gfs-400 m00 - proficy process systems front matter

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Proficy ProcessSystems

FundamentalsGFS-400B


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Proficy Process Systems Fundamentals

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GE Fanuc Intelligent Platforms Global Training Services www.gefanuc.com/ttc GFS-400B


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This course is designed to provide the student with working knowledge ofProficy Process Systems. It will provide new users with sufficient knowledgeand skill to develop, deploy and maintain Proficy Process Systems applicationsin a production environment. The focus is upon the core control, managementand display features within Process Systems, using the native tools and

applications of the Solution.

At the end of this course, you will be able to: Explain the architecture of Proficy Process Systems. Understand communication between components and third-party systems. Understand and use the Engineering Workstation. Program controller logic using the Logic Developer. Define data sources in the Global Namespace. Create and modify standard Function Blocks. Understand the Process Control Function Blocks.

Configure Alarms to be detected and generated in controllers. Design and build displays using Faceplates. Create Alarm views for use with Operator Consoles. Explain and implement Change Management with Proficy Process Systems. Use trending to monitor both real-time and historical data. Design and build a system-wide security strategy. Use a variety of utilities and Operating System administrative tools to troubleshoot

project or system process faults.

Proficy Process Systems


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SPECIAL FEATURES OF THIS BOOK

TIP!

In the text of some pages, you may find a TIP! Icon. Tips are either reminders or shortcuts to help you completea task more efficiently.

NoteNotes merely call attention to information that is especially significant to understanding the content of thismanual.

Glossary Termswill be shown in italics and bold using colour. Glossary terms will appear in an Appendix atthe end of this manual.

Copyright 2008 GE Fanuc Intelligent Platforms, Inc.All Rights Reserved

This document is based upon information available at the time of its publication. While efforts have beenmade to render accuracy to its content, the information contained herein does not purport to cover alldetails or variations in hardware or software, nor to provide for every possible contingency in connectionwith installation, operation, and maintenance. Features may be described herein which are not present inall hardware and software systems. GE Fanuc Intelligent Platforms, Inc. assumes no obligation of notice toholders of this document with respect to changes subsequently made.

GE Fanuc Intelligent Platforms, Inc. makes no representation or warranty, expressed, implied, or statutorywith respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulnessof the information contained herein.

Proprietary information of GE Fanuc Intelligent Platforms is furnished for customer use only. No other usesare authorized without written permission of GE Fanuc Intelligent Platforms.

Proficy and PACSystems are trademarks of GE Fanuc Intelligent Platforms, Inc.Microsoft is a trademark of The Microsoft Corporation, Inc.

CIMPLICITY and iFIX are registered trademarks of GE Fanuc Intelligent Platforms, Inc.


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TABLE OFCONTENTS

MODULE TITLE PAGE

1................ Introduction to Proficy Process Systems ...................................................................... 1-1Objectives.................................................................................................................................................. 1-1Overview.................................................................................................................................................... 1-3Lab Exercises .........................................................................................................................................1-12Lab Exercise 1: Classroom Orientation and Layout...........................................................1-14Lab Exercise 2: Instructor Walkthrough of a completed PPS project........................1-15Review Questions ................................................................................................................................1-19Review.......................................................................................................................................................1-20

2................Engineering Workstation Controller & IO...................................................................2-1Objectives.................................................................................................................................................. 2-1Overview.................................................................................................................................................... 2-3Proficy Process Systems Engineering Workstation..............................................................2-3Engineering Workstation Use Cases............................................................................................ 2-4

Proficy Process Systems Engineering Workstation (Offline)............................................. 2-4Engineering Workstation Instance Running and Online System Monitoring ........... 2-6Proficy Process Systems Engineering Workstation Instance (Online).......................... 2-6Proficy Process Systems Controller Firmware Upgrade..................................................... 2-6Logic Developer......................................................................................................................................2-7Engineering Workstation Environment.......................................................................................2-8EWS Logic Developer Tools............................................................................................................... 2-8Tools List..................................................................................................................................................... 2-9Navigator Tool Window....................................................................................................................2-10Inspector Tool Window.....................................................................................................................2-11Companion Tool Window.................................................................................................................2-12Tabbed Editor windows....................................................................................................................2-13

Feedback Zone Tool Window.........................................................................................................2-14Data Watch Tool Window................................................................................................................2-16InfoViewer Tool Window...................................................................................................................2-22The ToolChest Window .....................................................................................................................2-23Key Concepts in Engineering Workstation..............................................................................2-24Right-Click, Right-Click, Right-Click..............................................................................................2-24Help!...........................................................................................................................................................2-24Getting the right Tool .........................................................................................................................2-25Navigating through your project.................................................................................................2-25Properties and Inspector..................................................................................................................2-27Smart Lists...............................................................................................................................................2-28The ToolChest ........................................................................................................................................2-28

The Feedback Zone.............................................................................................................................2-29Proficy Process Systems Targets.................................................................................................2-30Lab Exercises .........................................................................................................................................2-33Lab Exercise 1: Backing up, deleting and restoring projects.........................................2-33Lab Exercise 2: Manipulating the EWS tool windows........................................................2-39Lab Exercise 3: Adding and deleting targets.........................................................................2-48Review Questions ................................................................................................................................2-50Review.......................................................................................................................................................2-51


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3 .Creating a Project ................................................................................................................3-1Objectives.................................................................................................................................................. 3-1Overview.................................................................................................................................................... 3-3Creating a new Engineering Workstation project..................................................................3-5Password protection for EWS projects........................................................................................ 3-7Documentaing a project ..................................................................................................................3-10

Validating, Building and Downloading a project ..................................................................3-12Lab Exercises .........................................................................................................................................3-16Lab Exercise 1: Creating a Project ...............................................................................................3-16Review Questions ................................................................................................................................3-22Review.......................................................................................................................................................3-23

4................Hardware Configuration................................................................................................... 4-1Objectives.................................................................................................................................................. 4-1Overview.................................................................................................................................................... 4-3Working with HWC................................................................................................................................4-4Generate and Print a Hardware Configuration Report .......................................................4-5

Replacing A Rack ...................................................................................................................................4-6Replacing A Module..............................................................................................................................4-7Clearing A Rack....................................................................................................................................... 4-9Lab Exercises .........................................................................................................................................4-10Lab Exercise 1: Configure Controller Specifics......................................................................4-10Review Questions ................................................................................................................................4-21Review.......................................................................................................................................................4-22

5 ..................Programming with Logic Developer...............................................................................5-1Objectives.................................................................................................................................................. 5-1Overview.................................................................................................................................................... 5-3Offline vs. Online..................................................................................................................................... 5-4Online Equal vs. Online Not Equal.................................................................................................. 5-4Online Offline Functionality Table.................................................................................................. 5-6Offline .......................................................................................................................................................... 5-8Downloading to a GE Fanuc Controller....................................................................................... 5-9Downloading to a stopped GE Fanuc Controller .................................................................... 5-9Downloading to a running GE Fanuc Controller...................................................................5-11Developing Logic for the Controller ............................................................................................5-11Lab Exercises .........................................................................................................................................5-12Lab Exercise 1: Using the FBD Editor.........................................................................................5-12Lab Exercise 2: Mapping Variables to I/O Points .................................................................5-24Lab Exercise 3: Go Online, Download and Run Logic........................................................5-26Review Questions ................................................................................................................................5-34Review.......................................................................................................................................................5-35

6 ..................PPS Function Blocks...........................................................................................................6-1Objectives.................................................................................................................................................. 6-1Overview.................................................................................................................................................... 6-3MAVG ........................................................................................................................................................... 6-4LATCH.......................................................................................................................................................... 6-6ADAPT.......................................................................................................................................................... 6-8ADVANCED PID (ADV_PID).................................................................................................................. 6-9


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PULSE WIDTH MODULATOR (PWM)..............................................................................................6-16RAMP/SOAK (RAMPSOAK20) ..........................................................................................................6-20TOTALIZE..................................................................................................................................................6-22BUMPLESS TRANSFER (XFER) ..........................................................................................................6-23DEVICE CONTROL TWO STATE (DC2S).........................................................................................6-24DEVICE CONTROL THREE STATE (DC3S) .....................................................................................6-27

ANALOG INPUT......................................................................................................................................6-33ANALOG OUTPUT .................................................................................................................................6-36DISCRETE INPUT....................................................................................................................................6-37DISCRETE OUTPUT...............................................................................................................................6-38Lab Exercises .........................................................................................................................................6-39Lab Exercise 1: Build control logic with Function Blocks .................................................6-39Lab Exercise 2: Create EGD Exchanges, etc...........................................................................6-46Lab Exercise 3: Build A Cascade Control Loop......................................................................6-56Lab Exercise 4: Modify the cascade Loop...............................................................................6-62Review Questions ................................................................................................................................6-66Review.......................................................................................................................................................6-67

7................Ethernet Global Data (EGD).............................................................................................. 7-1Objectives.................................................................................................................................................. 7-1Overview.................................................................................................................................................... 7-3EGD Configuration Server.................................................................................................................. 7-4EGD OPC Server......................................................................................................................................7-4Class 4 Consumer Behaviour........................................................................................................... 7-5Dynamic Binding.................................................................................................................................... 7-5EGD Signatures.......................................................................................................................................7-6Proficy Process Systems EGD Exchange Creation ................................................................ 7-7Manual Consumed Exchange.......................................................................................................... 7-8Redundant EGD Network................................................................................................................... 7-8

Limitations................................................................................................................................................. 7-8EGD Configuration Server.................................................................................................................. 7-8EGD Exchange Properties..................................................................................................................7-9Lab Exercises .........................................................................................................................................7-11Lab Exercise 1: Launch Proficy Process Systems...............................................................7-11Lab Exercise 2: Launch the EGD Management Tool..........................................................7-15Lab Exercise 3: Launch the EGD Powertool ...........................................................................7-19Review Questions ................................................................................................................................7-25Review.......................................................................................................................................................7-26

8................Engineering Workstation CIMPLICITY Project Essentials ...........................................8-1Objectives.................................................................................................................................................. 8-1Overview.................................................................................................................................................... 8-3CIMPLICITY Workbench....................................................................................................................... 8-4Workbench At A Glance...................................................................................................................... 8-5Creating A PPS Project in CIMPLICITY........................................................................................... 8-7Proficy Process Systems Additions............................................................................................... 8-9Mimic Objects ........................................................................................................................................8-10Roles...........................................................................................................................................................8-11Process Systems OPC Port ..............................................................................................................8-12Configure Process Systems Roles................................................................................................8-14


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The Object Builder ...............................................................................................................................8-17Producer Status on the EGD Server vs. CIMPLICITY.............................................................8-21Lab Exercises .........................................................................................................................................8-28Lab Exercise 1: Create A CIMPLICITY PPS Project ................................................................8-28Lab Exercise 2: Using The Object Builder ................................................................................8-37Review Questions ................................................................................................................................8-44

Review.......................................................................................................................................................8-45

9................Engineering Workstation iFIX Project Essentials ......................................................... 9-1Objectives.................................................................................................................................................. 9-1Overview.................................................................................................................................................... 9-3iFIX Project Essentials ..........................................................................................................................9-4Project Customization ......................................................................................................................... 9-4The SCU ...................................................................................................................................................... 9-5Configuration........................................................................................................................................... 9-6Local Startup Configuration ............................................................................................................. 9-6Path Configuration................................................................................................................................9-7

Security....................................................................................................................................................... 9-8Workspace OPC Client......................................................................................................................... 9-9Lab Exercises .........................................................................................................................................9-10Lab Exercise 1: Create and Configure and iFIX Project ....................................................9-10Review Questions ................................................................................................................................9-11Review.......................................................................................................................................................9-12

10 ............. Engineering Workstation CIMPLICITY Visualization..................................................10-1Objectives................................................................................................................................................10-1Overview..................................................................................................................................................10-3CIMPLICITY Workbench.....................................................................................................................10-4Classes and Objects ...........................................................................................................................10-5ADV_PID: Object Configuration and Use ..................................................................................10-6ADV_PID: Object Properties.............................................................................................................10-7ADV_PID: Faceplate............................................................................................................................10-8CIMPLICITY CimEdit/CimView......................................................................................................10-22Testing Screens..................................................................................................................................10-26Lab Exercises ......................................................................................................................................10-27Lab Exercise 1: Create A CIMPLICITY Screen.......................................................................10-27Review Questions .............................................................................................................................10-39Review....................................................................................................................................................10-40

11 ............. Engineering Workstation iFIX Visualization................................................................11-1

Objectives................................................................................................................................................11-1Overview..................................................................................................................................................11-3EWS iFIX Visualization........................................................................................................................11-4Workspace Orientation.....................................................................................................................11-5The System Tree...................................................................................................................................11-6Documents..............................................................................................................................................11-7Proficy Process Systems Faceplates..........................................................................................11-8Faceplate Configuration...................................................................................................................11-9Faceplates at Run-time .................................................................................................................11-10Browsing the EGD OPC Server for Ordinary Animations ...............................................11-11


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15 ............. Alarm Viewing - iFIX.........................................................................................................15-1Objectives................................................................................................................................................15-1Overview..................................................................................................................................................15-3Proficy Alarm Viewer..........................................................................................................................15-4Lab Exercises .........................................................................................................................................15-7Lab Exercise 1: Add Alarm Objects to iFIX Pictures ...........................................................15-7

Review Questions ................................................................................................................................15-8Review.......................................................................................................................................................15-9

16 ............. Engineering Workstation Utilities.................................................................................16-1Objectives................................................................................................................................................16-1Overview..................................................................................................................................................16-3Data Monitor ..........................................................................................................................................16-4Data Watch List ....................................................................................................................................16-6Variable Reports................................................................................................................................16-10Working with Fault Tables............................................................................................................16-13Global Search .....................................................................................................................................16-15

Lab Exercises ......................................................................................................................................16-20Lab Exercise 1: Using the Data Monitor................................................................................16-20Lab Exercise 2: Creating and Using Data Watch Lists...................................................16-24Lab Exercise 3: Running Variable Reports ...........................................................................16-28Lab Exercise 4: Viewing and Clearing Controller Faults.................................................16-32Lab Exercise 5: Using the Search Function .........................................................................16-36Review Questions .............................................................................................................................16-38Review....................................................................................................................................................16-39

17 ............. Creating Reusable Code .....................................................................................................17Objectives................................................................................................................................................17-1Overview..................................................................................................................................................17-3The Toolchest.........................................................................................................................................17-3The Toolchest and Proficy Change Management ...............................................................17-9User Defined Function Blocks.....................................................................................................17-11Lab Exercises ......................................................................................................................................17-18Lab Exercise 1: Tank Calculation Block .................................................................................17-18Lab Exercise 2: Modified Divide Block....................................................................................17-28Challenge Lab: Add Totalize Block...........................................................................................17-34Review Questions .............................................................................................................................17-36Review....................................................................................................................................................17-37

18 ............. PPS System Server - Historian.......................................................................................18-1

Objectives................................................................................................................................................18-1Overview..................................................................................................................................................18-3Collectors.................................................................................................................................................18-4Lab Exercise: Explore the Historian Administrator .............................................................18-5Review....................................................................................................................................................18-15

19 ...............PPS System Server Change Management ................................................................19-1Objectives................................................................................................................................................19-1Overview..................................................................................................................................................19-3How a Proficy Change Management Server System is Organized.............................19-4


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How Proficy Change Management uses Microsoft Visual Source Safe....................19-5Proficy Change Management Server Configuration Utility.............................................19-6Configuring the Audit Trail Database.........................................................................................19-7Editing A Project on A Change Management Server..........................................................19-9Proficy Change Management Server Console....................................................................19-10Logging on to A Change Management System.................................................................19-16

Working Disconnected From The Change Management System.............................19-17Adding A Project to A Change management Server........................................................19-18Creating or Adding A Project While Disconnected from the Server.........................19-19How Change Management Handles Version Control.....................................................19-21Project History Reports..................................................................................................................19-22Lab Exercises ......................................................................................................................................19-24Lab Exercise 1: Adding A Logic Developer Project to The PCM Server....................19-24Lab Exercise 2: Adding A CIMPLICITY Project to The PCM Server...............................19-31Lab Exercise 3: Adding An iFix Project to The PCM Server ...........................................19-46Review....................................................................................................................................................19-47

20 ...............Exploring the Demo Project ...........................................................................................20-1Objectives................................................................................................................................................20-1Overview..................................................................................................................................................20-3PPS Operator Console........................................................................................................................20-3Lab Exercises .........................................................................................................................................20-4Lab Exercise 1: Explore the Demo Project Logic..................................................................20-4Lab Exercise 2: Explore the Demo Project Graphics .......................................................20-11Review ..................................................................................................................................................20-22

Appendix A......Glossary...............................................................................................................................A-1

Appendix B ......Answers to Review Questions .........................................................................................B-1

Appendix C...... Installation and Licensing ................................................................................................C-1

Appendix D......PPS Function Blocks...........................................................................................................D-1

Appendix E ......Batch Server Basics ........................................................................................................... E-1

Course Evaluation


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