpoint is being written to MV and the MV is not trying to Initialize.
3. The MV is not in SubController, not Initializing, and not in Supervisory Enabled or
Supervisory Control mode
141
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Application Objects
Controller Objects
CV Objects
FF Objects
[DMC]
MV Objects
Chg. Driven AOS
. VINDSP Mapping
Connection
Preliminary
August 2, 2011
Figure C-1. Method of Choosing Supervisory Setpoint
142
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Preliminary
The monitoring the status of communications between a DMCplus controller and its underlying
MV control blocks is maintained by the SSC mechanism by assigning the control blocks
representing the MV to an SSC group in the Control Stations's STATION block.
August 2, 2011
These relationships, as applied to a DMCplus controller, are diagrammed Figure C-2.
DMCplus M V C
supervisor setpoints
written by the
DMCplus Engine
an expired timer
causes a group back-calculated values
fallback support bumpless transfer
STATION REGULATORY
BLOCK CONTROL
CONTROL
GROUP BLOCKS
operator-set
The group timer is reset whenever auto/manual &
a setpoint is written. The group remote/local status
timer is enabled after a CP reboot.
OPERATOR
operator displays show SUMMARY &
current supervisory status
and block values BLOCK
FACEPLATE
DISPLAY(S)
143
B0700EE – Rev A Appendix C. SSC Based I/A Series System
NOTE
The I/A Series System Manipulated Variables do not need to be modified for data
collection and PRBS testing. They must be modified before a controller is
Preliminary
implemented.
August 2, 2011
Although the final structure is intricate, the required configuration in the CP is straightforward.
Follow the sections below to accomplish the following:
1. If necessary, add regulatory control blocks for SSC interface
2. Configure the CP resident control blocks for Supervisory Control and proper
Fallback.
3. Create the watchdog timer compound. It is automatically configured by the I/A Series
Configuration Utility.
Configuring SSC
As a standard approach, DMCplus controller exercises control over the process by writing its
outputs as setpoints to underlying I/A Series system regulatory blocks. As mentioned elsewhere in
this document, a number of different block types have SSC capability, and schemes involving any
of these block types are possible. However, for the purposes of DMCplus controller over
I/A Series systems, the preferred interface is to the supervisory setpoint of a PIDA control block.
Other types of PID controllers will also function correctly as well as analog output blocks.
Typically, regulatory control functions for DMCplus manipulated variables will already exist, in
the form of control blocks for gas or liquid flows or a similar variable such as solids tonnage.
These controllers may also be the secondary loops in existing cascade control structures. Such fast
responding loops are the ideal interface between DMCplus controller and the process. In this
case, if the control block is an earlier form of this function, i.e. PID, PIDE, PIDX, or PIDXE,
then you may wish to use the control configurator to replace it with an equivalent PIDA before
proceeding with the steps below.
However, occasionally the existing configuration will be a control block for a slower variable such
as temperature or composition directly manipulating the process through an AOUT block. This
output may be positioning a control valve or other final operator such as a variable speed drive. In
144
Appendix C. SSC Based I/A Series System B0700EE – Rev A
this case, interfacing the DMCplus controller to the slower control block function is not
appropriate, and it will write directly to an AOUT block.
Preliminary
2. it is possible that all of the MVs for a single DMCplus controller will not located in
the same CP, and thus cannot be assigned to the same group of a single STATION
August 2, 2011
block. In this case, the user should use the same supervisory group number in each
individual STATION block for a selected DMCplus controller.
3. if there are MVs for multiple DMCplus controllers in the same CP, assign them to
different groups.
4. if a group has been chosen to support a DMCplus controller, do not assign any blocks
other than that controller's MVs to that group
At each regulatory control or analog output block which will receive a supervisory setpoint, 4
parameters need to be configured to enable and support supervisory control.
♦ SUPOPT specifies whether this block can interface with a supervisory application; set
to 1 to enable supervisory control functions
♦ INITSE specifies the initial state of the supervisory enable (SE) bit when the block
initializes; set to 0 to initially operate on local control
♦ SUPGRP specifies the supervisory group (1-8) of which this block is a member.
♦ FLBOPT specifies the state to which the block will "fall back" if the timer in the
station block should determine that communications with the DMCplus controller
have failed
0 = take no fallback action
1 = set controller to Auto
2 = set controller to Manual
3 = set controller to Remote
4 = set controller to Local
Choosing options 1 or 2 will leave the R/L status in its current state. Choosing 3 or 4
will leave the A/M status in its current state. Normally, a regulatory control block will
already be in AUTO at fallback, so either option 3 or 4 is chosen.
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B0700EE – Rev A Appendix C. SSC Based I/A Series System
In addition, the setting of the PRIBLK parameter is important. This parameter supports proper
initialization in cascade schemes when the blocks execute at different periods. If the primary and
secondary blocks execute at the same period, this parameter may be left unset in standard
regulatory schemes.
However, if a regulatory block that is receiving a supervisory set point from the DMCplus
controller is also a slave in a regulatory cascade control scheme, the PRIBLK parameter of this
block must be set to 1 for the block to fallback to REMOTE, even if the period of the block
providing the remote setpoint is the same as that of the slave.
F V 1 0 7 (A O U T ) F IC 1 0 7 (P ID )
Preliminary
T o F i e l d D e v ic e
.O U T .O U T
.M E A S = :F IC 1 0 7 .O U T .R S P = :F IC 1 0 7 .S P T
August 2, 2011
.P R IB L K = 1 .P R IB L K = 0
.A U T S W = 1 .L IM O P T = 1 ( fo r P ID A )
.B C A L C O .IN IT I= 0
.IN IT S E = 0 .A U T S W = 0
.S U P G R P = x .L O C S W = 1
.F L B O P T = 0 .B C A L C O
.S U P O P T = 0 .F B K = :F V 1 0 7 .B C A L C O
.B C A L C I= :F V 1 0 7 .B C A L C O
.IN IT S E = 0
.S U P G R P = x
.F L B O P T = 0 o r 1
.S U P O P T = 1
D M C p lu s
( W r ite s to .S U P _ I N )
Figure C-3. SSC I/A Series System Configuration for a PID Block
146
Appendix C. SSC Based I/A Series System B0700EE – Rev A
NOTE
The FLBOPT=3; the PID controller FIC107 will fall back to "Remote" mode and
the cascade will be reestablished. (If it is desired to fall back to local control, set
FLBOPT=4.
Preliminary
.AUTSW=1 .LIMOPT=1 (for PIDA) .LIMOPT=1 (for PIDA)
August 2, 2011
.SUPGRP=x LOCSW=0 .LOCSW=1
.BCALCI=:FV107.BCALCO .BCALCI=:FIC107.BCALCO
.INITSE=0 .INITSE=0
.SUPGRP=x .SUPGRP=x
.FLBOPT=3 .FLBOPT=0
.SUPOPT=1 .SUPOPT=0
DMCplus
(Writes to .SUP_IN)
Figure C-4. SSC I/A Series System Configuration for a Salve PID Block in a Cascade Strategy
147
B0700EE – Rev A Appendix C. SSC Based I/A Series System
The block AOUT_FLBREQ should be part of this SSC configuration. Example code is found
below.
There is a potential problem with the Control Block where the AOUT block will go into
"HOLD" if it is not configured correctly. The configuration in Figure C-5 must be followed
exactly to avoid this problem.
Note that FLBOPT=2; the AOUT block FV107 will fall back to Manual mode for one cycle (this
clears the HOLD problem) and then the auto-switch (AUTSW) parameter seamlessly forces the
block back into automatic. The block AOUT_FLBREQ also addresses this HOLD problem and
clears the condition.
! CAUTION
If the user must use a different configuration, it must be extensively tested on a test
bed. The test must include the configuration behavior after a CP boot.
Preliminary
August 2, 2011
148
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Preliminary
.FLBREQ (Request fallback) .INITSE=0 .INITSE=0
.SUPGRP=x .SUPGRP=x
August 2, 2011
.FLBOPT=0 .FLBOPT=0
.SUPOPT=0 .SUPOPT=0
.MA
DMCplus
(Writes to .SUP_IN)
AOUT_FLBREQ (IND SEQUENCE)
.BI0001=:FV107.BLKSTA.SC
.BI0002=:FC107.MA
.SN0001=SPLITTER:FV103 (String)
Figure C-5. SSC I/A Series System Configuration for a Analog Output Block in a Regulatory Loop
NOTE
After the AOUT configuration is changed in the ICC and downloaded, it will likely
go into the "HOLD" state. The AOUT_FLBREQ sequence block will clear the
"HOLD" by transitioning the block through Manual. The MANSW parameter
must not be configured
149
B0700EE – Rev A Appendix C. SSC Based I/A Series System
NOTE
The FLBOPT=2; the AOUT block FV107 will fall back to Manual mode for one
cycle (this clears the HOLD problem) and then the auto-switch (AUTSW) parame-
ter forces the block back into automatic. The block AOUT_FLBREQ also addresses
this HOLD problem and clears the condition.
If the user must use a different configuration, it must be extensively tested on a test bed. The test
must include the configuration behavior after a CP reboot. After the AOUT configuration is
Preliminary
changed in the ICC and downloaded, it will likely go into the "HOLD" state. The
AOUT_FLBREQ sequence block will clear the "HOLD" by transitioning the block through
Manual. The MANSW parameter must not be configured
August 2, 2011
HC107 (AOUT)
To Field Device
.OUT
.MEAS=0
.PRIBLK=0
.AUTSW =1
.BCALCO
.INITSE=0
.SUPGRP=x
.FLBOPT=2
.SUPOPT=1
DMCplus
(Writes to .SUP_IN)
Figure C-6. SSC I/A Series System Configuration for a Stand-Alone Analog Output Block (HIC)
150
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Preliminary
Then paste it into the target CP. No further action is required.
When first created, the sequence block in this compound does not "know" to which supervisory
August 2, 2011
groups the MVs for this application have been assigned. The standard DMCplus configuration
process will configure this compound and its blocks as require by determining these assignments
and writing them into the string variables of the sequence block, as part of process of building the
application objects making this mechanism fully functional. Up to 8 different group references
can be handled by the sequence block, if the DMCplus controller's MVs are not all located in the
same CP. For documentation and maintenance purposes, it is helpful to use a consistent
assignment scheme; it is for this reason that MV blocks in separate CPs should be assigned to the
same supervisory group number.
Normally, this sequence block configuration is transparent to the user. However, if this
information should become corrupted, these assignments can be reestablished by rebuilding the
application objects.
! CAUTION
Do not use this code in production without testing it including a reboot test.
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B0700EE – Rev A Appendix C. SSC Based I/A Series System
INDEPENDENT_SEQUENCE{*******************************
** INDEPENDENT SEQUENCE **
** CONTROL BLOCK **
** AOUT FLBREQ **
********************************************}
{REVISION HISTORY:
REV. 1.0 01/23/01 Original code
REV. 1.1 10/14/04 HOLD Clear
A version of this block is used to support the Connoisseur Integration Product; it
has been altered to support the DMCplus Bridge. It must be tested for proper oper-
ation by the applying engineer.
The user may need to write directly to an analog output block that is a slave to a
regulatory controller. The AOUT is always kept in auto/remote via switches.
However, if DMCplus is closed loop and the top level controller is thrown into
Manual mode, the AOUT must be taken out of SSC so that the operator has
immediate access to the valve in case of an emergency. (The operator will not
have access to the AOUT block.)
This block writes to the AOUT FLBREQ parameter when the top level PID block
is changed from Auto to Manual while DMCplus is on. The AOUT controller is
Preliminary
allowed to stay in SSC if DMCplus was turned to closed loop while the top level
controller was in Manual.
August 2, 2011
This block also clears the HOLD state, by momentarily setting the MANSW parameter.
The HOLD state results from ICC configuration and improperly conducted supervisory
setpoint disables. If the fallback feature is not being used, do not configure
BI0001 through BI0008.
Up to 4 AOUT blocks are supported.
}
{DECLARATIONS}
#define say(m) SENDMSG("m") TO MSGGR1
CONSTANTS
VARIABLES
saout :S; {String holds name of AOUT. Storage location}
USER_LABELS
baoutssc1 :BI0001; {ON if AOUT is in SSC mode. Source C:AOUT.BLKSTA.SC}
bpidma1 :BI0002; {Top level PID controller A/M mode. Source C:TOP_PID.MA}
baoutssc2 :BI0003; {ON if AOUT is in SSC mode. Source C:AOUT.BLKSTA.SC}
bpidma2 :BI0004; {Top level PID controller A/M mode. Source C:TOP_PID.MA}
baoutssc3 :BI0005; {ON if AOUT is in SSC mode. Source C:AOUT.BLKSTA.SC}
bpidma3 :BI0006; {Top level PID controller A/M mode. Source C:TOP_PID.MA}
baoutssc4 :BI0007; {ON if AOUT is in SSC mode. Source C:AOUT.BLKSTA.SC}
bpidma4 :BI0008; {Top level PID controller A/M mode. Source C:TOP_PID.MA}
baouthld1 :BI0011; {ON if AOUT is in HLD mode. Source C:AOUT.BLKSTA.HLD (.B25)}
baoutma1 :BI0012; {ON if AOUT is in AUTO mode. Source C:AOUT.MA}
baouthld2 :BI0013; {ON if AOUT is in HLD mode. Source C:AOUT.BLKSTA.HLD (.B25)}
baoutma2 :BI0014; {ON if AOUT is in AUTO mode. Source C:AOUT.MA}
baouthld3 :BI0015; {ON if AOUT is in HLD mode. Source C:AOUT.BLKSTA.HLD (.B25)}
baoutma3 :BI0016; {ON if AOUT is in AUTO mode. Source C:AOUT.MA}
baouthld4 :BI0017; {ON if AOUT is in HLD mode. Source C:AOUT.BLKSTA.HLD (.B25)}
baoutma4 :BI0018; {ON if AOUT is in AUTO mode. Source C:AOUT.MA}
blastma1 :BO0001; {Last value of top level PID A/M}
152
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Preliminary
EXIT;
ENDEXCEPTION
August 2, 2011
{*************************************}
STATEMENTS
{Initialization Section}
blastma1 := FALSE;
blastma2 := FALSE;
blastma3 := FALSE;
blastma4 := FALSE;
<<BODY>>
{*************************************}
{Following true if the top level PID block transitioned from Auto to Manual
and the name of the PID is entered and the AOUT is in SSC mode..}
IF (bpidma1=FALSE) AND (blastma1=TRUE) AND (saout1<>"NONE") AND (baoutssc1=TRUE)
THEN
{Set the AOUT .FLBREQ parameter. Wait, then reset it.}
saout := saout1,".FLBREQ";
:'saout' := TRUE;
WAIT (2.0);
:'saout' := FALSE;
ENDIF;
{Now do the others.}
IF (bpidma2=FALSE) AND (blastma2=TRUE) AND (saout2<>"NONE") AND (baoutssc2=TRUE)
THEN
saout := saout2,".FLBREQ";
:'saout' := TRUE;
WAIT (2.0);
:'saout' := FALSE;
ENDIF;
153
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Preliminary
:'saout' := TRUE;
WAIT UNTIL ( baoutma1 = FALSE ) AFTER 10 GOTO CLEAR1;
<<CLEAR1>>
August 2, 2011
:'saout' := FALSE;
ENDIF;
IF (baouthld2=TRUE) THEN
saout := saout2,".MANSW";
:'saout' := TRUE;
WAIT UNTIL ( baoutma2 = FALSE ) AFTER 10 GOTO CLEAR2;
<<CLEAR2>>
:'saout' := FALSE;
ENDIF;
IF (baouthld3=TRUE) THEN
saout := saout3,".MANSW";
:'saout' := TRUE;
WAIT UNTIL ( baoutma3 = FALSE ) AFTER 10 GOTO CLEAR3;
<<CLEAR3>>
:'saout' := FALSE;
ENDIF;
IF (baouthld4=TRUE) THEN
saout := saout4,".MANSW";
:'saout' := TRUE;
WAIT UNTIL ( baoutma4 = FALSE ) AFTER 10 GOTO CLEAR4;
<<CLEAR4>>
:'saout' := FALSE;
ENDIF;
ENDIF;
{Store last value of top level PID A/M status}
blastma1 := bpidma1;
blastma2 := bpidma2;
blastma3 := bpidma3;
blastma4 := bpidma4;
154
Appendix C. SSC Based I/A Series System B0700EE – Rev A
WAIT (0.1);
GOTO BODY;
ENDSEQUENCE
Preliminary
.VIND .SUPBCO .SUPBCO .SUPBCO
.VINDSP .SUP_IN .SUP_IN .SUP_IN
.ACK 0 0 0
August 2, 2011
.BAD .SUPBCO.BAD .SUPBCO.BAD .SUPBCO.BAD
.IR .SUPBCO.INITC .SUPBCO.INITC .SUPBCO.INITC
.LHI .SUPBCO.LHI .SUPBCCO.LHI .SUPBCO.LHI
LLO .SUPBCO.LLO .SUPBCO.LLO .SUPBCO.LLO
.MVMODE 1 1 1
.LLO .SUPBCO.LLO .SUPBCO.LLO .SUPBCO.LLO
.OOS .SUPBCO.OOS .SUPBCO.OOS .SUPBCO.OOS
.SE .SE .SE .SE
.SRVIND 1 1
.FALLBK .FLBREQ .FLBREQ .FLBREQ
A new parameter, MVMODE, tells the FoxBridge application what sort of interface logic to use.
An MVMODE of 1 indicates that Supervisory Setpoint Control application should be used.
The VINDSP parameter is actually a constant. Special logic in the interface recognizes when
VINDSP is to be written to the process. A new variable TARGET stores the downstream
Compound:Block.Parameter for the SUP_IN Supervisory Setpoint. The ACK parameter is sent
down in the Status Bits of the SUP_IN variable to perform the required handshaking. This allows
the variable to be sent to the process each controller cycle, without regard to any deadband.
Sending the Supervisory Setpoint resets the CP Station Block Watchdog timer. The VINDSP
parameter also gets updated with the same value as SUP_IN.
155
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Preliminary
2 - without recovery at group level
SUPBCO 6 Supervisory Back Calculated Output for Bump-
August 2, 2011
less Init
BLKSTA (new bits) New status bits:
SE - Supervisory Enable
SC - Supervisory Control
FLB - Fallback State
156
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Units
Parameter Type C L S Range Def Description
SUPOPT B Y - - 0-1 0 Supervisory Option
0 = no SSC
1 = SSC
SUP_IN R - O Y RI1 (RI2 if 0.0 Supervisory Input
RATIO Bit 10 set by
SUPBCO to initialize
SUPGRP SI Y - - 1-8 1 Supervisory Group
SE B - - Y 0-1 0 Supervisory Enable
0 = disable
1 = enable
Preliminary
INITSE SI Y - - 0-1 0 Initial SE
0 = disable
August 2, 2011
1 = enable
2 = don’t change SE
FLBOPT SI Y - - 0-4 0 Fallback Option
0 = normal action
1 = set MA to Auto
2 = set MA to Man
3 = set LR to Remote
4 = set LR to Local
FLBREQ SI - O Y 0-2 0 Fallback Request
0 = no fallback req
1 = fallback at block or
group level
2 = fallback at block
level only
SUPBCO R - O - RI1 0 Back-Calc SSC Value
Bit 10: 1=Initial
SUP_IN
Bit 13: 1=SUP_IN is
Limited High
Bit 14: 1=SUP_IN is
Limited Low
157
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Units
Parameter Type C L S Range Def Description
BCALCn R - O - RI1 0 Back-Calc (n=1-2)
Bit 10: 1=Initial Primary
Output
Bit 13: 1=INP1/INP2
is Limited High
Bit 14: 1=INP1/INP2
is Limited Low
RESVLn I Y - - 0-32767 sec 8 Reset Value (n=1-8)
TIMVLn I - O - 0-32767 sec 8 Timer Value (n=1-8)
FLBRQn B Y I U 0-1 0 Fallback Request (n=1-8)
SUPENA PB - O Y 0x00-0xFF 0x00 Supervisory Enable
Bits 1-8 Sup Ena Req
for Groups 1-8
1=Enable 0=Ignored
Preliminary
Bits 9-16 Sup Dis Req
for Groups 1-8
August 2, 2011
1=Disable 0=Ignored
TIMENA PB - O Y 0x00-0xFF 0x00 Timer Enable
Bits 1-8 Enable/Disable
for Groups 1-8
1=Enabled 0=disable
Bits 9-16 Timer Reset
Req for Groups 1-8
1=Reset timer 0=Ignored
INITTE PB Y - - 0x0000- 0x5555 Initial Timer Enable
0xAAAA Bits 1-2 Timer #1
00 - Disable
01 - Enable
10 - Leave Alone
Bits 3-4 Timer #2
.
.
Bits 15-16 Timer #8
TIMSTA PB - O - 0x00-0xFF 0x00 Timer Status
Bits 1-8 Expired State
for Groups 1-8
1=expired 0=not exp
Bits 9-16 Active State
for Groups 1-8
1=active 0=inactive
158
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Units
Parameter Type C L S Range Def Description
FLBSTA PB - O - 0x00-0xFF 0x00 Fallback Status Param
Bits 1-8: Fallback
States for Groups 1-8
1=Fallback
0=Not Fallback
Preliminary
Y Displayable and Editable
August 2, 2011
L (linkability): - Not Linkable
I Linkable Input (source or sink)
O Linkable Output (source only)
159
B0700EE – Rev A Appendix C. SSC Based I/A Series System
O
A U P R
A O T P P I P A S
O U S P I I D I T S W
U T E I D D X D I T C
T R L D E X E A O A H
BCALCn (n=1-2) X X
FLBOPT X X X X X X X X
FLBREQ X X X X X X X X
FLBRQn (n=1-8) X
FLBSTA X
INITSE X X X X X X X X
INITTE X
RESVLn (n=1-8) X
SE X X X X X X X X
Preliminary
SUPBCO X X X X X X X X
SUPENA X
SUPGRP X X X X X X X X
August 2, 2011
SUPOPT X X X X X X X X
SUP_IN X X X X X X X X
TIMENA X
TIMSTA X
TIMVLn (n=1-8) X
160
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Bit Bool 4.1 RSP SUP_IN SPT BCALCO SUPBCO BCALCI OUT
0 B16 TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE
1 B15 TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE
2 B14 TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE
3 B13 TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE
4 B12 TYPE Used Used Used Used Used Used Used
only in only in only in only in only in only in only in
SETVAL SETVAL SETVAL SETVAL SETVAL SETVAL SETVAL
5 B11 OM OM OM OM OM OM OM OM
6 B10 OM OM OM OM OM OM OM OM
7 B9 OM OM OM OM OM OM OM OM
Preliminary
8 B8 BAD BAD BAD BAD BAD BAD BAD BAD
9 B7 SECURE SECURE SECURE -0- FS -0- SECURE SECURE
10 B6 ON ACK ACK -0- INITC INITC INITC ACK
August 2, 2011
11 B5 OOS OOS OOS OOS OOS OOS OOS OOS
12 B4 SHADOW -0- -0- -0- -0- -0- -0- SHADOW
13 B3 ACK -0- -0- LHI LHI LHI LHI -0-
14 B2 - -0- -0- LLO LLO LLO LLO -0-
15 B1 ERROR ERROR ERROR -0- UNITU -0- -0- ERROR
161
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Preliminary
22 DSR BLKSTA.B10 DSR Mismatch (GDEV)
DF Device Fail (MDACT, DPIDA)
August 2, 2011
21 ILK BLKSTA.B11 Interlock
RED Redundant Input (DPIDA)
20 WLCK BLKSTA.B12 WLCK Workstation Lock
19 SBX BLKSTA.B13 Executing SBX Statements (Sequence)
TEST Test Mode (PLB)
SPDN Set Point Ramp Down (DPIDA)
HRQ Hold Request (MDACT)
18 PAUS BLKSTA.B14 Paused (DEP)
SIM Simulation Mode (PLB)
SPUP Set Point Ramp Up (PIDA)
INER Input Error (OUTSEL)
17 TRIP BLKSTA.B15 Tripped (MON)
FTN Feedforward Tune Active (PIDA, DPIDA)
LM2 Limit Switch 2 On (GDEV)
RAMP Ramp Option
16 ACT BLKSTA.B16 Active/Inactive (Sequence Blocks)
FTNI Feedforward Tune Inactive (PIDA, DPIDA)
REPT Repeat Option (RAMP)
LM1 Limit Switch 1 ON (GDEV)
15 ON BLKSTA.B17 Compound On
14 UDEF BLKSTA.B18 Undefined
13 BLKSTA.B19 Unused
12 BAD BLKSTA.B20 BAD I/O (I/O Blocks only)
11 MA BLKSTA.B21 MA Manual (false) or Auto (true)
10 LR BLKSTA.B22 LR Local (false) or Remote (true)
162
Appendix C. SSC Based I/A Series System B0700EE – Rev A
Preliminary
BADR Bad Redundant I/O (AINR, AOUTR)
0 MTN BLKSTA.B32 Manual Tune Mode (EXACT Tuning)
August 2, 2011
SEL Redundant I/O Selected (AINR)
163
B0700EE – Rev A Appendix C. SSC Based I/A Series System
Preliminary
August 2, 2011
164
Appendix D. Sizing
This appendix pertains to the I/A Series System sizing required to support the FoxBridge
software.
Required Information
For each Controller to share the same FoxBridge Host:
Preliminary
Object Manager Sizing
August 2, 2011
Import Table Sizing
The FoxBridge application uses one entry in the Import Table for each MV in the controller. The
import table should be sized to be that much larger than the value currently specified. The current
value can be seen by typing:
show_params
OM Object
The I/A Series software ships with the ability to create 1,250 Shared Variables or OM Objects.
Application Objects use the same type of resources as Shared Variables and since most DMCplus
applications require dozens of Application Objects each with a hundred or so attributes, one must
raise this limit. The normal maximum limit is 4,000, but is recommended that this number be
increased to at least 10,000 by the procedure below.
The FoxBridge software uses Application Objects for data storage holders for all DMCplus data.
The DMCplus Controller Reads and Writes only to these Application Objects which reside in
Object Manager Shared Memory on the FoxBridge Host AW. A separate application, Application
Object Services mapping, handles the communication between the Application Objects and the
Blocks in the Control Processor. Application Objects have a Compound:Block.Parameter format,
known as Application:Object.Attribute.
For each Controller, an Application (similar in function to a Compound) is created with the
Controller name. Each Tag in the Controller (CV, MV, FF, SB) is an Object (similar to a Block).
So, as far as the OM Number of Objects required for the Controller is one per Tag and
SubController plus one for the Controller Level Operation. For example, a 20 x 40 Controller
with 2 SubControllers will have 63 Objects associated with it.
Each Object, however, has a number of Attributes (similar to Parameters) associated with it,
typically about 100 or more, depending on the type of the Object. For example, a CV has all of it
Tuning and Future Predictions as Attributes. The Attribute names come from AspenTech's
165
B0700EE – Rev A Appendix D. Sizing
DMCplus Data Entry Dictionary, limited to six (6) characters. While each Attribute is not
considered an OM Object, it does consume OM resources in Shared Memory.
The maximum number of OM Objects can be increased from 4,000 to 20,000. This value affects
not only the number of OM Objects that can be created, but also the amount of Object Manager
shared memory reserved to store the objects. So, even though the Attributes required for the
FoxBridge application do not appear as objects, they do consume shared memory. If the AP or
AW is running the FoxBridge application, then this limit should be raised to 10,000 to ensure
that enough OM Shared Memory is available for the Application Objects and their Attributes.
Raising the limit past 10,000 is not necessarily recommended, but may be required if several large
controllers are to be configured.
Resizing the OM
Please refer to the Application Object Services User’s Guide, B0400BZ for Object Manager sizing
instructions. A copy of this document is included in the document folder on the FoxBridge for
Windows CD-ROM.
FoxAPI Sizing
Please refer to the Application Object Services User’s Guide, B0400BZ for FoxAPI sizing
Preliminary
instructions. A copy of this document is included in the document folder on the FoxBridge for
Windows CD-ROM.
August 2, 2011
166
Appendix E. File System
Organization
This appendix describes how the FoxBridge file system is organized.
The layout of the FoxBridge related files is as shown in Figure E-1 and Table E-1.
/opt
aos dmcplus
Preliminary
dmccv dmcmv dmcs
August 2, 2011
dmcff dmcop
167
B0700EE – Rev A Appendix E. File System Organization
Directories Description
dmcplus Files related to the FoxBridge product. These files include some provided
by AspenTech and some provided by Invensys Systems, Inc.
dmcplus/apps Files related to each of the specific instances of the DMCplus controller
running on the host computer.
aos Files related to the implementation of Application Object Services. See
Appendix A “Application Object Services” for details concerning
application objects.
data Directory
Preliminary
The data directory contains the data files required by the DMCplus controller executable and/or
the configuration programs and scripts.
August 2, 2011
Copies of these files must reside in the d:\opt\dmcplus\data directory are listed in Table E-2.
fvdd Directory
The fvdd directory contains the standard I/A Series Detail Displays and Overlays for the
FoxBridge Application Objects, i.e., the DMCOP, DMCCV, DMCFF, DMCMV and DMCSB
objects.
168
Appendix E. File System Organization B0700EE – Rev A
displibfv Directories
The files in the directory displibfv display elements (Table E-3) used to build the standard
Summary, Economics, and Tuning displays.
Table E-3. Elements for Building Summary, Economics, and Tuning Displays
Preliminary
ffSummary Information line used in the Economics display for DMCFFs.
mvCost Information line used in the Economics display for DMCMVs.
August 2, 2011
mvCostHdr Header for the DMCMV lines in the Economics display.
mvHeader Header for the DMCMV lines in the Summary display.
mvSummary Information line used in the Economics display for DMCMVs.
mvTune Information line used in the Tuning display for DMCMVs.
mvTuneHdr Header for the DMCMV lines in the Tuning display.
new_buttons
Summary_bttns Buttons used on the Summary Display
Summary_hdr Header for the Summary display.
Tune_bttns Buttons used for the Tuning display.
fvenv Directory
This directory contains the environment provided with the FoxBridge, DMCplus_Eng and
DMCplus_Opr. These files are copied to the d:/opt/fox/env directory during installation or the
creation of displays.
logs Directory
Each script is built to place a log file in the log directory whose name is the same as the scripts
name. These logs facilitate debugging of the FoxBridge product. Since the log file is rewritten
with each execution, it does not grow without bound.
The log file is rewritten with each execution. Since the previous file is overwritten, it does not take
up additional space.
169
B0700EE – Rev A Appendix E. File System Organization
Script Files
The following script files (Table E-4) are shipped with the FoxBridge product.
Preliminary
Open Loop.
Install.wp Installation script for non-host WPs and AWs.
August 2, 2011
MakeSVs Script to create shared variables for Trend and Description button
support.
MkColFileList Script to create a list of Data Collection files in
d:\opt\dmcplus\datacol and saves it to.col files.
MkColList Script to create a properly formatted Data Collection file
(<NAME>.pts) from a list of C:B.P’s.
MkMenusFV Script to create menu picks.
MkMapFile Script to create the Map file from the object templates.
MkMenus Script to Create Display Manager menu picks.
MkObjList Script used by ReconcileAOD to develop a list of required objects
from a CCF.
MkTuningConstants Script used to extract tuning information from a DMCplus 5.3 SIM
file and build a file to set the variables.
MkWP30DDs Script used to build WP30 formatted Detail Displays.
MkWP30Disps Script called by Configure to build WP30 formatted Summary
Displays. Calls MkWP30DDs.
NormalizeAOD Script to put an AOD file into a standard format.
ReconcileAOD Script to build the AOD file from the CCF file and/or reconcile the
AOD if changes have been made in the CCF file.
RemoveAOD Script called by ReconcileAOD to clean up the AOD file before
modifying it.
SaveTuning Script used to set the SIMSWC to save a SIM file and get
miscellaneous data such as Validity Limits.
SegmentAODForECO Script to Segment the AOD file for the Economics display support.
170
Appendix E. File System Organization B0700EE – Rev A
Preliminary
or other custom CCF parameters.
SetLimits Script called by MKTuningConstants to calculate engineering limits
based on the Operator and Validity limits.
August 2, 2011
SetupInits Read CCF File to set INIT values, CLPENB and ETENB
SetupRamps Read CCF to look for ramp CVs to set up RAMPVR parameter.
Also look for Intermitter Signal CVs such as Analyzers to set ISSIG
parameter.
SetupWatchdog Run by the startup to set up Watchdog Timers for the controllers and
perform other initialization functions.
StopCollect Script used to Stop Data Collection and reset Watchdog Timers.
Upgrade Script to upgrade FoxBridge Software. Rebuilds the Cim-IO logical
devices.
buildCLP Script to build the Composite LP (ETC) Display (DM)
buildCLPFV Script to build the Composite LP (ETC) Display (FV)
buildET Script to build the External Target (ETC) Display (DM)
BuildETFV Script to build the External Target (ETC) Display (FV)
buildETC Script to build the External Target/Composite LP (ETC) display
(DM)
buildETCFV Script to build the External Target/Composite LP (ETC) Display (FV)
buildEco Script to build the Economics Display (DM)
buildEcoFV Script to build the Economics Display (FV)
buildECOFVMV Script to build the Economics Display with MVs first (FV)
buildFVDisps Script to convert Display Manager Summary displays to format and
patch name and build Detail Displays with standard Trend elements
(50 Series stations only).
buildHist Script to add FoxBridge Application Object into the Historian for
Recent Trend History Support
171
B0700EE – Rev A Appendix E. File System Organization
Preliminary
buildWP30Sum Script to build the WP30 Summary Displays
check_state.sh Script used in startup to check the state of the Controller in Manage as
August 2, 2011
delete, exists, loaded, or running.
checkpoint.sh Script invoked to checkpoint Application Object into the Database.
dm_cvTrend Display Manager script to setup for CV Trend (50 Series stations only)
dm_dmcon Script used to toggle DMCON parameter and set Watchdog timer in a
proper state for I/A Series systems.
dm_mvTrend Display Manager script to setup for MV Trend (50 Series stations
only)
enable_MVs Script called from the DMCSB to enable MVs within a particular
subcontroller and to turn the subcontoller on. Used for adding
Subcontroller into already Closed Loop Controller.
go_DMCPLUS Script that can be used to start FoxAPI, create and map the Application
Objects and start the Controller.
init_collect Script that can be used to clear out the String variables of the
FoxBridge Host
packWP30Disps Used to run pdfpack on the WP30 disps.
runAppObjSrv Run from the Tools menu to invoke the AppObjSrv on the FoxBridge
Host
runConfigure Run from the Tools menu to invoke Configure on the FoxBridge Host
runExtract Run from the Tools menu to invoke Data Extract utility of the
FoxBridge Host.
runManage Run from the Tools menu to invoke the Manage utility on the
FoxBridge Host.
runShowLog Run from the DMCOP Detail Display to display the latest prt file in a
read only textedit window.
172
Appendix E. File System Organization B0700EE – Rev A
Work Areas
The files and subdirectories in d:\opt\dmcplus\app\<appname>\workAreas are created and
deleted as needed by the various configuration utilities. Nothing in this area requires user
maintenance. The contents of this directory vary according to the current operation of the
FoxBridge and its configurators. Nothing in it is relevant to the proper operation of the
FoxBridge,
Preliminary
The files and directories related to each configured DMCplus controller are stored in the
d:\opt\dmcplus\app directory.
August 2, 2011
The use of application specific directories allows the user to separate his configured controllers
from the FoxBridge product directories and should simplify the updating of the FoxBridge
product.
fvAppMenus Directory
The fvAppMenus directory contain a subdirectory for each configured DMCplus Controller, e.g.,
DMCPLUSD.
Application Menus
The d:\dmcplus\app\fvAppMenus directory contains a subdirectory for each configured
DMCplus controller, such as, DMCPDEMO. The files and directories contained in each control-
ler specific directory are described in Table E-5.
173
B0700EE – Rev A Appendix E. File System Organization
Preliminary
SUMMARY This I/A Series display manager script raises the first Summary display for this
controller, that is, /opt/dmcApps/<appName>/disp/<appName>.SUM0.
ET_CLP This I/A Series display manager script raises the first External Target and
August 2, 2011
Composite LP display for this controller, i.e.,
/opt/dmcplus/app/<appName>.ETCO
TUNING This I/A Series display manager script raises the first Tuning display for this
controller, that is, /opt/dmcApps/<appName>/disp/<appName>.TUN0.
ECONOM- This I/A Series display manager script raises the first Economics display for this
ICS controller, that is, /opt/dmcApps/<appName>/disp/<appName>.ECO0.
The subdirectories of AppMenus and the files that they contain are automatically generated
during the FoxBridge configuration process.
174
Appendix E. File System Organization B0700EE – Rev A
here by the user. Log files written by the Controller will be put in this directory. Files generate by
the Configure utility will be place in the data, disp, or dd directories.
data Directory
The files in the data directory are documented in Table E-7.
Preliminary
File Name Description
<appName>.aod Cross reference of DMC Tags to I/A Control Objects - Used
August 2, 2011
to build MAP file.
<appName>.map List of all Application objects and Attributes. Required by
Application object Services to build database and generate
objects.
<appName.hst Historical data list that can be added to the Historian using
cfgpts.
<app- Segmented AOD file for Subcontroller <NAME>.
Name>.aod.SUB.<NAME>.n
<appName>.aod.SUM.n Segmented AOD file for Summary display.
<appName>.aod.ECO.n Segmented AOD file for Economics display.
<appName>.aod.ETC.n Segmented AOD file for External Target and Composite LP
display.
<appName>.aod.TUN.n Segmented AOD file for Tuning display.
logs Directory
The logs directory is used to hold the logs generated during the use of the Application Object
Services configuration utility. They are stored here so that they may be reviewed later and so that
two instances of the configurator do not conflict.
175
B0700EE – Rev A Appendix E. File System Organization
datacol Directory
The datacol directory should be used to hold the files used by the collect utility and that program
should be run in this directory.
disp Directory
The disp directory contains the automatically generated Summary, Economics and Tuning
displays. There may be multiple displays of each type. The naming convention is:
<appName>.<type><index>
where
<appName> is the name of the controller,
<type> is SUM, ECO, TUN or SUB and
<index> is 0...n where n is the number of required pages of display.
For example, valid display names are:
DMCPDEMO.SUM0
DMCPDEMO.SUM1
DMCPDEMO.ECO0
Preliminary
August 2, 2011
176
Appendix F. Troubleshooting
This appendix provides troubleshooting techniques.
General
♦ To understand the I/A Series Supervisory Setpoint Control Mechanism.
Please read B0193RY, Supervisory Setpoint Control. This standard manual can be
obtained from the Customer Satisfaction Center, your Foxboro Representative, or the
FoxDOC CD-ROM.
♦ DMCplus and IP21, SMCA, Or Other CIM-IO application need to run on the
same AW.
If other CIM-IO based applications are on a system, not all of the required entries in
c:\windows\system32\drivers\etc\services will be made. Examine the file
d:\opt\dmcplus\data\CIMIO_SERVICES to see the entries that should be made.
Preliminary
Manage Program
August 2, 2011
The manage program commonly used on DMCplus software installations should not be used to:
♦ Load,
♦ Unload,
♦ Start,
♦ Autostart, or
♦ engage in activity that manipulates the controller.
The FoxBridge software provides all these functions in a carefully controlled environment. The
use of manage program can cause a controller to malfunction. In addition, it skips certain steps,
e.g., setting the Watchdog Timers, which are necessary for proper operation.
The manage program can be and should be used to examine controllers. It is quite useful as a
diagnostic tool.
If the Autostart function is specified, the FoxBridge will not work properly. To remove the
autostart flag, do the following:
♦ Start manage from a DOS Command window.
♦ Select option 5
♦ Select option 8
♦ Enter controller name at the following prompt:
Enter controller name, or 'quit' to stop []: T_411
♦ Turn off autostart by typing no to the following prompt:
Set controller T_411 to autostart? (Y/N) [N]:
177
B0700EE – Rev A Appendix F. Troubleshooting
FoxBridge
Summary Display Read Problems
Cannot read the Summary display because there are blue lines on the display. The blue lines
represent the location on the display that is used when the Object Descriptions are shown. The
lines are blue because the Application Objects used to support this function have not been cre-
ated.
Three files are involved in the creation of these Application Objects:
1. d:\opt\fox\customer\hi\dmcfg - which defines the FVs used on each WP/AW in
the control system
2. d:\opt\dmcplus\scripts\MakeSVs - which reads the DM Configuration file and
creates the script CreateSVs
3. d:\opt\dmcplus\scripts\CreateSVs - which actually creates the AOs required to
support this function.
The most common causes of the problem are:
1. MakeSVs was not run, e.g., the controller was started without using the provided
Preliminary
go_DMCplus script. This is the responsibility of the implementor. Normally, the
go_DMCplus script is used to start the DMCplus Controllers at bootup by placing a
August 2, 2011
line like: d:\opt\dmcplus\scripts\go_DMCplus <appName>. However, some
application engineers may wish to start the controllers using a different mechanism. If
so, the alternate approach must perform all of the functions implemented in
go_DMCplus.
2. The display manager configuration file does not contain a line for each and every
display manager in the system. This is the responsibility of the I/A Series Application
Engineer responsible for the system. Invensys recommends that the display manager
configuration file contain a record for all FoxView licenses in the system and that the
file be identical on all AWs/WPs in the system.
178
Appendix F. Troubleshooting B0700EE – Rev A
1. CCF file
2. MAP file
3. A Print File for a cycle in which the problem is observed.
4. A snapshot of a bad Message Display.
Verify the following:
1. In the CCF file, the .OMSG001 to .OMSG024 DMC tags are correctly mapped to the
AOAs as shown above and are CH(80) (80 character and ASCII). In DMCplus Build,
it is possible to change them from 80 character to larger and it is possible that some-
one may have done this.
2. In the MAP file, the DMCOP.MSG00 to DMCOP.MSG23 are 80 characters.
The likely source of the problem is the CCF file.
Operational Notes
Controller Will Not Start - DMCOP or dmcplus_state
The Controller will not start from DMCOP or dmcplus_state program returns 8, 9, 11, 16.
Preliminary
The log file d:\opt\dmcplus\app\<controllerName>/logs/startup contains the trace of the
startup process.
August 2, 2011
If the controller will not start examine this file and look for lines that read:
+ Check_State
Immediately below this line, the following should appear:
+ /opt/dmcplus/exe/dmcplus_state <controllerName>
state=3
If the state shown is not one of the following, there is a problem:
0 - Loading and Running New Controller
1 - Loading and Running Existing Controller
3 - Unloading, Loading, and Running controller
7 - Controller is Running
The state reported by dmcplus_state is actually a bit map of different conditions as shown in
Table F-1.
One possible error that the controller has been marked as AutoStart using the application manage.
In this case, Bit 3 is set. When this bit is set, the returned state will be 8, 9, 11, or 16.
179
B0700EE – Rev A Appendix F. Troubleshooting
Preliminary
Enter the controller name at the prompt that reads:
Enter controller name, or 'quit' to stop []:
Enter N to the question that reads:
August 2, 2011
Set controller DMCPLUSD to autostart? (Y/N) [N]:
Select sub-option 9 > DMCplus Main Menu... to return to the main menu.
Select Option 1 > List controllers to confirm that the A flag has been removed.
180
Appendix F. Troubleshooting B0700EE – Rev A
Preliminary
4. Use the DMCplus Manage Tool (manage) to check the controller status.
If a controller shows "STOPPED" on the DMCOP detail display, check the following:
August 2, 2011
1. In a NutCracker shell window, type manage list. If the controller engine is running
there will be an asterisk (*) to the left of the controller name.
2. If the controller is running, check the RI0001 on the WATCHDOG block to see if it
is "stuck" at 150 (actually, 2.5 times the value of CTLINT). If it is, this indicates a
problem either with AOS mapping or FoxAPI.
3. Make sure FoxAPI is still operating properly using foxtst.
To get out of this problem, first STOP the controller from DMCOP even though it already shows
stopped. Then try to stop and restart AOS mapping using the tool AppObjSrv. It may be necessary
to kill the aos map process manually if the AppObjSrv or AOSMAP scripts cannot stop it.
181
B0700EE – Rev A Appendix F. Troubleshooting
Preliminary
reset value for the controller's group is the correct value (2.5 times the controller period and usu-
ally 150s).
August 2, 2011
If the controller is running and trying to go to closed loop, the Timer column should be counting
down and the status should be Active.
The Enable/Disable column should be Enable.
182
Appendix F. Troubleshooting B0700EE – Rev A
Preliminary
the AOUT block will go into Hold until a computer setpoint from the DMCplus
Controller is received. If a computer setpoint is not received, then the AOUT block
August 2, 2011
will fall back into Manual mode after the configured timeout period.
183
B0700EE – Rev A Appendix F. Troubleshooting
Most FoxBridge functions initiated by display or menu picks are associated with a script located
in the d:\opt\dmcplus\scripts directory. All FoxBridge scripts write to a log file in either the
d:\opt\dmcplus\logs or the d:\opt\dmcplus\app\<APPNAME\logs directories.
Where <APPNAME> is the name of the Configured Controller.
Preliminary
DMCplus Controller and Collection Related Files
The DMCplus Controller and collection related files are defined in this section.
August 2, 2011
♦ DMCplus Executables (AspenTech):
d:\opt\dmcplus\bin
♦ Data Collection Files:
d:\opt\dmcplus\datacol
♦ Environment Variables file (read by all FoxBridge scripts):
d:\opt\dmcplus\data\ENV_VARIABLES
♦ DMCplus Validity Error file used by both Control and Collect (AspenTech):
♦ FoxBridge Environment Files for FoxView. (These files are copied to d:\opt\fox\env
during FoxBridge software installation.)
d:\opt\dmcplus\fvenv
♦ FoxBridge Summary Display Templates:
d:\opt\dmcplus\displib
♦ FoxBridge Detail Display Templates:
d:\opt\dmcplus\dd
♦ Sample Sequence Logic:
d:\opt\dmcplus\seqCode
184
Appendix F. Troubleshooting B0700EE – Rev A
Preliminary
♦ Application Object Services executables:
d:\opt\aos\exe
August 2, 2011
♦ Application Object Services data and environment files:
d:\opt\aos\data
♦ Application Object Services default logs directory:
d:\opt\aos\logs
CIM-IO
AOS CIM_IO Server with Multiple DMCplus Controllers
The AOS CIM-IO Server can support about 8 DMCplus Controllers.
NOTE
Once a box is running more controllers, various startup problems can occur. Error
messages indicating CIM-IO failure to connect or validate may appear in the
<LocalDrive>:\Program Files\AspenTech\CIM-IO\log\IMIO_MSG.log file.
185
B0700EE – Rev A Appendix F. Troubleshooting
Preliminary
CIMIOFOXIA1 3010/tcp #CIMIOFOXIA DLGP Task
CIMIOFOXIA1READ 3011/tcp #CIMIOFOXIA READ DIOP
August 2, 2011
CIMIOFOXIA1WRITE 3012/tcp #CIMIOFOXIA WRITE DIOP
CIMIOFOXIA1UNSOL 3013/tcp #CIMIOFOXIA UNSOLICITED
CIMIOFOXAO1 3015/tcp #CIMIOFOXAOS DLGP Task
CIMIOFOXAO1READ 3016/tce #CIMIOFOXAOS READ DIOP
CIMIOFOXAO1WRITE 3017/tcp #CIMIOFOXAOS WRITE DIOP
CIMIOFOXAO1UNSOL 3018/tcp #CIMIOFOXAOS UNSOLICITED
CIMIOFOXIA2 3020/tcp #CIMIOFOXIA2 DLGP Task
CIMIOFOXIA2READ 3021/tcp #CIMIOFOXIA2 READ DIOP
CIMIOFOXIA2WRITE 3022/tcp #CIMIOFOXIA2 WRITE DIOP
CIMIOFOXIA2UNSOL 3023/tcp #CIMIOFOXIA2 UNSOLICITED
CIMIOFOXAO2 3025/tcp #CIMIOFOXAO2 DLGP Task
CIMIOFOXAO2READ 3026/tcp #CIMIOFOXAO2 READ DIOP
CIMIOFOXAO2WRITE 3027/tcp #CIMIOFOXAO2 WRITE DIOP
CIMIOFOXAO2UNSOL 3028/tcp #CIMIOFOXAO2 UNSOLICITED
CIMIOFOXIA3 3030/tcp #CIMIOFOXIA3 DLGP Task
CIMIOFOXIA3READ 3031/tcp #CIMIOFOXIA3 READ DIOP
CIMIOFOXIA3WRITE 3032/tcp #CIMIOFOXIA3 WRITE DIOP
CIMIOFOXIA3UNSOL 3033/tcp #CIMIOFOXIA3 UNSOLICITED
CIMIOFOXAO3 3035/tcp #CIMIOFOXAO3 DLGP Task
CIMIOFOXAO3READ 3036/tcp #CIMIOFOXAO3 READ DIOP
CIMIOFOXAO3WRITE 3037/tcp #CIMIOFOXAO3 WRITE DIOP
CIMIOFOXAO3UNSOL 3038/tcp #CIMIOFOXAO3 UNSOLICITED
186
Appendix F. Troubleshooting B0700EE – Rev A
Table F-5. Configuration of Services File Required to Support CIMIOs on Multiple AWs
Data Source AW Entry in Services File
CIMIO Service Name Port/ Comment
Protocol
AW0001 CIMIOFOXIA1 3010/tcp #CIMIOFOXIA DLGP Task
AW0001 CIMIOFOXIAREAD 3011/tcp #CIMIOFOXIA READ DIOP
AW0001 CIMIOFOXIA1WRITE 3012/tcp #CIMIOFOXIAa WRITE DIOP
AW0001 CIMIOFOXIA1UNSOL 3013/tcp #CIMIOFOXIA UNSOLICITED
AW0001 CIMIOLOGGER 3014/tcp #CIMIO Logger
AW0001 CIMIOFOXAO1 3015/tcp #CIMIOFOXAOS DLGP Task
AW0001 CIMIOFOXAO1READ 3016/tcp #CIMIOFOXAOS READ DIOP
AW0001 CIMIOFOXAO1WRITE 3017/tcp #CIMIOFOXAOS WRITE DIOP
AW0001 CIMIOFOXAO1UNSOL 3018/tcp #CIMIOFOXAOS UNSOLICITED
AW0002 CIMIOFOXIA2 3020/tcp #CIMIOFOXIA2 DLGP Task
AW0002 CIMIOFOXIA2READ 3021/tcp #CIMIOFOXIA2 READ DIOP
AW0002 CIMIOFOXIA2WRITE 3022/tcp #CIMIOFOXIA2 WRITE DIOP
AW0002 CIMIOFOXIA2UNSOL 3023/tcp #CIMIOFOXIA2 UNSOLICITED
AW0002 CIMIOLOGGER 3024/tcp #CIMIO Logger
Preliminary
AW0002 CIMIOFOXAO2 3025/tcp #CIMIOFOXAO2 DLGP Task
AW0002 CIMIOFOXAO2READ 3026/tcp #CIMIOFOXAO2 READ DIOP
AW0002 CIMIOFOXAO2WRITE 3027/tcp #CIMIOFOXAO2 WRITE DIOP
August 2, 2011
AW0002 CIMIOFOXAO2UNSOL 3028/tcp #CIMIOFOXAO2 UNSOLICITED
AW0003 CIMIOFOXIA3 3030/tcp #CIMIOFOXIA3 DLGP Task
AW0003 CIMIOFOXIA3READ 3031/tcp #CIMIOFOXIA3 READ DIOP
AW0003 CIMIOFOXIA3WRITE 3032/tcp #CIMIOFOXIA3 WRITE DIOP
AW0003 CIMIOFOXIA3UNSOL 3033/tcp #CIMIOFOXIA3 UNSOLICITED
AW0003 CIMIOLOGGER 3034/tcp #CIMIO Logger
AW0003 CIMIOFOXAO3 3035/tcp #CIMIOFOXAO3 DLGP Task
AW0003 CIMIOFOXAO3READ 3036/tcp #CIMIOFOXAO3 READ DIOP
AW0003 CIMIOFOXAO3WRITE 3037/tcp #CIMIOFOXAO3 WRITE DIOP
AW0003 CIMIOFOXAO3UNSOL 3038/tcp #CIMIOFOXAO3 UNSOLICITED
4. Tell the DMCplus Controller host PC about those data sources by creating separate
FOXIA and FOXAOS entries for node in the cimio_logical_devices.def file. In this
file, you will specify the server names and hosts. Table F-6 provides an example
configuration of an example Multi-Source cimio_logical_devices.def file.
Table F-6. Configuration of an Example Multi-Source cimio_logical_devices.def file
LogicalDeviceName NodeName DLGPServiceName HistoryDLGPService-
Name
FOXIA1 AW0001 CIMIOFOXIA1
FOXAO1 AW0001 CIMIOFOXAOSI
FOXIA2 AW0002 CIMIOFOXIA2
FOXAO2 AW0002 CIMIOFOXAOS2
FOXIA3 AW0003 CIMIOFOXIA3
FOXAC3 AW0003 CIMIOFOXAOS3
187
B0700EE – Rev A Appendix F. Troubleshooting
NOTE
A FoxBridge license is required for each AW running CIMIO.
The port numbers shown above are generally acceptable, but the port numbers used
must be unique within the Services file and they need to match on both the AWs
and the host PCs.
FoxAPI Software
The Customer Satisfaction Center and/or Field Service should be consulted to determine the
latest available version of the FoxAPI software and that version should be applied.
Preliminary
The nocsaonread option should be set to 1. This will speed the data set opens.
The ctdlay setting should be 200 (2 seconds) to slow down the rate at which large numbers of
August 2, 2011
I/O points are opened. This is important since large numbers of points can temporarily overload
the CPs' communication buffers and cause them to not respond.
NOTE
The FoxBridge software does not work with FoxAPI software V5.x.
188
Appendix F. Troubleshooting B0700EE – Rev A
Scripts
All scripts record their operation in a log file whose name is the same as the script. The log files
can be found in following directories:
d:\opt\dmcplus\logs
d:\opt\dmcplus\app\<appName>\logs
d:\opt\aos\logs
Most script log files are found in the d:\opt\dmcplus\app\<APPNAME>\logs directory; where
<APPNAME> is the name of the controller.
All scripts read the Environment Variables set up the file d:\opt\dmcplus\data\ENV_VARIABLES.
It is important to note that these files are re-written with each execution. Thus, the log files do not
grow without bound. However, no history is preserved. A simple alteration of the scripts that
would support one level of history can easily be made.
The current scripts all contain the following lines of code at their beginning to setup their log file.
These lines resemble:
#!/bin/sh
LOGS=/opt/dmcplus/logs
Preliminary
...
exec >$LOGS/`basename $0` 2>&1
set -x
August 2, 2011
If a history file is desired, revise these lines to read as follows:
#!/bin/sh
LOGS=/opt/dmcplus/logs
...
LOG_FN=$LOGS/`basename $0`
cp $LOG_FN $LOG_FN.old
exec >$LOG_FN 2>&1
set -x
Common Problems
Problem:
The controller is built and started my controller, but the state is still STOPPED.
Solution:
Check the startup log file in the d:\opt\dmcplus\app\<APPNAME>\logs directory. Make
sure that the controller was able to load in manage. If not, make sure that the CCF was
created using the latest FoxAosWiz template (not the one provided on the DMCplus
CD-ROM). Use the manage utility under tools to try to manually load the CCF. Check
the d:\opt\dmcplus\etc\valid.err file for error messages.
189
B0700EE – Rev A Appendix F. Troubleshooting
Problem:
The MVs will not initialize when Go Closed Loop is selected.
Solution:
Check the following:
1. Check the DMCplus messages from the Messages button
2. Make sure that all I/A Series Blocks connected to MVs have the SUPOPT parameter
set to 1 or 2.
3. Make sure that the I/A Series Blocks connected to MVs are not in Hold or Track.
4. Check the Reset Timer RESVLn for the Supervisory Group n on all CPs that have
I/A Series blocks connected to MVs. It should be set to 2.5 times the Controller
Interval, for example, 150 for a 60 second controller. This is normally done when
starting the Controller, but if they are not correct, set them using the Control
Configurator.
5. Make sure there is no other Controller or OP compound using the same Supervisory
Group.
Preliminary
Problem:
The controller is built and the MV VIND values are all 0.
August 2, 2011
Solution:
Check the MV CBP configuration. Most likely the SUPOPT is not set to 1 (SPC) or 2
(DDC)
Problem:
When Closed Loop is attempted, the MVs go to Fallback state very quickly.
Solution:
Check the RESVL1-8 time in Station Block Control Stations that contain MVs. These
should be set to 2.5 times the Controller Cycle time (150 seconds for a 60 second
controller). Manually adjust these values if they are not correct.
Problem:
The FoxBridge application will not stay running and the Watchdog timer always expires.
Solution:
The way the watchdog timer works is as follows:
1. The DMCplus Controller sets the AOA called CNTDWN
2. The AOS software:
a. See the change (0 to 150 say) and
b. Copies the value from CNTDWN to the RI0001 parameter of the
WATCHDOG block in the <cntlrName>OP compound.
3. The WATCHDOG block sees the change from 0 to CNTDWN and does the
following:
190
Appendix F. Troubleshooting B0700EE – Rev A
Preliminary
3. WATCHDOG could be stopped (INACTIVE or in error).
4. Communication could be heavily loaded on the target CP (common on older pre-
CP60s; not common on CP60s; never seen (to date) on xCP270s).
August 2, 2011
The thing to do is:
1. In the Historian
a. Monitor <cntlrName>:DMCOP.CNTDWN - indicates CIMIO and
WATCHDOG are working (changes)
b. Monitor <cntlrName>OP:WATCHDOG:RI0001 - indicates AOS is working
(changes)
c. Monitor <cntlrName>OP:WATCHDOG:RI0002- indicates the block is running
(changes)
d. Monitor <cntlrName>OP:WATCHDOG:ACTIVE - indicates the block is
supposed to run (1)
e. Monitor <cntlrName>OP:WATCHDOG:MA - indicates the block is supposed to
run (1)
2. In FoxView, create a trend for these values
3. Watch the trend
Once this is setup, you will be able to determine what the problem is.
PCWS Software
Users of the PCWS product must adjust the TagWizard file supplied with the FoxBridge software
to mark the PCWS variables as LOCAL. The PCWS variables not marked as LOCAL will cause
various problems with the CIMIO interface linking the DMCplus Controller to the I/A Series
system. In particular, this issue has been noticed with PCWS plot high and low limits (BARIU,
BARIL, BARDU, & BARDL).
191
B0700EE – Rev A Appendix F. Troubleshooting
Preliminary
August 2, 2011
192
Index
.bin 30
.ccf 38
.clc 30
.cle 30
.ext 30
.mdl 38
A
Access Levels 55
ALLDemo Display 79
AOA xvi
AOD 4, 43, 44
AOD File 42
Preliminary
aod File xv
AOS xvi, 117
August 2, 2011
AOs xvi, 117
aos 118
Application xv
Application Definition xvi
Application Object Attribute xvi
Application Object Database 51, 128
Application Object Services xvi, 130
Application Object Templates 120
Application Objects xvi, 50, 118
AppObjSrv 1, 57, 130
AspenTech Software 14
AWSCOD 58
B
Build 4, 38, 39
C
CBP xvi
CCF 3, 21
Cimio Test API 23
cimio_logical_devices.def 22
CIMIOINFO 31
CIMIOLIST 31
Client Displays 18
Collect 27, 34, 37
Troubleshooting 37
collect 4, 7, 27, 34, 35
Collect File Types 29
193
B0700EE – Rev A Index
Collection File 30
Collection Input 30
CollectStatus 4, 28, 35
Composite Display 76
Composite LP Display 60
Composites Display 80
Configure Utility 41
Configure.bat 41
Control Station 52
Controlled Variables 71, 73
Controller 55
Startup 11
Controller Configuration File 38
Controller Model 21
Controller Names 7
Controller Object Names 7
Controller Preparation 27
Controller Summary Display 60, 63
Controller Tuning Display 73
ctdlay 10
Preliminary
D
August 2, 2011
Data Collection 27
Data Collection Display 69
Data Storage 117
Data Transfer 37
DDC Control 9
Demo
Compounds 19
Environment 19
Detail Display 45, 49
Detail Displays 84
displib 60
displibfv 108
DMCCV 3
DMCCV Detail Display 96
DMCFF 3
dmcfg 13, 25
DMCMV 3, 120
DMCOP 3, 84
DMCOP Faceplate 87
DMCOP Summary Data 87
DMCPDEMO 28, 30
DMCplus Collect Columns 36
DMCplus Collect Procedure 28
DMCplus Connect 1
DMCplus Controller shutdown procedure 107
DMCplus Demo Displays 69, 70
DMCplusCollect 28, 35
DMCPLUSD 28, 30, 53
DMCSB 3
194
Index B0700EE – Rev A
E
Economics Display 47
Economics Summary Display 60
Environments 55
EOFCHOICE 31
Eternal Target Display 76
External Target Display 60
Extract 36
extract 4, 27, 29, 36
F
Fallback 53
Fallback Blocks 49
Preliminary
fastest_rsr 10, 37
Feed-Forward Variable 66
Feed-Forward Variables 66
August 2, 2011
File Transfer 39
FOXAOS 23
foxaos.tcc 38
FoxAosWiz.tcc 38
FoxAPI 10, 50
Configuration 10
foxapi.cfg 10, 11, 13
Foxboro Tag Wizard 1
FoxBridge Demos 19
G
go_ 108
go_DMC.ksh 57
go_DMCplus 56, 57, 108
go_DMCplus.ksh 57
H
Historian Configuration 48
Historical Trend 104
Hosts 22
I
IDLINEA 31
Input File
.cle 37
Install
195
B0700EE – Rev A Index
AOS 16
FoxBridge 17
SQL 15
Installation 13
Installation Commands 18
L
Limitations 8
logical name xvii
global xvi
local xvii
LOOPST 58, 59
M
Manipulated Variable 64
Manipulated Variables 64, 72, 74
map file xvii, 125
Map Files 125
Preliminary
Mapping 57
mapping xvii
August 2, 2011
Mappings 129
MASTERWDT 53
maxobj 10
MAXSAMP 31
MDL 38
MkColList 28, 32, 33
MkLoadAll.bat 17
MkMapFile xv
Model 7, 21
Modeling 38
N
Naming Conventions
Controller 7
Controller Object 7
Variables 7
NOMSGS 31
NUMSAMPTAG 31
O
Object Manager xvii
Object Names 7
Object Template xvii
OFFSET 31
OM Object 165
OM Objects 9
OM_NUM_OBJECTS 9
Operation 4
196
Index B0700EE – Rev A
Operator Displays 60
opsys_usr.cfg 10
OM_NUM_OBJECTS 10
R
reconfig_IA prep_reboot 10
Remote Controller 21
RemoteCtlr 25
Resizing 9
RRATE 34
S
SAMPLEPER 31
Scripts 130, 189
services File 22
setpars 19
Shared Variables 9
shared variables 117
Preliminary
show_params 10
Sizing
OM 10
August 2, 2011
SSC 53
SSC Blocks 49
Standard Display 46
start_ 108
startup 108
STATUSTAG 32
Subcontroller Summary Displays 48, 60
SubControllers Display 75
Summary Display 44, 47
Summary Displays 60
Summary of SubControllers Display 75
System Loading 37
T
Table Sizing 165
Tag Wizard 38
Tuning Display 47, 60
U
user_apps.dat 108
user_rules.cfg 10
OM_NUM_IMPORT_VARS 10
OM_NUM_OBJECTS 10
V
Vectorization 27
197
B0700EE – Rev A Index
VERSIONNUM 31
W
Watchdog Timers 53
WATCHDOGTAG 31
Preliminary
August 2, 2011
198
Preliminary
August 2, 2011
199
B0700EE – Rev A
Index
Preliminary
August 2, 2011
Invensys Operations Management
5601 Granite Parkway Suite 1000
Plano, TX 75024
United States of America
http://www.iom.invensys.com