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Getting Started with ControlWave Designer

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1. the function block being called a Initial value Ey variable The reason is that the ae function block is referred to in the program by an instance name which Description A Lead Lag smooths out fluctuations in the is like a variable name The instance input value name allows the program to distinguish between different lt Show all variables of worksheets Getting Started with ControlWave Designer 32 Example Creating A Simple Project instances of the same type of function block for example if you had two different LEAD_LAG function blocks in the same POU You can optionally enter a name of your choice for the function block or just use the default You can also enter a comment in the Description field as we have done Now click on the OK push button A graphical representation of the LEAD_LAG function block will be displayed on the screen Each parameter name for the function blocks in the ACCOL3 library begins with two or more lowercase letters These lowercase letters which we will call the prefix identify whether the parameter is an input an output or both an input and output followed by the possible data types for the parameter LEAC LAG 1 n Ll he identifier for The type of Input orOutput this function block variable irDerivative is LEAD LAG1 precedes the parameter name irIntegral ibFkeset The first letter is alwa
2. the prefix letters for the parameter name r REAL b BOOL Getting Started with ControlWave Designer 36 Example Creating A Simple Project NOTE You ll notice that you have the option of defining the new variable as either Local or Global If the Local Global options are grayed out de select the Show all variables of worksheets button to access them As we noted before Local variables are only accessible within this POU If you define a variable as a local variable and you create another POU you will NOT be able to access the local variables in the first POU they are completely unknown to the second POU If you define a variable as global it is accessible in the current POU and in any other POUs you define for this project This distinction isn t too important for this particular example however it is discussed in detail in the ControlWave Designer Programmer s Handbook document D5125 We recommend however that if you are NOT defining an I O variable for an I O board that you choose Local Alternatively if you do choose Global make sure you choose the Default variable group or some other variable group you have defined Do NOT choose the TO_GLOBAL_VARIABLES group for any non I O variables Choose the proper Data type in this case REAL and enter an Initial value if desired In this case the initial value is the default value of 0 0 some of the other variable
3. C Documents and Settings 4ll Users Application Data Bristol Controhave Now that we have our I O configuration completed 3 Libraries we can create a program which uses the I O we have r e CI Data Types defined 3 8 Physical Har Insert 95 Program gal Control r SS Function To start locate the Logical POUS object in the vee ere S Function Block Project Tree Right click on it and choose ee Insert gt Program from the pop up menu Properties POU stands for Program Organizational Unit it basically means a program or sub program in an IEC 61131 language IEC 61131 supports five different programming languages this example uses FBD Function Block Diagram language however you can choose any of the five languages when you create your own programs Creating A Program The Insert dialog box opens Insert Enter a name Hame for the e program Flow _ControlProgram Type Language Program CL Choose Function s Program Function Block Sa L For this example we choose FBD Choose lt independent gt hoose lt independents gt PLE type Processor type independent gt lt independent gt wt For this example choose Program for the type and FBD for the Language Enter a name for the program we are defining In this case we have decided on the name Flow_Control_Program The PLC type should be lt indep
4. They will all appear in RED This option is only available on certain boards When checked it will create a variable which allows you to turn OFF the I O board s diagnostic LEDs to save on power LEDs are turned OFF when the variable is set ON NOTE For this to work the LED enable jumper on the board must be in position 2 3 otherwise the software cannot disable the LEDs only a hardware jumper can See manual Cl ControlWaveMICRO for details When set to ON allows the number of counts to be reset This occurs automatically whenever the board is restarted NOTE This function only applies when a CX X_DI16 board is used as a low speed counter When checked counters on the board will NOT be initialized to zero on a warm start of the unit NOTE This function only applies when a CX X_DI16 board is used as a low speed counter When selected will cause a variable to be created to store the timestamp of the last sample collected by this I O board NOTE This function only applies when a CX X_DI16 board is used as a low speed counter When all pins have been configured click on Done You can then proceed to select and configure pins for another board Getting Started with ControlWave Designer IS Configuring I O High Speed Counter HSC Boards Configure List of Available High Speed Counter Channels List of Available Channels Channel Name Done H SCl2 2 1 CHANNEL 2 Channel Properties Add Board CHANNEL 3 Statu
5. irDeriy ative ir Setpoint orError 4 O000000E 001 O 0000000E 000 VOOS irIntegral irOeadband b 9999999E 001 voia O OO00000E 000 WOO ibReset irProportion 2 WOOQ000E 000 wood irIntegral c OO00000E 001 WO10 Derivative 0 d g0 00E 000 A WOil IrReset 0 OO00000E 000 WOle ibTrack Step 9 Save Your Project You can now exit Debug Mode if you haven t already by clicking on Online gt Debug again and save your project To save the project click on File gt Save Project As Zip Project As and specify a path and filename for the project Beginning with OpenBSI 5 8 you can include spaces in the path and filename Prior to that they were prohibited If you save the project as is 1 e uncompressed it will have a file extension of Mwt and will also have a sub directory of files associated with it with the same name as the project If you choose to zip the project i e compress it 1t will have a file extension of Zwt NOTE If you intend to copy the project to a different location or a different PC it is strongly recommended you zip the project first to ensure that all files are copied NOTE If you are using the Variable Extension Wizard see the ControlWave Designer Programmer s Handbook D5125 and you rename your project File gt Save Project As Zip Project As you must re run the Variable Extension Wizard and save your initialization files again NOT
6. 1 is the next highest priority and so on NOTE If you chose DEFAULT as the task name the task will NOT execute according to an interval but instead will be executed whenever time is available It serves as the idle task When finished click on OK and the task will have been defined Now that the task exists however it is necessary to associate the program that we wrote with the task Otherwise we will just have an empty task executing To associate the program with the task right click on the icon for the task in the project tree and choose Insert and Program instance from the pop up menu E E Flow_Lontrol_Program H a Physical Hardware B Controtave IPC_40 ATULRESOURCE Controlw ave a Tasks i5 na wener Insert Description worksheet I0_Configuration Delete Delete Task ko Cut Ctrl Program instance EF Copy Ctrl c E The Insert dialog box opens Choose Program instance as the Type First choose Progra Instance Insert Program instance Type Then assign a J unique name here Program type GG Program type shoul N Flow _Control_Frogram a Programm instance be the type of program you defined In this case Flow_Control_ Program Click OK when you finish When we insert the program we are actually creating something called a program instance Each program instance must be assigned a unique name in this
7. 2 Watch 3 Watch 4 If there are errors or warnings click on the Errors or Warnings tab for more information Creating data templates Processing code Processing data Creating ask D are Creating initialir tior code af 0 Errorisi A rningia s Message Window ta Y EO Build Errors Warning Infos PLC Errors Print If there are errors or warnings generated during the compilation you can view them by clicking on the Errors or Warnings tabs respectively Often you can double click on the error listed in the error window and the compiler identifies its location in the project MEX Illegal data type of b Allow Docking Double click on the 4 a Right click on the error message to error and choose jump to the location Clear Help on Message in the file where the Copy all to clipboard from the pop up compiler detects the menu to view more E 30 fo error information about the error error Help on Message E a Message Build h Errors A Warnings j Infos FLE Errors Frint For more information about what a particular error message means right click on the error message then choose Help on Message from the pop up menu if it is available 45 Getting Started with ControlWave Designer Example Creating A Simple Project Step 8 Download the program into your ControlWave unit or the I O Simulator WARNING Users should never attempt to dow
8. Automation Solutions RAS division of Emerson Process Management shall not be liable for technical or editorial errors in this manual or omissions from this manual RAS MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND IN NO EVENT SHALL RAS BE LIABLE FOR ANY INCIDENTAL PUNITIVE SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PRODUCTION LOSS OF PROFITS LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL FUEL AND POWER AND CLAIMS OF THIRD PARTIES Bristol Inc Bristol Babcock Ltd Bristol Canada BBI SA de CV and the Flow Computer Division are wholly owned subsidiaries of Emerson Electric Co doing business as Remote Automation Solutions RAS a division of Emerson Process Management FloBoss ROCLINK Bristol Bristol Babcock ControlWave TeleFlow and Helicoid are trademarks of RAS AMS PlantWeb and the PlantWeb logo are marks of Emerson Electric Co The Emerson logo is a trademark and service mark of the Emerson Electric Co All other trademarks are property of their respective owners The contents of this publication are presented for informational purposes only While every effort has been made to ensure informational accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein
9. PIM PIM PIM PIM Fin Used You can change the pin name here ControlWave Designer uses the name you enter here to reference the pin in the rest of the program Configure List of Available Analog Pins Pin Name F101_INPUT Done Fin Properties m Add Board Status erm 0000000 Add Last Operati Span 500 000000 m ea Add Overrange Status Mark All Pins J Used lick on Done when you finish When finished click on Done to return to page 3 of the I O Configuration Wizard then click on lt lt Back lt lt to return to page Step 2 of 3 and add another board 27 Getting Started with ControlWave Designer Example Creating A Simple Project Now define an Analog Output board Repeat the same general process used to create the Analog Input board Be sure you use a different I O slot number for the Analog Output board and be sure you specify a unique pin name for the analog output and set its zero and span The figure below shows the pin definition for the analog output We have set a zero and span of 0 and 100 respectively this range covers the percentage at which the control valve is to be opened ou can change the pin name here ControlWave Designer uses the name you enter here to reference the pin in the rest of the program Configure List of Available Analog Pins List of Available Pins Double click ae on the pin aia F101 OUTPUT Done name to PIN 2 activate it PIN
10. Project Go Pous EN Libraries FEY Hardw PI Settings Getting Started with ControlWave Designer 46 Example Creating A Simple Project The Resource Settings dialog box opens If you will initially be downloading into the I O Simulator choose Simulation 1 If instead you will be downloading directly into a ControlWave controller choose DLL and use the DLL list box to choose the DLL which will provide your desired type of connection OpenBSI connection serial connection or TCP IP connection Click on OK when you have made your choices Resource settings for IPC_40 Fort COM O COMe2 COM3 Data area CO COM4 Cancel Simulation 1 Help Either choose the DLL Simulation 2 OpenBSI Serial or _ Stack check on PLC Array boundary check An PLE DL Force BUOLS for byolean variables TCP IP which provides a connection to the ControlWave or choose the simulation Generate bootprzject during compile I O Simulator All globahyariables All global variables Marked variables Marked variables Use reserve AIPOUs O Marked POUs No reserve NOTE For purposes of this example we will use the I O Simulator 47 Getting Started with ControlWave Designer Example Creating A Simple Project Next click as follows Online gt Project Control The I O Simulator opens If necessary minimize the I O Simulator in order to uncover the RTU Resource dialog bo
11. Stamp of Last When selected will cause a variable to be created to store the Sample timestamp of the last sample collected by this I O board Mark All Pins Used When checked will activate all channels on this I O board They will all appear in RED Set No Init Counter Flag When checked counters on the board will NOT be initialized to zero on a warm start of the unit Requires 04 41 or newer firmware Turn off Leds Not Shown This option is only available on certain boards When checked it will create a variable which allows you to turn OFF the I O board s diagnostic LEDs to save on power LEDs are turned OFF when the variable is set ON NOTE For this to work the LED enable jumper on the board must be in position 2 3 otherwise the software cannot disable the LEDs only a hardware jumper can See manual CI ControlWaveMICRO for details Remote I O Status Board Remote I O Status Board The Remote I O Status Board is a virtual board i e there is no actual physical board By including it within your ControlWave project global variables will be created to store communication statistics information and board ID strings for the ControlWave I O Expansion Rack Board Statistics Board ID Strings For more information about these variables and the software configuration for the ControlWave I O Expansion Rack please see the ControlWave I O Expansion Rack Quick Setup Guide document D5122 Getting Started with Contro
12. a single resource VO Configuration Wizard Step of 3 Select List of Boards Sed First choose E low E Selected Boards List the type of ya ae wate Next select the ControlWave ee board you want to series MEER use from the list of controller you i Eeen boards for that are configuring li el controller type in the Unit i J Type list box i REMOVE Then click on Add to add the board to the Selected Boards List Finally click on Next Q Board Selected 8 or 16 Analog Input Board Finish Cancel Variable Hames 25 Getting Started with ControlWave Designer Example Creating A Simple Project Our particular project will require two different process I O boards An analog input board 1s needed to handle the analog input which provides the flow data An analog output board is also needed to send control data out to the valve We will describe in detail how to define the analog input board once it is done the analog output board should be defined by the same basic approach First choose the type of ControlWave controller you are using in the Unit Type field CW ControlWave LP_ ControlWaveLP CWM ControlWave MICRO CXX_ CW10 or CW30 Choose the analog input board used in your unit then click on ADD Then click on Next gt gt On the third page click on the board in the Selected Boards List and its par
13. dialog box opens Getting Started with ControlWave Designer 42 Example Creating A Simple Project Enter a Name for the task In this case we have chosen Task1 If you enter DEFAULT for the name the task will run whenever time is available this is sometimes referred to as the idle task In general CYCLIC should be chosen for the Task type Click on OK when finished Enter a name for the task Insert Hame Task type Cle Choose Cyclic for the task inally click OK Type Task Help The Task Settings dialog box opens Choose the rate of execution of the task by entering a value in the Interval field The interval is measured in milliseconds Generally Watchdog Time is set to the same value as the Interval A Watchdog condition is reported if the task does not execute within the watchdog time This allows task slippage to be detected In a cyclic task the interval between executions is measured in milliseconds Task settings for IPC_40 Interval Priority Watchdog Time Stack Small Medium Lange O Large 0 is the highest priority 1 is the next highest etc Help Options Save FFU _ Mo Suspend 43 Getting Started with ControlWave Designer Example Creating A Simple Project If desired specify a Priority for the task 0 is considered the highest priority
14. group from the tree and clicked on the Global button So now we have defined data types for all of our variables entered initial values where necessary etc 4 Getting Started with ControlWave Designer Example Creating A Simple Project LEAD LAG 1 PIDSTERM 1 ain ay it ir Input or lutput ir Input irerivative irSetooint OorError irIntegral irOeadband ibReset irProportion irIntegral irDeriv ative irReset ib Track Our program POU is done In order to make it do anything however it has to be associated with a task Step 6 Create A Task Which Can Run The Program Tasks determine how fast a program or program s are executed When a task is started it reads all inputs from the input process I O boards it then performs all calculations in the programs of a task and then it writes output data out through the output process I O boards Tasks are found below the Physical Hardware branch of the Project Tree To create a task right click on the Tasks icon in the project tree and choose Insert and Task from the pop up menu Sy Logical POs Flow Control Prograrn i Flow Control Prograrnt Flow Control Program oy Flow Control Program Physical Hardware Sa ControMave IPC_40 ight click on Tasks and choose Insert gt Task Contro ave Insert Task IO Cc Fe j Expand All The Insert
15. loved w INPUT BOO variable or constant o ddi INPUT DINT variable or constant ew nee O i nr REAL variable or const Fi INPUT PUNT variable or constam das INPUT USINT variable or constant ob OUTPUT BOOL variable or constant Getting Started with ControlWave Designer 34 Example Creating A Simple Project Click on the dot feeding into the irInput parameter of the LEAD_LAG function block then go to the menu bar and click as follows Objects gt Variable Alternatively you could just double click on the dot The Variable Properties dialog box opens A default variable name of VOO1 appears as well However the LEAD _LAG function block must receive its input from the F101_INPUT pin on the Analog Input process I O board defined earlier in Step 4 that is the variable we want Variable Properties Name YOO w Data Type REAL w Usage VAR v RETAN Initial value r0 address Description jroo orc x Cancel Definition scope Local Vanable Groups Goel Global Vanable Groupes o a Physical Hardware B a ControMvave 2 ATU_RESOURCE 5 Default me f0 _GLOBAL WARIA lt I Show all variables of worksheets In the Global Variable Groups section of the dialog box click on the signs to expand the folder tree Continue this until you have highlighted the IO_GLOBAL_VARIABLES item We want to highlight this item because it will contain the I O varia
16. see previous examples of this process on pages 35 to 37 Don t forget to choose the correct data type in this case REAL or BOOL and for the input variables assign appropriate initial values for this example The table below shows the correct data types and some recommended initial values for this example PID3TERM Parameter Data Type Initial Value for this example Name TrDeadband REAL 0 Derivative REAL 0 oo Reset REAL S YOO Variable Properties Mame Definition scope F101 OUTPUT w Local C Global Data Type Local Variable Groups Usage Global Variable Groupe Z RETAIN H Physical Hardware Choose F101_OUTPUT which Initial value B a Controwave S A ATU_RESOURCE is the name of PIN1 on the Default I O address 0 GLOBAL VARIA analog output board 0138 E SYS YAR WZ DA Description PoD oPC C Show all variables of worksheets That just leaves the orOutput parameter of the PID3TERM Remember that we need to feed the output of the PID controller out to the analog output process I O board so it can actuate the flow control valve thereby controlling the flow in the pipeline We defined the output pin for this purpose to be F101_OUTPUT we can reference that now Double click on the orOutput and choose F101_OUTPUT from the Name field in the Variable Properties dialog box Remember that to do this you have chosen the IO_GLOBAL_VARIABLES
17. suffixes can be altered by the user if desired The different pages of the Global Output Variables Names dialog box are accessible by clicking on the tabs Make changes on the various pages then click on OK to save all the changes Global Output Variables Names LO Pin Mapping Remote Local Boards Analog Input Analog Output Digital 1 0 High Speed Counters Update Default Value Hold Last Output PHOLDLO UCO LUCOFLG UCD UCD MAL Actual Output Value PACTUAL Cancel 23 Getting Started with ControlWave Designer Example Creating A Simple Project NOTE This example shows one possible way to approach a problem There are many different solutions available The fictitious Sunken Valley Water Company wants to set up a PID proportional integral derivative loop for controlling the flow of liquid through a pipeline They have a flow control valve to vary the flow FIC and a flowmeter to measure it 107 Both the valve and flowmeter are connected to a ge ControlWave controller i 101 a 3 FCVIO Before trying to create a project which will perform the PID control we need to make a list of each thing the project will be doing e Bring in the flow data from the pipeline The flow in the pipeline is measured by the flowmeter FT101 The flow rate ranges from O to 500 gallons per minute This data will come in through an analog input process I O board e Slow down reaction to fl
18. worksheet should never be manually edited by the user these should only be modified through the IO Configuration Wizard Z Getting Started with ControlWave Designer Configuring I O I O Configuration Wizard Step 1 of 3 Most users can skip to Step 2 The first page of the I O Configuration Wizard allows the user to select from the available I O configurations and I O resources NOTE Because most projects utilize a single configuration and resource this page is skipped when first starting the I O Configuration Wizard It is accessible however by clicking on the lt lt Back lt lt button from the second page of the Wizard WO Configuration Wizard Step 1 of 3 Select I 0 Section and Re fa O f Ayvallable Configurations Available Resources gt gt Next gt gt Finish Cancel Varnable Hames Available This lists all configurations in the current project Select the I O Configurations Configuration Section for which you are defining the I O NOTE Typically projects utilize a single I O configuration section Available Resources This lists all resources for the selected I O configuration Choose the resource for which I O is to be defined NOTE Typically projects utilize a single resource Click on Next gt to proceed to the next step Getting Started with ControlWave Designer 8 Configuring I O I O Configuration Wizard Step 2 of 3 The second page of the I O Configuration Wizard allows the use
19. E If after unzipping a project you try to save it and you encounter a message Cannot copy file file_path filename TXT Command aborted go in Windows Explorer to the path and filename listed and delete the named file s Then try to save the project again If a similar message appears repeat this process as necessary You will then be able to successfully save the project 5 Getting Started with ControlWave Designer Getting Started with ControlWave Designer User Manual D5085 May 2010 Emerson Process Management Remote Automation Solutions 1100 Buckingham Street Watertown CT 06795 Phone 1 860 945 2262 Fax 1 860 945 2525 www EmersonProcess com Remote Emerson Process Management Remote Automation Solutions 6338 Viscount Rd Mississauga Ont L4V 1H3 Canada Phone 905 362 0880 Fax 905 362 0882 www EmersonProcess com Remote Emerson Process Management SA de CV Calle 10 145 Col San Pedro de los Pinos 01180 Mexico D F Mexico T 52 55 5809 5300 F 52 55 2614 8663 www EmersonProcess com Remote Emerson Process Management Ltd Remote Automation Solutions Blackpole Road Worcester WR3 8YB United Kingdom Phone 44 1905 856950 Fax 44 1905 856969 www EmersonProcess com Remote Emerson Process Management AP Pte Ltd Remote Automation Solutions Division 1 Pandan Crescent Singapore 128461 Phone 65 6770 8584 Fax 65 6891 7841 www EmersonProcess com Remote NOTICE Remote
20. GV described above This is recommended because prior to OpenBSI Version 4 1 tools such as DataView only recognized the first 20 characters and so that is the only portion of the variable name those tools will display Newer versions recognize up to 64 characters e If you decide to use longer variable names up to 128 characters are allowed only the first 30 characters will be recognized within ControlWave Designer If you have variables in your ControlWave POU worksheet with more than 30 characters however make sure there are no two variables in which the first 30 characters are the same or else those two variables will be treated as the same variable For example two variables named COMPRESSOR_STATION_FOUR_STATUS_ON and COMPRESSOR_STATION FOUR_STATUS_OFF should not be included in the same worksheet because the first 30 characters COMPRESSOR_STATION_FOUR_STATUS are the same and therefore the difference between the _ON and _OFF would not be recognized by the compiler Here are some legal variable names COMPRESSOR_4 STATUS _PUMP_START tank_level_hi_alarm Here are some ILLEGAL variable names and the reason they are illegal 1_ STATION4 MAINSWITCH illegal because it starts with a number PUMP 4_START illegal because the character is NOT allowed 29 Getting Started with ControlWave Designer Example Creating A Simple Project Step 5 Create A Program Which Implements Your Control Strategy 3 43 Project
21. Make the most effective use of our hardware and software e Know your system As you know a well trained staff is essential to your operation Emerson offers a full schedule of classes conducted by full time professional instructors Classes are offered throughout the year at various locations By participating in our training your personnel can learn how to install calibrate configure program and maintain your Emerson products and realize the full potential of your system For information or to enroll in any class go to http www EmersonProcess com Remote and click on Educational Services or contact our training department in Watertown at 860 945 2200 Table of Contents Drome a Te A ONNE E unanenenaians l S O E a amet een aeeeT tot Tree eeEn at Peitert ne il perpen ree ehens Prt ent Ranert nee nT mt 3 A i csravincs crema test ceiramiy E EER 3 Oe areca researc EES 7 I O Configuration Wizard Step 1 of 3 Most users can skip to Step 2 eeeeeeeeeeees 3 I O Configuration Wizard Step 2 OEM scivnicisteccteinrnssinrenteerrsisrentementarnarenenaseie 9 TOU Con ornon a e be ite ke E a S 11 Pampo Lro aune A 0 iee A EEEE NEE 24 Sol Sa COAN ae Desane rriro anaE E AN EEE EE 2a e ee eens tates eters teenie enti Aa Step 3 Start the I O Configuration Wizard ossessseeessssssssseeeesssssssscererssssssseeeresssssseees 23 Step 4 Define Process I O boards snosssssoeenssssssssseeersssssssscerrsssssssscerressssssseeerr
22. Programs Programs are essentially groups of functions and function blocks which have been logically connected together to perform some task Programs are the only type of POU which can actually be executed Users can create more than one program in a project and in fact they can create multiple instances of the same program Programs can contain persistent memory There are two types of libraries Firmware libraries are libraries of functions and function blocks created specifically for this controller model The ACCOL3 library is a firmware library containing functions and function blocks created specifically for the ControlWave series of controllers It is automatically loaded when you choose the Control Wave Template in the New Project dialog box User libraries are optionally created by the user They are libraries of programs functions and function blocks called in from other previously saved projects The Data Type worksheets can be used to define customized data type structures For example arrays of numbers NOTE The data entered here 5 Getting Started with ControlWave Starting ControlWave Designer Opening A Project only defines the data type it doesn t actually set aside memory for storing the data that occurs in a variable declaration Physical Hardware Physical hardware defines details of the actual controller which will execute the project It is divided into several sections RTU_CFG is the type of code genera
23. Server or by the OpenBSI Signal Extractor This is necessary when data is to be extracted and sent to a database When edits have been made to this page click on the Show xxx Information button The name on this button and the pin configuration details vary depending on the type of board being configured See the pages that follow for the standard board types NOTE If you are using RIO Open Modbus board types please see the I O Configurator section of the ControlWave Designer Programmer s Handbook document D5125 Getting Started with ControlWave Designer 12 Analog Boards Configuring I O Configure List of Available Analog Pins List of Available Pins Pin Mame Ale 11 Done Pin Properties Add Board Status ZETO 0 000000 Calibration Error apan 100 000000 Board Add Overrange Status Jamie a Mark All Ping Range Type WOLTS Used Bottom Range 1 000000 Top Range F 000000 Analog Input Board Page CWM_AIS8 board some of these fields do NOT appear for other models Pin Used Configure List of Available Analog Pins List of Available Ping Pin Name A811 Done Pin Properties Value 0000000 E ee Zero 0000000 EIEN Span fono gis Add Overrange Status Set Actual Qutput Value iw Configure Hold Values Mark All Pins E Used Update Default Value Hold Last Output User Configured Output Pin Used Analog Output Board Page CW_AO8 board some of these fie
24. User Manual Document D5085 Part D301416X012 May 2010 CCorntrolWave Designer Getting Started with ControlWave Designer ControlWave Designer my_simple Flow_Control_Program F low_Control_Program TF File Edit view Project Build Objects Layout Online Extras Window F DEH Ta ef AMAR DIES EDD Bl if SO Fi a mannan z EEEE QBln 80 23 i701 he i Project Tree Window A x x S E Project C 0penBS projects mny_ simple Libraries fea PROCONOS LEAD LAG 1 PIDSTERM 1 tea ACCOLS LEAD IAG i IDSTERM Eg Data Types rInput or Sutput irInput My_DATA_TYPES irDerivative irSet point Sys VAR Wee TYPES Sy Logical POUs I Sel Flow Control Prograrn li Flow Control Program irIntegral Flow _ Control Prograrny ree re a Flow Control Program E a Physical Hardware 3 ControMave IPC_40 3 RATU_RESOURCE Controt Sa Tasks Seal Task CYCLIC ALARM_ANALOG_1 o Flow Flow Cor eee 5 Global Variables l0_Configuratior ia4larnvar ouislarmSeq at gt ea A E h Be Fioscorea Tephi Ee 256 irIntegral irDeadband ibReset irProportian irk eset ibTrack ibDisable odiStatus For Help press F1 Remote Automation Solutions E M E RSO N www EmersonProcess com Remote IMPORTANT READ INSTRUCTIONS BEFORE STARTING Be sure that these instructions are carefully read and understood before any operation is attempted Improper use of this device in some application
25. allation option on the OpenBSI CD ROM e To use counters DI you must enable counters in the Remote I O Toolkit software e The IP address entered for a ControlWave Remote Ethernet I O board in the ControlWave Designer I O Configuration Wizard must MATCH the IP address entered in the Remote I O Toolkit e If you are using high speed counters 32 bit counters must be enabled within Remote I O Toolkit e For analog inputs outputs AI AO you must NOT change the default scaling within Remote I O Toolkit Changes should only be made within the ControlWave Designer I O Configuration Wizard e Be aware that if you are using counters Digital Input or High Speed Counter restarting of Getting Started with ControlWave Designer 22 Configuring I O the ControlWave Remote Ethernet I O will cause a large jump in counts e If you intend to use TPO Time Proportioned Outputs for any point you must enable TPO for those points Changing Default Variable Names All board types As you proceed to define your I O the I O Configuration Wizard will automatically create variable names associated with the I O board to store status information zeros and spans etc These variable names are based on the pin name you define with an appropriate suffix added To see the default suffix click on the Variable Names button previously called Settings visible on certain pages of the I O Configuration Wizard While NOT recommended the variable
26. ame will be used when configuring pins for the board Information Only Depending upon the type of board separate memory areas called maps are reserved for either inputs or outputs Some boards have both an input map and an output map For example a digital output board has outputs DOs in its output map but it may also have inputs which indicate board status conditions and errors For more detailed information on the input and output maps for various boards see the I O Mapping section of the ControlWave Designer Programmer s Handbook document D5125 NOTE If you have an older ControlWave project in which you changed the map type from the default choice this may cause errors to be Il Getting Started with ControlWave Designer Configuring I O Start End Address Slot Number IP Address Related Task Mark Variables as PDD OPC generated when the project is rebuilt If this occurs you should delete the board definition and re define the board Displays the range of memory addresses used by the board Displays either the physical I O slot in the ControlWave controller which holds the board or if this is a Mixed I O Board MIOB it displays a board selection number For ControlWave and Control Wave Micro I O slot numbers are positive integers e g 1 2 3 etc For the ControlWaveLP the slot number is O for all boards except for the AO for the AO the slot can be 8 to 13 NOTE I O Slot number is NOT the sa
27. ameters will be displayed on the right hand side of the dialog box Enter the proper slot number for the board in the Slot Number field Then click on Show Analog Pins Information to configure the individual I O pins a I O Configuration Wizard Step 3 of 3 Configure Selected 1 1 0 O ni i 3 eat Boards List Selected Board s Parameters nter the vO naa BoardName anei ooo slot number in the Click on the KERER BOTH A controller board name l which holds to display its Start Address this board parameters End Address Slot Humber Related Task IGNORE TASK l Click here to configure the I O pins Mark Variables as peo f OPC Show Analog Ping Information Cancel Varnable Names Getting Started with ControlWave Designer 26 Example Creating A Simple Project To activate a particular pin double click on it in the List of Available Pins Active pins are shown in red Then select the pin and configure it You can change the default name in the Pin Name field Analog inputs should have Zero and Span values defined as well List of 4 vailable Ping Double click on the pin name to activate it Active pins show in red To configure 5 a particular PIN pin click on PIN it in the list PIM FIH You must define TR a Zero and FIN Span here If FIN not the program FIN uses a default of FIN 0 to 100 PIN
28. are which boards reside in the ControlWave controller or its configured ControlWave Remote Ethernet I O unit s or ControlWave I O Expansion Racks To remove a board from the Selected Boards List double click on it or click on it once and then click on REMOVE To remove all boards click on REMOVE ALL Click on Next to verify configuration information adjust slot numbering define zeros and spans for analog inputs etc Getting Started with ControlWave Designer 10 Configuring I O I O Configuration Wizard Step 3 of 3 The third page of the I O Configuration Wizard displays configuration details for each board To see the details click on the board abbreviation and the configuration details will be displayed on the right hand side of the page NOTE The fields available for particular boards vary from platform to platform Selected Boards List Board Name Map Type WO Configuration Wizard Step 3 of 3 Configure Selected 4 0 E O X Selected Board s Parameters Board Name D321 Map Type INPUT Start Address 0 End Address f Slot Number f Related Task IGNORE TASK Mark Variables as POD OPC Show Digital Ping Information gt gt Mest gt Cancel Variable Hames Displays all boards selected on the previous page Click on a particular board abbreviation to display configuration details for the board A name for the board can be specified here This n
29. arting stopping of the counters in the ControlWave Remote 21 Getting Started with ControlWave Designer Configuring I O Add Freshness Counter Clear Counters Convert RTD value to tenths Show Pins Analog Pins Digital Pins Done Ethernet I O board These counters are used with digital inputs DI When selected will cause a variable to be created to store a freshness counter value The freshness counter represents the number of program executions since new data has been collected through this Ethernet I O board A value of O indicates the data is as new fresh as possible Sets all counter values associated with this board to 0 For RIO 4RTD 4 Digital Input Board ONLY When checked causes values from the Resistance Temperature Device board to be divided by 10 thereby providing greater precision When clicked on calls up a dialog box for configuring the individual pins for the board Click here when configuration for this board is complete Additional Configuration For ControlWave Remote Ethernet I O Besides the I O configuration within ControlWave Designer additional configuration for Ethernet I O hardware must be performed using the Remote I O Toolkit software not to be confused with what used to be known as the OpenBSI Technician Toolkit Documentation on the Remote I O Toolkit software is provided in the form of on line help screens The Remote I O Toolkit software is included as an inst
30. ble defined earlier In the Scope section click on the Global button Global refers to anything that is accessible to all POUs in this ControlWave project Local refers to something that is confined to the current POU Click in the Name list box to see a list of variables Select F101_ INPUT from the list box since that is the variable we want Finally click on OK Select F101_INPUT Variable Properties se FIT INPUT SA F101 INPUT SPAN F101 INPUT ZERO Usage rom the list box Definition scope Local Local Varnable Groups Global Variable Groupes Global Gow O hoose Global for the scope VAR_GLOBAL CI RETAIN Initial value Po l0 address Description jroo Jorc E 8 Physical Hardware ga CWave Micro 3 a ATU_RESOURCE Py Default Fl 10_GLOBAL_ VARIA E C Show all variables of worksheets 35 Getting Started with ControlWave Designer Example Creating A Simple Project LEAD LAG 1 The F101_INPUT variable will now be displayed onthe n i INeuT GAE ae eet irInput parameter of the LEAD_LAG function block irDertvative irIntegral ibReset Next we can proceed to define variable names for the other inputs irDerivative irIntegral and ibReset Double click on the IrDerivative parameter A variable name will automatically be assigned in this case V002 You can enter a different name or accept V002 Alter
31. can be stopped by clicking on the Stop button Then execution can be re started using either the Warm or Cold buttons In the I O Simulator icons will now appear for all configured process I O boards In this example we have two process I O boards one analog input board and one analog output board In the figure below they are shown as Slot 1 and Slot 2 respectively 49 Getting Started with ControlWave Designer Example Creating A Simple Project A lO SIMULATOR Slots Boards l Board Options Window Help For Help press F1 ot Click on either of the board icons and a graphical representation of the board showing simulated values for all pins on the board will appear In addition you can view the values of other variables in your program by entering Debug Mode To do this click on Online gt Debug NOTE The same command again allows you to exit Debug Mode If you then examine the graphical representation of the project values for each of the variables Getting Started with ControlWave Designer 50 Example Creating A Simple Project will be displayed next to the parameter names of each function block and the FIO1_ OUTPUT variable should change as you modify the F101_INPUT LEAD LAG 1 PIDSTERM 4 Li E ay Pae F101_IHPUT O 0000000E 000 w irImput or utput irInput or Output 101 GUTPUT 1 s493436E 002 vO1s VOOE 4 0000000E 001 Woo
32. case we chose Flow1 The program instance is essentially a copy of the Flow_Control_Program program we created Copies are used because theoretically you might want to use the same program in different tasks and if you didn t use a copy there would not be available memory for internal local variables for each separate copy All local variables created in a POU are only for a particular instance This becomes very Getting Started with ControlWave Designer 44 Example Creating A Simple Project important if you want to create a user defined function block from one of your POUs User defined function blocks are discussed in the ControlWave Designer Programmer s Handbook document D5125 Click on OK when finished Step 7 Compile the Program and if necessary correct any errors Now the program can be compiled The compilation process takes your project programs function blocks tasks etc and generates machine readable code from it that can be run in your ControlWave controller or in the I O Simulator The compilation process checks for any syntactical errors in your program and also issues warnings about possible problems with the structure of the program It does NOT check for logic errors in your control strategy however To compile the program click on the icon shown at left or go to the menu bar and click as follows Build gt Make Various messages scroll by on the screen Watch 1 Watch
33. e created to store the status of the last conversion operation information This is only present for certain platforms When checked will cause a variable to be created to store error information This variable will be set to TRUE whenever there 1s bad calibration data in the EEPROM This is only present for certain platforms When checked will cause a variable to be created to store information about board time out errors Board time outs occur if there is a problem with conversion operations When checked will activate all pins on this I O board They will all appear in RED When checked enables other fields on the page for configuring a hold value for this pin A hold value is the value used by the I O card if it detects a watchdog of the ControlWave CPU The I O board maintains this value at the pin until the unit is restarted When checked allows the User Configured Output hold value to 15 Getting Started with ControlWave Designer Configuring I O Value Hold Last Output User Configured Output Point Type be changed on line otherwise the hold value can only be set in the I O Configurator When checked specifies that during a watchdog failure the hold value for this pin will be whatever value was on the pin when the failure occurred NOTE Hold Last Output and User Configured Output are mutually exclusive Either one may be configured for a particular pin but NOT both When checked allows the user
34. endent gt and the Processor Type should also be specified as Getting Started with ControlWave Designer 30 Example Creating A Simple Project lt independent gt Click on OK when finished A new empty program will be added to the Project Tree Double click on the Flow_Control_Program icon to define the program B 23 Project C Documents and Settings 4ll Users ap Libraries i fe PROCONDS This part allows you to enter a textual he ACCOL3 description of the program optional Data Types Ey Logical POUs m Flow Control Prograrn Li Flow Contro _ProgramT This part lists variables associated with Flow Control Prograniys Flow Control Program the program Physical Hardware B ControMyave IPC_40 RTU_LRESOURCE Controlw ave Double click on this part to actually CA Tasks define the program 5 Global_Variables prog TH 0 Configuration Inserting Function Blocks in the program Now click in the right most portion of the screen ControlWave Designer Untitled Flow_Control_Progpram Flow_Control_Program Zit File Edit View Project Build Objects Layout Online Extras Window 7 lick in this portion of the screen Project Tree Window Sg Project C Documents and Settings All Users 4pplication Data Brista Libraries tea PROCONOS i ACCOLI Data Types B Logical POUs a Flow Control Prograrn i Flow Control Program Flow Control P
35. er to the LEAD_LAG function block so that the orOutput of the LEAD_LAG connects with the irInput of the PID3TERM Drag the PID3TERM function block over to the LEAD_LAG function block so that the orOutput of LEAD _LAG connects with the irlnput of PIDSTERM LEAD LAs i PIDSTERM 1 Lt ain a Pan Fi0i IMPUT ir Input or utput ir Input WOO2 IrOerivative ir Sekooint orError woos irIntegral irOeadband v a ibReset irProaportion irIntegral irDeriy ative irReset ib Track Drag the PID3TERM back over to its previous position This stretches the connection between the two function blocks LEAD LAG 4 E Gi Lt PIDSTERP_ 1 ain ay Pan Fidi IMPUT irImput or utp irInput orkut irDerivative irSetooint orError irIntegral irOeadband ibReset irProportion irIntegral Derivative IFReset ib Track Once the connection has been established the PID3TERM can be dragged back to its previous location the connection between them will stretch accordingly NOTE This method is only appropriate if you have a small number of function blocks and a small number of connections to make Getting Started with ControlWave Designer 40 Example Creating A Simple Project Now you can proceed to define the irSetpoint irDeadband irProportion irIntegral irDerivative irReset ibTrack and orError variables of the PID3TERM by double clicking on each parameter
36. er will start Then click on the ge ASsutidhe Va 2it4 New Project icon shown above or click on Eile Edit view Project Build Online Extras File gt New Project New Project Ctrl DE E Open Project Unzip Project Cbri a 5 Getting Started with ControlWave Starting ControlWave Designer Opening A Project The New Project dialog box will appear New Project General Project wizard EEE LA Micro Double click on the ControlWave icon or the CWMicro icon if you are using a ControlWave Micro series unit and a project tree will be created which automatically includes the ACCOL3 function block library bes Project C Documents and Settings Vall Users 4pplication D atasBristol Control ave Designers 0 300 JNTITLED E E Libraries lea PROCONOS ba ACcoL3 Data Types Logical POU g a g Physical Hardware a ControMave IPE 40 a a ATU_RESOURCE ControMave 22 Tasks 5 Global Variables IO Configuration We will briefly discuss some of the terminology associated with the project tree The project tree includes a series of folders and worksheets which define the various elements of your project Among the most important elements of the project tree are Getting Started with ControlWave Designer 4 Starting ControlWave Designer Opening A Project Logical POUs Libraries Data Types Program Organization Units POUs hold the program code for your projec
37. esigner can also SONON YANES IENE FENNA Goen BSI be used to download and test hardware Downloader Process Automation 4 Retrieve Data via Controller Web Pages IEC 61131 Real Time System Data Access Other software ControlWave System Firmware pe ActiveX in which the p Controls ActiveX controls Load executable a have been placed Configuration Parameters 4 oy HTML a a awe Web pages running Third lt lt ObjectServer gt Project Source compressed NN i Party OPTIONAL S software 4 OpenBSI Utilities PROCESS I O BOARDS e g DataView Harvester Data From Field Input Devices I Getting Started with ControlWave Introduction What is ControlWave The tools which make up the environment are e ControlWave Designer load building package offers several different methods for generating and debugging control strategy programs including function blocks ladder logic structured languages etc The resulting process control strategy programs projects are fully compatible with IEC 61131 standards Various communication methods are offered including TCP IP serial links as well as communication to OpenBSI software and networks ControlWave Designer incorporates the KW MULTIPROG wt IEC 61131 programming tool e The I O Configuration Wizard accessible via a menu item in ControlWave Designer allows you to define process I O boards in the Control Wave series controller and configure the individual mapping
38. fy RAS and save RAS harmless from any liability or damage which RAS may incur or suffer due to such party s failure to so act ELECTRICAL GROUNDING Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to Design Safety Standards for Electrical Systems 29 CFR Part 1910 Subpart S dated April 16 1981 OSHA rulings are in agreement with the National Electrical Code The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically operated devices such as lights switches relays alarms or chart drives EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge ESD voltage Depending on the magnitude and duration of the ESD this can result in erratic operation or complete failure of the equipment Read supplemental document S14006 for proper care and handling of ESD sensitive components Remote Automation Solutions A Division of Emerson Process Management 1100 Buckingham Street Watertown CT 06795 Telephone 860 945 2200 Emerson Process Management Training GET THE MOST FROM YOUR EMERSON INSTRUMENT OR SYSTEM e Avoid Delays and problems in getting your system on line e Minimize installation start up and maintenance costs e
39. it will be set to TRUE Getting Started with ControlWave Designer 14 Range Type Bottom Range Top Range Set Actual Output Value Add Board Status Add Last Operation Status Calibration Error Board Time Out Mark All Pins Used Configure Hold Values Update Default Configuring I O For some boards you can specify whether the board input is in current or voltage Choose VOLTS or AMPS NOTE For example if 4 to 20 milliamps of current drive the board you would choose AMPS then enter 0 004 for the Bottom Range value and 0 020 for the Top Range value The lowest usable value for VOLTS or AMPS for this board input For example if the board input can range from to 5 VOLTS the Bottom Range would be set to 1 0 If this board input can range from 4 to 20 milliamps Bottom Range would be set to 0 004 Other ranges are possible as well The highest usable value for VOLTS or AMPS for this board input For example if the board input can range from 1 to 5 VOLTS the Top Range would be set to 5 0 If this board input can range from 4 to 20 milliamps Top Range would be set to 0 020 Other ranges are possible as well When selected this will cause a variable to be created which displays the actual value which was written to the output pin When selected will cause a variable to be created to store board status information When selected will cause a variable to b
40. lWave Designer 20 Configuring I O IP address is defined Notes About Ethernet I O Boards here Unlike process I O boards which are physically installed in the ControlWave controller ControlWave Remote Ethernet I O boards are in a separate location and communicate to the ControlWave unit using TCP IP The IP address for the Ethernet I O board is configured from the third page of the Map Type I O Configuration Wizard Selected Board s Parameters Board Hame Start Address 0 End address fi Slot Number o 0 0 Related Task IGNORE TASK Redundant Expanded Rack IF Address Mark Yanables as FPEO OFC Certain parameters must be _ specified for the Ethernet I O units MAJ Ue Ue which hold the boards Once this is done however the configuration of Unit Number m the individual board pins 1s identical to that described earlier Add Driver Status Add Freshness Counter Activate Counters Clear Counters NOTE The dialog box shown at Convert RTD value to tenths right includes possible fields for the ControlWave Remote Ethernet I O however not all of these fields are visible in all cases Unit Number Specifies the Modbus unit address number associated with this ControlWave Remote Ethernet I O unit Add Driver Status When selected will cause a variable to be created to store I O driver status information Activate Counters Creates disables a variable which allows the user to control the st
41. lds do NOT appear for certain models 13 Getting Started with ControlWave Designer Configuring I O Configure List of Available Analog Pins List of Available Ping Pin Name LL4_1_1 Done Pin Properties Add Board Status ero 0 000000 Add Last perati span 1 000000 z nS Add Overrange Status Mark All Pi Point Type E lec ne TC 100C to 1820C E Pin Used Low Level Analog Input Board CX X_LL4 Board List of Available Displays a list of the individual pins I O points on this process I O Pins board If the pin is displayed in RED that pin is active If the pin is left grayed out that pin is considered unused Pin Name Defines a name identifying this pin IMPORTANT This name is used as a variable name to reference the I O pin in your POU Value Defines the initial value for this I O pin in floating point format NOTE This is not available for analog input pins Zero Defines the lowest value of the range for this I O pin Used to scale the input output value Span Span is added to the ZERO value to define the highest value of the range for this I O pin Used to scale the input output value Add Over Range When selected will cause a variable to be created to store the value of Status the overrange status bit Over range conditions occur when an attempt is made to drive the variable associated with this pin outside the range defined by the zero and span When this occurs the over range status b
42. lick on Active pins ib Pin Properties ae Done when show in red ao inish i Value 0 000000 E are you finish FIH Aero 1 000000 To configure PIN ane ae a particular Span 1 00 ooooon TE ee In click on in the list Add Overrange Status Mark All Pins Set Actual Output value lees Configure Hold Values You define a Zero and Span here Pin Used When you finish with the I O configuration go to page Step 3 of 3 and click on the Finish button Getting Started with ControlWave Designer 28 Example Creating A Simple Project Some notes about choosing variable names e Variable names consist of a combination of letters A Z a z numbers 0 9 and the underscore character _ e The first character of a variable name CANNOT be a number e Variables are NOT case sensitive 1 e MY_VARIABLE my_variable and mY_vAriaBLe are all considered to be the same variable name e Although you won t always see it in addition to the variable name you enter the system automatically precedes every variable by one or more instance names separated by periods depending upon where the variable was defined GV for global variables task and function block instance names for local variables e g GV F101_INPUT or Flow1 V003 e If you have OpenBSI Utilities Version 4 0 or earlier we recommend your variable names be limited to 20 characters or less including the instance name or
43. me as the chassis slot number Chassis slots which hold the power supply and CPU boards are not considered to be I O slots so the first I O slot is typically the third chassis slot ControlWave Remote Ethernet I O boards are identified by their Internet Protocol IP address instead of the I O slot number The same is true for boards residing in a ControlWave I O Expansion Rack Shows the name of the task which uses this board In some cases for example when using Ethernet I O or analog boards in an RTU 3340 it is important to associate a board with the task which uses the board When a board is associated with a task that board will be read written to at the rate cycle associated with the task thereby ensuring up to date information for calculations performed in the task When no task is associated with the board board execution is associated with the default task which runs at a lower priority and therefore may not provide sufficient up to date I O information when it is required by a task This determines how values of the I O variables associated with this board will be made available to other software programs Checking PDD allows the controller to reference variables by name which is necessary if you intend to access a variable by external software which requires read by name access such as DataView or one of the other OpenBSI Utilities Checking OPC adds this variable to a collection list used by the Object
44. n Hame List of Available Pins Pin Name Set Pin Status Enable Counter Processing PIN PIN PIN PIN PIN PIN Fin Used D03211 Done Pin Properties ddd Board Set Pin Status Status Mark All Pins Used Digital Output Board Page Displays a list of the individual pins I O points on this process I O board If the pin is displayed in RED that pin is active If the pin is left grayed out that pin is considered unused Is a name identifying this pin This name is used as a variable name to reference the I O pin in your POU Sets the initial value for this digital output DO NOTE This option is not available for digital inputs Turns on or off the counters associated with the digital input DI process I O board Counters are used in certain applications For 17 Getting Started with ControlWave Designer Configuring I O Add Board Status Mark All Pins Used Turn off Leds Reset Point Count Set No Init Counter Flag Add Time Stamp of Last Sample example if a mixed I O board is used with a ControlWaveLP a digital input DI can be used as a low speed counter 30 millisecond filter Enabling counter processing in such a case will allow interrupt processing to occur for that DI NOTE This option does not apply to all board types and platforms When selected will cause a variable to be created to store board Status information When checked will activate all pins on this I O board
45. natively you can just enter a constant value here instead of a variable name if this parameter does not have an ia or iany prefix see table on page 34 and you know that this value will never need to be changed and you don t intend to collect display it at the PC If you encounter the error Operand not implemented or area exceeded at download this indicates that you should NOT have used a constant because this parameter has an ia or iany prefix This is a default name ControlWave Designer You can reference a assigns automatically You can change it if Global variable outside desired or leave it as is of this POU Any I O variable must be Global If you want to define a non l O variable as Name Definition scope Global we recommend Yo02 Al Local Global m you do NOT mix I O and Data Type Local Variable Groups non 1 O in the same REAL o B a variable worksheet Page Global Vanable Groups wR CIRETAN amp Gl Physical Hardware ou can only reference a Infial value EM iid CWave Micro Local variable within this gira a POU Typically you should cles I0_GLOBAL_VARIA choose Local unless this is an I O variable which references data going directly form to an I O board or it is being shared among more than one POR 6 oPc C Show all variables of worksheets POU nter an initial value here Variable Properties Choose the data type based on
46. nload an untested program into a controller if the controller is currently connected to a running plant or industrial process Safeguards must be taken prior to downloading to ensure that the controller is isolated from the process and I O is disconnected Failure to take such precautions could result in injury to persons or damage to property Physical Hardware Before a download can be performed the Sa Contolwave IPC 40 resource which will receive the download must em PATU RESOUACE ControMave be properly configured o a Tasks Sle Taski CYCLIC The IEC 61131 real time system which will 0 Flow Flow_Control Program 5 Global Variables execute your compiled program code runs either fal 10_Configuratior in the PC resident I O Simulator or in the ControlWave controller If the I O Simulator will receive the download only the choice of simulation must be made 3 Physical Hardware If the ControlWave controller will S a Controtwave IPC_40 SE ATU_RESOURCE Controlwavg receive the download the DLL Ga Tasks aie which will be used to perform the aw _ CYCLIC Delete Delete op Flow Flow Contra download must be identified 5 Global Variables lo Cut ate O_ Configuration Bel Copy Chrl e To choose the resource right te click on the resource and choose Expand Al Settings from the pop up menu Exclude Create Global Variables From Externals Update External Variables From Globals Properties F
47. of I O points for digital and analog inputs and outputs e The ACCOL3 Function Block Library which is imported into ControlWave Designer includes a series of ControlWave specific function blocks These pre programmed function blocks accomplish various tasks common to most user applications including alarming historical data storage as well as process control algorithms such as PID control e The I O Simulator allows the control strategy programs projects generated through ControlWave Designer to be tested on a PC with simulated analog and digital inputs and outputs The I O Simulator utilizes the identical IEC 61131 real time system used in the Control Wave controller this allows initial I O testing and debugging to be performed in a safe isolated environment without the need for a running Control Wave series controller and process I O boards e The ObjectServer a package you purchase separately that allows real time data access by any OPC compliant third party software package e A series of Web Page Controls are also available for retrieval of real time data values historical data values and communication statistics The web controls utilize ActiveX technology and are called through a set of fixed Web pages compatible with Microsoft Internet Explorer Alternatively developers can place the controls in third party ActiveX compatible applications such as Visual BASIC or Microsoft Excel or in their own user defined web pages to
48. olWave CW_30 or CW_ 10 Controller Once you select the type of controller the boards which can be installed in that unit will be displayed as possible choices For ease of configuration select the boards from the list in ascending order of their slot number in the ControlWave unit Clicking once on the board abbreviation will cause a description of the board to be displayed at the bottom of the Wizard page Double clicking on the board abbreviation or clicking once on the board and then clicking on ADD will add the board to the Selected Boards List The I O Configurator section of the ControlWave Designer Programmer s Handbook document D5125 lists the various types of boards This lists boards which may be installed in the ControlWave I O Expansion Rack If this ControlWave series controller is configured to use an I O Expansion rack select the appropriate boards in ascending order of their slot number in the rack Double clicking on the board abbreviation or clicking once on the board and then clicking on ADD will add the board to the Selected Boards List This lists boards used in ControlWave Remote Ethenet I O units If this ControlWave controller is configured to use Remote Ethernet I O select the appropriate boards Double clicking on the board abbreviation or clicking once on the board and then clicking on ADD will add the board to the Selected Boards List This list allows the user to decl
49. or their use or applicability RAS reserves the right to modify or improve the designs or specifications of such products at any time without notice All sales are governed by RAS terms and conditions which are available upon request 2010 Remote Automation Solutions division of Emerson Process Management All rights reserved EMERSON
50. ow changes so as to reduce the amount of wear and tear on the valve We want to ensure that we don t wear out the control valve trying to respond too quickly to changes in flow To do this we need to delay response to the input flow data using a LEAD_LAG function block e Perform the actual PID calculation To perform the actual PID control we can use the pre defined PID3TERM function block e Send data to the control valve The controller will have to send data out to the flow control valve FICIOI FCV101 in order to vary the position of the valve to regulate the flow This will require an analog output process I O board Now that we know roughly what we re trying to do let s create our project Getting Started with ControlWave Designer 24 Example Creating A Simple Project Step 1 Start ControlWave Designer Click as follows Start gt Programs gt OpenBSI Tools gt ControlWave Tools gt ControlWave Designer Step 2 Open A New Project Click as follows File gt New Project Choose the ControlWave template or CWMicro if you have a Control Wave MICRO in the new project dialog box and click on OK step 3 Start the I O Configuration Wizard Click as follows View gt IO Configurator Step 4 Define Process I O boards NOTE By default the I O Configuration Wizard will skip the first page of the dialog box because most applications including this example use a single configuration and
51. provide a customized human machine interface HMI KW MULTIPROG wt is an industry standard tool developed by Kl pper und Weige Software GmbH KW MULTIPROG wt is used by various PLC and RTU vendors for generating IEC 61131 code Getting Started with ControlWave 2 Starting ControlWave Designer Opening A Project Installing the Software ControlWave Designer software is included on the OpenBSI CD ROM To install it choose Install OpenBSI from the choices provided in the CD browser and then select ControlWave Designer with ACCOL IIT For more information on the installation process see Chapter 2 of the OpenBSI Utilities Manual document D508 1 Starting ControlWave Designer ControlWave Designer is your IEC 61131 program development tool It allows you to create a control strategy project in any of five standard IEC 61131 languages compile the program debug it and download it into your ControlWave controller To start ControlWave Designer click on Start gt Programs gt OpenBSI Tools gt ControlWave Tools gt ControlWave Designer IMPORTANT If this is the very first time ControlWave Designer has been started on this particular computer you will be reminded to register the software Otherwise the software can only be used for a maximum of 60 days For more information on the registration process see Chapter 2 of the OpenBSI Utilities Manual document D5081 Li Opening A New Project ControlWave Design
52. r Method 1 We want to feed the output of the LEAD_LAG function block i e a smoothed out flow value into the input of the PID3TERM There are various ways to do this in this method click on the Connect Objects icon shown above then click on the green dot representing the orOutput parameter of the LEAD_LAG function block Move the mouse horizontally and you will notice that a red line is drawn as you move the cursor Dot representing Dot representing the Output parameter the Input parameter LEAD Lac i Ll iE Ll PIDSTERM 1 ain far Fi0i IMPUT irInput orlutout irImput Wooe irDerivatiwe ir Setpoint woos irIntegral irDeadband Wood ibReset irProportion irIntegral Move the irDerivative cursor to irReset make a line Etra which connects the two dots Position the cursor on the blue dot representing the irInput parameter of the PID3 TERM function block and click The connection has now been made A connection has now been established LEAD LAG 1 PIDSTERM 1 ain ay it Fi0i IMPUT irImput or lutout ir Input irDeriy ative ir Setpoint orError irIntegral irDeadband ibReset irProportion irIntegral irDerivative IrReset ib Track 39 Getting Started with ControlWave Designer Example Creating A Simple Project Connecting Function Blocks Together Method 2 Another method for making the connection would have been to drag the PID3TERM function block ov
53. r to specify which process I O boards are actually installed in the ControlWave series controller as well as boards which are installed in separate devices such as I O Expansion Racks or Remote Ethernet I O units N VO Configuration Wizard Step of 3 Select List of Boards Saks Unit Type Ow Selected Boards List ADD REMOVE REMOVE ALL d Board Selected 16 or 32 Digital Input Board gg Back e gt gt Next gt Finish Cancel Varable Hames Boards should be selected from the selection boxes in the ascending order of their slot number First use the Unit Type list box to identify which type of ControlWave controller you are configuring then select the desired boards and click on ADD If this controller has associated I O racks or Remote Ethernet I O units choose those boards in the Ext Rack Board and Remote IO Boards selection boxes and click on ADD For more information on the various fields see below Unit Type This field allows you to identify the type of ControlWave series controller you are configuring so that the proper board types can be 9 Getting Started with ControlWave Designer Configuring I O Ext Rack Boards Remote IO Boards Selected Boards List displayed for it The types of controllers include CW _ ControlWave Process Automation Controller CWM __ ControlWave MICRO Process Automation Controller iP ControlWave Low Power LP Process Controller CXX__ Contr
54. r will actually send data out to another function block the PID3TERM function block Let s add that function block now To insert the PID3TERM function block click in an open area of the window pane Again in the Edit Wizard you must choose lt ACCOL3 gt for the Group then scroll down to locate the PID3TERM function block and double click on it The Variable Properties dialog box will appear You can optionally enter a name other than the default You can also optionally enter a comment in the Description field Then just click on OK The PID3TERM function block will appear We now have two function blocks LEAD LAG and PID3TERM Getting Started with ControlWave Designer Edit Wizard u 0 Group Mame Description 4 TE PDO se PIDSTERM T PORTATTRIB PORTCONTROL Variable Properties Name Definition scope PIDSTERM_1 Data Type Local Variable Groups Fy Default Usage Global Variable Groups a Initial value 140 address Description K E Show all variables of worksheets Now we have two different function blocks LEAD LAG 1 PIDSTERM_ 1 EAL l i EMATEEN Fi0i INPUT irInput irInput orDukput v irDerivative ir Setpoint orError vous irIntegral irDeadband voo4 ibReset irPropartion irIntegral irDerivative irkeset ibTrack 38 Example Creating A Simple Project Connecting Function Blocks Togethe
55. rograniy Ei Flow _Control_FProgram 3 Physical Hardware ControMfave IPC_40 RTU_RESOURCE Controlw ave 24 Tasks Global variables IO Configuration 31 Getting Started with ControlWave Designer Example Creating A Simple Project 3 Now you must use the Edit Wizard located in the lower left corner of the screen If the Edit Wizard is not visible click on the icon shown at left to activate it Choose the ACCOL3 Group to access the ACCOL3 function block library then use the scroll bar to see which function blocks belong to the library In order to smooth out fluctuations of the flow input and protect the flow control valve we want to feed our flow input into a LEAD_LAG function block Locate the function block named LEAD_LAG then double click on it s Edit wizard AYE Group lt 4 amp CCOLS gt ka Name Description Choose the 505167 lt ACCOL3 gt group LETI 2 s EAD LAG LICENSE F LIQUID_DENSNY LIST_ELE_NAME STOO LIsToz0 HF LIS T030 se the scroll bar to LisToso locate the desired LIST100 function block then i MU 7 double click on that F FDO name to add that T PIDATERM function block to J FPORTATTRIB i i J PORTCONTROL Variable Properties Definition scope The Variable Properties dialog box EITE shown at r ight opens Data Type Local Variable Groups EJ Defaut v You might ask at this point Why is a eia E7
56. s Add Time CHANNEL 4 Add Input Channel State tice e F Stamp of Last CHANNEL 6 CHANNEL 7 CHANNEL amp Pin Lleed Select Filter 30 MS Y Sample Reset Point Count Mark All Pins Used Set No rit Counter Flag High Speed Counter Page Not all fields are present for all board types List of Available Channels Channel Name Add Input Channel State Reset Point Count Select Filter Add Board Status Displays a list of the individual channels counter I O points on this process I O board If the channel is displayed in RED that channel is active If the channel is left grayed out that channel is considered unused Is a name identifying this channel This name is used as a variable name to reference the channel in your POU When selected displays the TRUE FALSE value of the channel When set to ON allows the number of counts to be reset NOTE This occurs automatically whenever the board is restarted Specifies how the board will operate for this channel None Defaults to 30 millisecond filtering 30 ms Turns on 30 millisecond filter Typically used for push button debouncing l ms Turns on 1 millisecond filter Used for low speed counter applications HSC Channel High Speed Counter Default for CWM_RTU board When selected will cause a variable to be created to store board Status information 19 Getting Started with ControlWave Designer Configuring I O Add Time
57. s in this example will require initial values Although we aren t using them in this example the RETAIN PDD and OPC fields are useful The RETAIN box is checked if you want the last value of this variable to be used on re start after a power failure or warm download Checking the PDD box allows the controller to reference this variable by name Reference by name is necessary if you intend to access this variable by external software which requires read by name access such as DataView or other OpenBSI Utilities Checking the OPC box adds this variable to a collection list used by the ObjectServer or by the OpenBSI Signal Extractor This is necessary when data is to be extracted and sent to a database Finally click on OK when finished LEAD LAG 1 Repeat this process for the other input variables in the E LEAD_LAG function block irIntegral and ibReset The 9 FU 4NPUT teinput Srp irIntegral will be of the REAL data type and should be voie 0 Tie assigned an initial value of 0 7 The ibReset will be of the O03 irIntegral BOOL data type and should be assigned an initial value of v004 ibReset FALSE i e OFF When finished the LEAD LAG function block should appear similar to the figure shown at right 3 7 Getting Started with ControlWave Designer Example Creating A Simple Project Notice that we have not defined the orOutput parameter yet This Output paramete
58. s may result in damage or injury The user is urged to keep this book filed in a convenient location for future reference These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation operation or maintenance Should problems arise that are not covered sufficiently in the text the purchaser is advised to contact Emerson Process Management Remote Automation Solutions division RAS for further information EQUIPMENT APPLICATION WARNING The customer should note that a failure of this instrument or system for whatever reason may leave an operating process without protection Depending upon the application this could result in possible damage to property or injury to persons It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices output limiting fail safe valves relief valves emergency shutoffs emergency switches etc If additional information is required the purchaser is advised to contact RAS RETURNED EQUIPMENT WARNING When returning any equipment to RAS for repairs or evaluation please note the following The party sending such materials is responsible to ensure that the materials returned to RAS are clean to safe levels as such levels are defined and or determined by applicable federal state and or local law regulations or codes Such party agrees to indemni
59. sssssssees 23 Step 5 Create A Program Which Implements Your Control Strategy eee 30 Step 6 Create A Task Which Can Run The Program c cecccccccccceceesseeeeeeeeeeeeeeeeeeeees 42 Step 7 Compile the Program and if necessary Correct ANY errors cceeeceeeeeeeeeeeeeees 45 Step 8 Download the program into your ControlWave unit or the I O Simulatot 46 SpF a TOE Ee ra E EAT 51 iii Introduction What is ControlWave Introduction What is ControlWave The ControlWave programming environment uses industry standard tools and protocols to provide a flexible adaptable approach for various process control applications in the industrial automation business The ControlWave Programming Environment consists of a set of integrated software tools which allow a user to create test implement and download complex control strategies for use with the ControlWave series of Process Automation Controllers o Build your Control Strategy Create a new control strategy from scratch lt ACCOL 3 ControlWave Function Block _p _ Designer Library Development lt I O Configuration Wizard Environment Test your Control Strategy I O Simulator SAh E p Download your Control Strategy Load executable a OpenBSI Downloader can perform downloads ControlWave D
60. t They are defined on three separate worksheets One worksheet can optionally contain a textual description of the POU a second worksheet lists the variables associated with the POU and a third worksheet defines the POU code POUs can be up to 640 K bytes in size and there is an enforced limit of 512 POUs per project There are three types of POUs Functions Sometimes the term function is abbreviated as FU These are the simplest type of POU They can take multiple inputs but they generate only one output The memory allocated for a function s data is not persistent 1 e once the function completes execution that memory is released Functions are generally used to perform mathematical operations an example of a function is R_INT which truncates a real number to an integer Functions can only call other functions Functions can only be executed when included as part of a program POU Function Blocks Sometimes the term function block is abbreviated as FB Function blocks can take multiple inputs and they can generate multiple outputs Unlike functions they can have persistent memory Most of the POUs provided in the ACCOL3 library are function blocks for example the AVERAGER the INTEGRATOR the PID3TERM the LEADLAG etc User defined function blocks can be created which consist of logical connections of various functions and function blocks Function blocks can only be executed when included as part of a program POU
61. tion required for the controller for ControlWave this always begins with IPC and it is always configured via the IO Configuration Wizard RTU_RESOURCE defines the type of run time system used in this case it is always ControlWave Tasks are the actual mechanism by which programs are executed When you have completely defined a program you must associate a program instance with an executing task and define the rate of execution Global_Variables is where any user created global variables are defined IO_Configuration defines the inputs and outputs of the process I O boards in the ControlWave series controller and optionally the ControlWave Remote Ethernet I O and or Control Wave I O Expansion Rack s This section should only be edited via the IO Configuration Wizard do NOT attempt to edit 1t manually Additional worksheets are added to the project tree as you build your project Some of these are added automatically others must be manually added by the user IMPORTANT Do not rename items in the project tree created automatically by ControlWave Designer such as the IO_Configuration item ControlWave Designer looks for worksheets under specific items of the tree and if you rename those items ControlWave Designer will be unable to locate those worksheets NOTE We have introduced a lot of terminology in this section Don t worry about absorbing all of it now The most important parts should become clearer to yo
62. to enter a value for this pin which will be used as the hold value in the event there is a watchdog failure of the ControlWave NOTE Hold Last Output and User Configured Output are mutually exclusive Either one may be configured for a particular pin but NOT both Not Shown Appears for CXX_LL4 Low Level Analog Input Board only Specifies the type of low level analog input See the table below for a list of supported temperature voltage ranges for inputs to the CXX_LL4 board Range 100 C to 1820 C 270 C to 1000 C 210 C to 1200 C 270 C to 1370 C Thermocouple Type R 50 C to 1720 C 50 C to 1760 C 270 C to 400 C 220 C to 850 C 10 mV to 10 mV Thermocouple Type S Thermocouple Type T Resistance Temperature Device RTD Voltage When all pins have been configured click on Done You can then proceed to select and configure pins for another board Getting Started with ControlWave Designer 16 Digital Boards Configuring I O Configure List of Available Digital Pins List of Available Ping Pin Hame PIN PIN PIN PIN PIN Pik Pin Used DM6_1_1 Done Pin Properties Add Board Status Enable Counter Processing ena Pls Reset Point Count Set No rit Counter Flag Add Time Stamp of Last Sample Digital Input Board Page Not all fields are present for all board types Configure List of Available Digital Pins List of Available Pins Pi
63. u as you proceed through the Configuring I O and Example sections later in this manual Getting Started with ControlWave Designer 6 Configuring I O In order to reference I O points on the process I O boards of your controller you need to configure them within your project Although it is possible to manually edit the IO_Configuration section of the project tree we strongly recommend you use the I O Configuration Wizard as it will perform syntax checking and is easier for most users The I O Configuration Wizard is accessible from within ControlWave Designer by clicking as follows View gt IO Configurator When started any existing I O configuration data will be read and displayed in the I O Configuration Wizard The Configuration Wizard is a multi page tool gt gt Next gt gt and lt lt Back lt lt buttons are provided to allow you to move between the pages A Settings push button allows the user to rename default variable names if necessary See Changing Default Variable Names later in this section NOTE Page 1 allows the user to define multiple resources Typically only a single resource is used so by default page 2 will appear first since most users do not need to use Page 1 IMPORTANT The IO Configuration Wizard will add a variable group to the Global_ Variables worksheet called IO_GLOBAL_VARIABLES Both the IO_GLOBAL_VARIABLES group in the Global_Variables worksheet and the I O_Configuration
64. x 2 10 SIMULATOR Slots Boards Sele Board Options Window Help E A slots Boards No Boards Available For Help press F1 2 Click on the Download button in the RTU Resource dialog box x RTU_RESOU State On Stop Cod Reset Warm Hot Upload Ero Getting Started with ControlWave Designer 48 Example Creating A Simple Project The Download dialog box opens Download Project Bootproyect _ Include Bootproject Include Sources Include OPC data Download Source Include User Libranies Include Pagelayouts Include Backend Code Download File Click on the Download button in the Project section of the Download dialog box NOTE The Download button in the Bootproject portion of the dialog box is ONLY used if you want to tae ue download into the boot area of the ControlWave unit the Cold bootproject is a project which will start whenever the controller is Reset wam Warm re booted or power is restored following a power failure The RTU_Resource dialog box will re appear Click on either the Download Warm or Cold buttons The Warm button only re initializes non retentive variables The Cold button re initializes all variables Close J Help Info Help If desired execution
65. ys an i for INPUT or an o for OUTPUT If a parameter can be both an INPUT and an OUTPUT the second letter is an o Otherwise the second and any other letters in the prefix indicate the various data types allowed for this parameter The possible types are ab ais ar arb aus di S Si S Str ud udi ui us a any BOOL variable required NO constants allowed STRING or INT variable required depending on the usage No constants allowed REAL variable required NO constants allowed REAL or BOOL variable required NO constants allowed USINT variable or array of USINT required No constants allowed BOOL variable or constant DINT variable or constant INT variable or constant REAL variable or constant SINT variable or constant STRING Note Character strings must be surrounded by single quotes UDINT variable or constant UINT variable or constant USINT variable or constant if not followed by any other prefix letters then any of the following variable types REAL SINT INT DINT are valid however NO constants allowed 33 Getting Started with ControlWave Designer Example Creating A Simple Project The table below summarizes the meaning of the letters in the parameter name prefix Parameter Name Input or Output Valid Data Types Prefix REAL SINT INT DINT NOTE You CANNOT use constants on parameters with the ia or iany prefix only variables may be used fy nput REAL variable NO cnsns

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