Adaptable Control Engineering System General Description

Technical Data 9. Auto Start

This function can be used for motors that are stand-by for
ACESYS covers the following control tasks: each other, or when the drive is running in a pulse/pause
sequence, controlled by e.g.: a timer. The start is released
- Group control by a logical ‘1’ on the ‘Auto Start’ bit. The ‘Auto Start’ is
- Route control only operational after a Group start.
- Uni-directional Motor
- Bi-directional Motor 10. Delay Stop Enable
- Change Over Gate This interlocking is normally used for cascaded stop of a
- Positioner department, for example for emptying conveyors. The
- Valve stop timer is released by a logical ‘0’ on the ‘Delayed
- Select point stop’ bit. The ‘Delayed stop’ is only operational after a
- Digital alarm ‘Group Stop’ or a ‘Master Stop’.
- Analog measuring
- PID controller 11. Select Enable
With logical ‘1’ on these interface flags the select point is
Definition of Interlockings enabled and changes status normally. With logical ‘0’ on
1. Group/Route Ready these interface flags the select point keeps its status, but
Motor Group/Route ready is an interlocking indicating if selecting/deselecting is disabled.
motors in the Group/Route are OK and ready to start.
12. Group Flag Transfer
2. Group/Route Off This interface byte is a local byte from the Group, made
This interlocking is used as an interface to the for the programer, so that he could modify the
Group/Route for indication that all drives have stopped. functionality of a drive, if the drive varies from standard.

3. Group/Route On The procedure is that before calling the function block,

This interlocking is used as an interface to the
Group/Route to indicate that all drives are running.
4. Start Interlocking
This interlocking is necessary only for starting the
machine; as soon as the motor is running the interlocking
is overruled.
5. Operational Interlocking
It is necessary for normal operation of the drive.
6. Protective Interlocking
It is an iterlocking designed for protection of the
motor/valve itself and personnel, and it is always
operational regardless of which mode the drive/valve is
in. The interlocking is generated from all signals
indicating a fault on the motor, beside the signals
monitored by the function block itself.
7. Safety Interlocking
It is used for protection of the machine and personnel,
and it is always operational regardless of which mode the
drive is in. It is generated from the process of equipment
built on to the machine for protection of the relevant
drive.
8. Machine Interlocking
A machine interlocking is used for protection of either
machines or personnel, but it is only operational when
the drive is in ‘Automatic’ or ‘Single Start Mode’. It is
generated from equipment built on to the machine for
protection of the relevant drive.
specific for each module, the program must evaluate
proper interlockings and conditional flags associated
with the drives.
PLC Specifications
The process stations are based on fast and reliable
Programmable Logic Controllers, PLCs, from Allen-
Bradley, Siemens, or Modicon. Each PLC covers a
certain process area, where it controls motors and valves
and supervises alarms, discrete signals and process
measurement.
FLS Automation reserves the right to vary these specifications
without prior notice
FLS Automation Philosophy
In FLS Automation we have engineering expertise and
capability to design and implement process control
systems of every size, up to and including systems for
total plant control.
The key feature of the company’s approach to design of
its Adaptable Control Engineering (ACE) systems is
flexibility. Which means that, although our systems are
designed to serve as standards, the simplicity of
documentation and clarity of the systems themselves
enable us to adjust them to the particular customer’s
needs.
Furthermore, within FLS Automation we maintain a
strict policy of remaining independent of hardware
manufacturers. This independence is of considerable
benefit to our customers, since it permits both new
plants and upgrades to be designed with precisely the
equipment the customer wants.
Compatibility with a broad variety of hardware in a
multi-vendor environment and process optimisation are
achieved by the use of advanced programming tools,
both for system integration, and for interface with
individual hardware.
What is ACESYS?
ACESYS is an acronym for Adaptable Control
Engineering SYStem. It is a Programmable Logic
ACESYS
Controller (PLC) programming standard, defining
control objects, data and program structures needed to
implement an efficient PLC-based process control
system for cement. The ACESYS standard is based on
experience gained from the successful engineering,
programming and commissioning of more than 1000
systems worldwide.
Incorporating profound knowledge of cement
production into the common standards we can ensure
that the ACESYS-based process control system is well
suited for optimizing the production process, and
guarantees long and trouble-free operation.
Due to ACESYS we provide our major stakeholders
with the following benefits:
• Plant Management
- high protection of equipment
- efficient plant operation
- minimisation of the total investment, spare parts and
system life cycle cost due to one single non-
proprietary computer hardware platform
• Operator
- easy operation dialogue
- group and route control
- PID control with built-in recipe
• System Specialist
- ease of customisation
- simplified operator training and adaptation due to
the presence of one common Human Machine
Interface (HMI)

Adaptable Control Engineering System Product Profile

July 1999 General Description
Adaptable Control Engineering System
ACESYS and ECS/OpStation philosophy
Modern plants often require 10,000-20,000 Inputs/Outputs
to be communicated to the supervisory control system. This
indicates that a very effective communication between the
Expert Control System (ECS)/OpStation, i.e. the operators
supervisory system and the process station are essential to
ensure well performing systems. Relying on the experience
from several hundred installations, we have developed, in
FLS Automation, an efficient data communication
philosophy, involving both special data handling in the PLC
programs, as well as sophisticated communication drivers
for the ECS system.
In addition, to establish a high speed communication link,
our main objective in the communication driver
development has been to ensure high data availability and
data integrity.
Availability
High data availability is achieved by supporting redundant
communication links to the PLCs. If a PLC is equipped with
multiple communication cards the communication drivers
allow for automatic switching between the communication
lines in the case of network or communication card failure.
Integrity
It is of greatest importance, that the operator can rely 100%
on the validity of the data displayed at the ECS/OpStation.
Any communication error or problem must be indicated
immediately. A basic indication is to keep track of the status
of each PLC, and to alert the operator immediately if a PLC
is not running correctly. We have used a watchdog
mechanism to implement this basic supervision.
Furthermore, the communication drivers are constantly
monitoring the performance of the communication links,
and alarms are generated in case of problems. At the PLC
level, programs are laid out so that Input/Output modules
get automatically a visible error indication at the
ECS/OpStation.
- Typically data corresponding to an object or process device
General Description
General Operational Philosophy is organized in data blocks with a predefined layout. Each 2. Alarm Release
In order to facilitate and structure the work for the operator, basic ACESYS object has a data block associated. To Under normal conditions stopped motors are having their
the process is divided into several departments, that are in ensure efficient communication with the ECS system, the alarms suppressed, but this function is used for motors there
Highis copied to a separate data file.
value of each object are stopped and were one wants to have the alarm
turn divided into groups (sequences) and routes. Each Furnace High O2
sequence represents equipment that normally operates suppression cancelled.
temp.
together in a single group. A group may be subdivided into The major benefits of the object-based drivers mean that
routes representing alternative material transportation users need only to configure one tag per object or process
Group stopped = "1" >=1
selections. At the lowest level the equipment can only be device; all the related process information and PLC Steaply &
Steam
controlled in local mode when needed. parameters areLowthenOautomatically
2 connected to the object.Decr. Alarm Release O2 Trend Alarm message
Prod.
Combined with the faceplates in ECS/OpStation this allows O2 goes into alarm
list
General Alarm Philosophy for a level of integration comparable to Distributed Control
System(DCS) systems. Alarm message &
High
In order to prevent damage to equipment and potential Steam
from PLC &
Alarm message NoO 2 Level
Alarm only
production stops, it is of vital importance that a fault is For a specific PLC, ACESYS constitutes an understandable
Prod. Enable status text
detected and that the operator is alerted immediately, in
collection of PLC subroutines. All controlled units are
order to counteract the potential consequences of the fault. treated as objects in the PLC program. This ensures that the
At the same time, however, it is important that the operator
basic functions are of a well proven design and that changes Please also refer to "Alarm Enable".
is alerted only when a fault has actually occurred, in order to the behaviour of an object can be done in a safe way.
not to distract her/him by any insignificant alarms. 3. Inching Release
Each Function Block (FB) contains the program If the drive is used for positioning were the on/off pulses are
Due to the presence of advanced tools for plant monitoring corresponding to a particular object. A typical program < 2 sec., then a supervision of the Return Signal 1 or 2
and supervision, operators are able to react properly to a
includes: makes no sense. Therefore by programming a logical "1"
process upset. The main purpose of these tools is to provide signal will cancel the Return Fault supervision.
clear information on the reason and location of an alarm and
• Various interlocks (e.g.: Protective, safety, operational
thus assist the operator in finding the original alarm that has interlockings - further extended definition of particular 4. Alarm Messages Enable
created a cascade of problems, and to present alarms interlockings is included within the Technical Data This parameter enables/disables the alarm message on the
according to their location, priority and class.
below) ECS system.
Definition of an Object
• Start/Stop of object (e.g.: unit start from group) If the parameter is logic "1" the messages is enabled, if "0"
The ECS system identifies data in the PLC through data the message is disabled.
points. There are two kinds of points that are supported: • Selection of object (e.g.: unit select from group)
analog A-points and digital B-points. A-points are used for Please note that even though the alarm messages is
analog inputs and outputs, as well as calculated values, • Object mode control (e.g.: Local test permission, external disabled, the alarm interlock remains active.
while B-points are used for digital (binary) inputs and set-point, force down)
outputs. A point’s behaviour is determined via its associated Under normal conditions stopped motors are having there
conversion algorithm. • Miscellaneous object enablers (e.g.: delayed stop, alarm messages suppressed, but running motors will, by
controller auto mode, alarm enabled) means of this parameter, also have suppressed their alarm
Control of a production process with a high number of messages if a common fault in the department occurs e.g.
motors requires handling of a very large amount of digital • Object function block call department E-Stop, Control voltage fuse is blown etc.
information. That is why we emphasize an efficient
handling of digital information for a successful control • Object commands to MCC Program structure 2
system installation. The ECS ACESYS communication
concept includes a unique approach to map digital • Object status segment
Segment 11: Direction select 2
information for an object, a motor for example, into a 16-bit
( Direction select 2 )
word. Being able to read all 16-bit information in one scan, You can read the complete PLC program in ‘top down’ & = F Y.02
rather than in 16 separate 1-bit scans, increases structure, where the complexity is highest at the bottom. We
communication speed. have written all programs in graphical function code Segment 12: Move group Cmd´s to motor
allowing people with only little knowledge of the electrical
( Group Commands ) --> FW X.X
Each object type defined in the ACESYS standard field to read and understand the programs. However,
programs has its corresponding B-point conversion programs inside the objects are written in a text code, to Segment 13: Tag Name for Bi-motor
algorithm. B-point algorithms are defined using the B-point allow higher complexity. All Inputs/Outputs and internal
Motor No. Bi-Motor
algorithm editor. With the algorithm editor any variables are named in a structured way, so that you do not Alarm Release
combination of the 16 Machine Status Word (MSW) bits need to have detailed knowledge of their physical Inching Release
can be given a value, a status, a colour, a symbol offset, an addresses. Furthermore, we have attached a text description Alarm Enable
Overload
alarm state, and can initiate statistical calculations. to all names to increase readability. The program is well Ready Command to MCC Dir. 1
documented, with headlines and descriptions. Return 1 Command to MCC Dir. 2
While the concept of conversion algorithms ensures object Return 2 Mimic Lamp 1
Local Start 1 Mimic Lamp 2
orientation in the handling of data - due to the object based An example of program documentation Local Start 2 Auto Start Flag
drivers, we take this even a step further. Where a standard Local Stop Run Delay Flag 1
Automatic Run Delay Flag 2
communication driver reads and writes point information Input Parameters/Flags Safety Switch Run Flag 1
only, the object based driver allows to read and write blocks Speed Monitor Run Flag 2
1. Module Number OK
of data in the PLC.
This parameter must be assigned each module, within a
range of 1-250, in order to distinguish between each of
them.