Standard PLC Program Alarm

ACESYS Program

Alarm

Doc-To-Help Standard Manual By FLS Automation

FLS Automation A/S

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VersionAceV6.5.4

$Revision:: 0 $

Last modified$Modtime:: 1. September 2001 $

AuthorPoul Nielsen AUTHOR \* MERGEFORMAT

Last modified by$Author:: Finn Kousgaard Poulsen $

Name of Word File$Workfile:: alarm.doc $

Index Range0-1000

Disclaimer:

Information in this document is subject to change without notice and does not represent a commitment on the part of FLS Automation A/S.

The present documentation from FLS Automation A/S is subject to the content of the ordered, confirmed and supplied system configuration.

Options specified and described in the FLS Automation A/S documentation as part of the general description but initially neither ordered by the customer nor confirmed by the seller - will not commit the supplier to any further and future supply and/or installation.

FLS Automation A/S assumes no responsibility for any errors that may appear in this document.

Copyright FLS Automation A/S. All rights reserved.

Contents

1Alarm Module

Introduction1Operating modes2List of Abbreviations3Input Parameters / Flags41. NO Module Number.42. APS - Power Supply.43. AIN Fault input.44. AME - Alarm Messages Enable45. AMR - Alarm Message Release46. AINTL - Fault interlock to Group.47. AEN - Alarm Enable.4Output Parameters / Flags51. AOK - Alarm OK52. ALAMP - Lamp5Timers61. Enable Timer.62. Delay Timer.63. Repeat Time.6MMI Presentation7ECS-Faceplate Alarm8Alarm status to ECS9Siemens S7-program structure10Reserved Function-blocks in STEP710Reserved data blocks10ECS-Faceplate: Info11Function block FB1112Step7 program structure13Control Logix program structure14Calling Subroutines for Digital Alarms15B-Point address Configuration16Concept program structure17Special input pins for ALARM.17Special output pins for ALARM.17ECS-Faceplate: Info18Concept program structure19B-point address Configuration.20

Alarm Module

Introduction

With the alarm annunciation module a signal from the process can be displayed on the ECS system as an alarm messages. There are two basic applications for the alarm module.

The first one is to announce alarms for drives which are not signalled by the drive itself, e.g. belt skew switches, pull robe switches, digital bearing temperatures and other protective-, safety-, and machine alarms.

The other main application is annunciation of various process alarms such as silo levels, air duct temp. etc.

Operating modes

The alarm annunciation module is provided with two digital inputs. Both signals is programmed as fail safe inputs, meaning that the input must be logic 1 when the alarm is healthy.

The first signal is for supervision of the circuit breaker for the power supply of the sensor or transducer in the field, when it has its power supply of it's own. In case of open circuit breaker, this input goes low, then the associated process alarm will be suppressed and the only alarm messages that will appear on the ECS system will be Tagname, power supply, alarm .

The second input is the process alarm itself, if the power supply is ok and this signal goes low and the conditions are present (timers, enable etc.) then the alarm will be presented on the ECS system, in the alarm banner and in the alarm list. This goes of course also for the above mentioned power supply alarm. The output of the alarm block is, when the alarm is healthy, also logic 1.

List of Abbreviations

FLSAHTCSignal descriptionInterface

AINMSTOAlarm Input \Relate "alarm.doc!1", "Alarm Input" \D2HTargetDefault Digital Input Flag

APSMPSPower Supply \Relate "alarm.doc!2", "Power Supply" \D2HTargetDefault Digital Input Flag

AMEMMFRAlarm Message Enable \Relate "alarm.doc!3", "Alarm Message Enable" \D2HTargetDefault Digital Input Flag

AINTLMMZSFault Interlock to Group \Relate "alarm.doc!4", "Fault Interlock to Group" \D2HTargetDefault Digital Input Flag

AMRMSTBAlarm Message Release \Relate "alarm.doc!5", "Alarm Message Release" \D2HTargetDefault Digital Input Flag

AENMAMVAlarm Enable \Relate "alarm.doc!6", "Alarm Enable" \D2HTargetDefault Digital Input Flag

AOKMAZSAlarm Output \Relate "alarm.doc!7", "Alarm Output" \D2HTargetDefault Digital Output Flag

ALAMPMLPZAlarm Output Lamp \Relate "alarm.doc!8", "Alarm Output Lamp" \D2HTargetDefault Digital Output Flag

Input Parameters / Flags

1. NO Module Number.

This parameter must be assigned each module, within a range of 1 500, in order to distinguish between each of them.

2. APS - Power Supply.

This parameter must be assigned with the input from an auxiliary contact of the circuit breaker supplying power to the alarm sensor or transducer.

Logic 0 at this interface will regardless of all other parameters assigned to the block, will initiate the alarm message: Tagname, power supply, alarm .

3. AIN Fault input.

This parameter must be assigned with the actual alarm input from the sensor or transducer.

4. AME - Alarm Messages Enable

This parameter enables/disables the alarm messages on the ECS system.

If the parameter is logic 1 the messages is enabled, if 0 the message is disabled.

Please note that even though the alarm message is disabled, the alarm interlock remains active.5. AMR - Alarm Message Release

Under normal conditions a fault in a stopped group will not generate an alarm, but only indicate Fault in Group if a fault is active, and the interface shall therefore be programmed with logic 0.

But if the alarm shall be announced regardless of the Group condition, then program the interface with logic 1 or the relevant conditions.

6. AINTL - Fault interlock to Group.

Under normal conditions a fault in a stopped group will not generate an alarm, but only indicate Start Interlocked. So if the transferring of this fault condition back to the Group module shall be eliminated, one can program logic 0 on this interface.

7. AEN - Alarm Enable.

When the Alarm enable bit is low, the ECS system annunciates no alarms, and the alarm symbol changes from green (healthy) to brown (fault). This input can be used for instance if a pump is building up a pressure, to disable the alarm if the pump is stopped. This input is related to the Enable Time that can be adjusted from the faceplates (se the section Timers). Output Parameters / Flags

1. AOK - Alarm OK

The "Alarm OK" output will go to logical "0" when the digital input goes low and the timers mentioned above has expired. It remains logical "0" until the input goes high and there has been made "alarm Silence" and "Alarm Reset".

2. ALAMP - Lamp

The alarm lamp output will flash on incoming faults and go steady red after silence has been made. When the fault conditions are OK again and after alarm reset has been made, the alarm will disappear and the symbol will change to green.

Timers

All timers can be read out and adjusted (password protected) from the ECS system and they are all adjustable in a range from 0 - 32676 sec.

1. Enable Timer.

Pre-set value = 0 sec.

The Enable timer starts counting every time the Alarm enable bit changes from logic 0 to logic 1. It starts always from the pre-setted value, meaning the timer is not accumulating.

When the Alarm enable bit is low, the ECS system annunciates no alarms, and the alarm symbol changes from green (healthy) to brown (fault).

If the Alarm enable bit is high and the timer has elapsed, and if a fault occurs then the ECS system brings up an alarm messages immediately.

Example: A compressor has to build up an oil pressure right after start, and if the pressure is not present after the enable time has elapsed, an alarm must be announced. In this case use the "run" bit from the compressor as enable bit and set the enable timer to the for building up oil pressure.

2. Delay Timer.

Pre-set value = 0 sec.

The Delay timer starts counting every time the Alarm input changes from logic 1 to logic 0. It starts always from the pre-setted value, meaning the timer is not accumulating.

The alarm will then be active after the pre-setted delay time.

3. Repeat Time.

Pre-set value = 600 sec.

The Repeat timer starts counting every time the Alarm is active. If the operator has acknowledged an alarm, and if there is a pre-set value >0 programmed. Then the alarm messages will be repeated after this interval.

MMI Presentation

The following symbol is a part of the FLSA standard library for use with digital alarms.

The above shown symbols are changing colour according to status of the process. These symbols are used on the process flow pictures clicking with the right hand mouse on the text or symbol will bring up a faceplate for the alarm.

ECS-Faceplate Alarm

Above is an example of the FLSA faceplate, and below the HTC Siemens faceplate.

Alarm status to ECS

The ECS system is polling a data block in the PLC for retrieving status from the alarms. The table below is showing the various states an alarm can be in.

The Digital alarm uses B-point algorithm no.16 in the ECS system.

Siemens S7-program structure

The programming language STEP7 corresponds to IEC standard IEC 1131-3 and DIN EN-61131-3.

STEP7 is used for SIMATIC Functions, it stores programs in FC-blocks and is using Function Blocks (FBs) as subroutines.

In ACESYS FB-blocks are already pre-programmed for all motors, valves, gates and dampers, which can be programmed. The following diagram shows in which Function blocks (FCs) that the subroutines (FBs) are to be programmed.

Reserved Function-blocks in STEP7

The programming language STEP7 used for SIMATIC Plc's stores programs in blocks. In ACESYS blocks are already laid out in advance for all alarms. The following diagram shows in which blocks the alarms are to be programmed:

Reserved data blocks

For the purpose to store and organise data for ECS communication and internal status of a function block, Data Blocks are used.

In the following table the overview of used DBs is shown:

In ACESYS alarms are stored in DB11. Status is placed in data word: Alarm No * 4, e.g.. Alarm No. 2 (2 x 4 = DW8). Time stamp is placed in the next word (2 x 4 + 1).

Data block No.: 1000 + Alarm No. is an instants data block for commands and status to/from the ECS system. This data block is only polled as per request.

ECS-Faceplate: Info

Function block FB11

The ACESYS Functionblock FB11 is used for alarms. The function block carries out the following tasks:

Alarm logic

Creation of status data word for ECS system (in data block DB11)

Processing of commands from ECS system (alarm stop/cancel)

Copy actual time value from alarm delay and Init. delay timer to

Status in Instant DB to facilitate status on ECS.

Creation of alarm status bits in M-flag area after the following formula :

Alarm bit for alarm #x := M (1000+x).7, i.e. alarm 27 is shown in

M 1027.7

Step7 program structure

Control Logix program structure

A AceSys subroutine called Z10_FLSA_DigitalAlarms is used for all digital alarms. One tag has to be created for each select point, as shown below:

It is possible to manipulate and monitor data in the data structures for the created tags. In general tags starting with int should not be changed since they are for internal use in the subroutine.

All digital alarms are divided in subroutines containing up to 50 alarms. The subroutine names are as follow:

E10_DIGITALALARMS

E11_DIGITALALARMS

.

.

E16_DIGITALALARMS

The following rungs are necessary for each digital alarm:

Alarm Input:

Calling the Subroutine:

The first instruction is use to assign the unit number. The following parameters has to be defined in the Jump To Subroutine instruction:

Routine Name:Z10_FLSA_DigitalAlarms

Input par.:Group/Route command

Input par.:Unit tag

Return par.:Unit tag

Calling Subroutines for Digital Alarms

The subroutines for digital alarms are call from the program A00_DISPATCHER:

Outputs:The output from the digital alarm can be used after the subroutine, or in other parts of the program:

B-Point address Configuration

The following picture illustrates the configuration of communication to the ECS-system.

The CLX PLC is not using fixed PLC-addresses, but is using names. The index for DIGITAL_ALR_STATUS corresponds to the variable NO assigned before calling the subroutine for the digital alarm.

Concept program structure

Special input pins for ALARM.

PARAno: Literal (Data type: UINT) pointing to 4xx-register where the parameter area for the ALARM is beginning. Each Alarm is taken up 20 words as parameter area. (See Data-layout for the Concept program Chapter 15 page 19)

Tpar: Variable (Data type: UINT) for pointing to Token information from the Group/Route, depending of which of them the Alarm is controlled by. Must come from the variable connected to the output pin (Tpar) on the Group/Route controlling this Alarm.

DEP_COM: Structured variable (Data type: DEPCOM) containing all Department commands. (See Group table 1)

Special output pins for ALARM.

STAT: Direct 4xx-register address (Data type: Word array of 2 words.) holding status information and timestamp for the Alarm. These 2 words are read by the ECS. 1.Word: contain status information about the Alarm. 2.Word: contain Timestamp for events in the Alarm. (Se Data-layout for the Concept program Chapter 15)

ECS-Faceplate: Info

Faceplate for statistical info for the Positioner: With this faceplate you get information about where to find this unit in the PLC.

Concept program structure

B-point address Configuration.

Next you will see the B-point address configuration of the ALARM in the ECS.

The point Code: UF01M01Z9.

PLC: 1 (PLC no. (In which PLC this point is reading)).

Input type: HR-16bit/Timestamp (Reading 2 words: 1.word=Status for the alarm. 2.word=Timestamp for when an event happened.)

Input Register: 3301 (equal to the data register address %4:03301 connected to the output pin STAT on the ALARM block)

Input Bit: Always zero.

Output type: None.

Output Register: Always zero.

Output Bit: Always zero.

Parameter type: Holding Register (Pointer for start reading data register area of 20 words).

Parameter Register: 27001 (equal to the data type UINT connected to the input pin PARAno on the ALARM block)

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Value Text

Text Color

Alarm State

Symbol Offset

Operating

Hours

0

Alarm

Flash Red

Alarm

1

FALSE

1

Alarm

Red

Alarm

1

FALSE

3

Alarm

Red

Normal

0

FALSE

4

Normal

Green

Normal

0

FALSE

5

Not Enabled

Brown

Normal

0

FALSE

6

Not Enabled

Green

Normal

0

FALSE

7

Power Supply

Flash Red

Alarm

0

TRUE

8

Power Supply

Red

Alarm

0

TRUE

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Usage

Description

DB11

PLC(ECS

Status information to ECS: Alarm, Enabled etc.

Offset = Select No. x 4

Start offset

2 words, status and timestamp.

DB Select No. + 1000

Internal

Instants Data block Memory for FB-status

DB Select No. + 1000

ECS(PLC

Individual mode select-command from Faceplate

DB Select No. + 1000

PLC(ECS

Indication for MODE status to faceplate