ACESYS program

Unity Reference Manual

Introduction
F.L.Smidth A/S - Automation
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Index Range 0-1000
Contents
Introduction (Unity)....................................................................................3
General........................................................................................................................................3
Purpose.................................................................................................................................3
Hardware Requirements.......................................................................................................4
Software Requirements........................................................................................................4
General Configuration.................................................................................................................5
Memory Allocation..............................................................................................................5
General Elementary Variables.............................................................................................7
Watchdog......................................................................................................................7
ECS_CMD....................................................................................................................7
MSW_GROUPS............................................................................................................8
MSW_ROUTES............................................................................................................8
MSW_UNITS...............................................................................................................9
MSW_SELECT............................................................................................................9
MSW_ALARMS.........................................................................................................10
ANALOG_ALARMS.................................................................................................10
MSW_PID...................................................................................................................11
ACESYS Installation................................................................................................................12
ACESYS Implementation.........................................................................................................15
Program Organizing...........................................................................................................15
Master Block......................................................................................................................17
Watchdog....................................................................................................................17
Scan Time...................................................................................................................17
Enable Device Simulation..........................................................................................17
Master Link.................................................................................................................18
PLC Clock...................................................................................................................18
Department Block..............................................................................................................19
Manipulating with Group/Route Command......................................................................20
ACESYS Library...............................................................................................................21
Function Blocks..........................................................................................................21
Data Types..................................................................................................................22
Disclaimer:

The information in this document is subject to change without notice and should not be construed, as a commitment by
F.L.Smidth A/S. F.L.Smidth assumes no responsibility for any errors that may appear in this document.

In no event shall F.L.Smidth be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall F.L.Smidth be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.

Options specified and described in the F.L.Smidth 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.

The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.

Copyright © F.L.Smidth A/S.

All rights reserved.

Copyright © FLSmidth Automation. All rights reserved. Contents · i

 ECS Configuration....................................................................................................................23
Common Configuration.....................................................................................................23
General Configuration.......................................................................................................24
Link Configuration.............................................................................................................26
Status..................................................................................................................................27
Department Configuration.................................................................................................28
PLC Configuration....................................................................................................................29
Project Settings..................................................................................................................29
Connecting to the PLC.......................................................................................................30
Ethernet Configuration......................................................................................................31
Memory Consumption.......................................................................................................34
Device Simulation.....................................................................................................................35

ii · Contents Documentation Standards

Introduction (Unity)

General

Purpose
This manual contains a PLC specific description of ACESYS for the Schneider
Electric Unity controllers. This version of ACESYS for Unity is designed for the
HMI system ECS.
This manual has to be seen in consecutive with the generic ACESYS manual.
This manual will not cover information included in the Unity documentation from
Schneider Electric or ECS documentation. On the other hand some essential
information will be mentioned even they are part of the Unity/ECS documentation.

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 3

 Hardware Requirements
Developing, test and examples shown in this manual are based on the following
hardware components. Newer versions will probably be suitable, but are not tested:
140 CPU 651 60 Pentium controller

Software Requirements
The following software is used during developing and test of the ACESYS package
for Unity. Newer versions will probably be suitable, but are not tested:
Unity Pro XL V2.1.0
ECS Major Version 7.0.5
SdrModiconSvr30.exe Version 7.0.5.4
SdrModiconCfgUi30.exe Version 7.5.0.3
SdrModiconAcfgUi30.exe Version 7.5.0.3

4 · Introduction (Unity) Copyright © FLSmidth Automation. All rights reserved.

General Configuration

Memory Allocation
The Unity PLC operates with two different types of memory:
Located Memory
Unlocated Memory
Variables of the located memory type are linked to a fixed memory address by the
PLC-programmer. Variables linked to an unlocated memory location are
automatically assigned to an internal address when the PLC program is compiled.
The size of the located memory is limited to 64.000 words. Since it is mandatory to
use located memory for data exchange with ECS it is necessary to manage the
layout of this memory area. In addition located memory has to be used for field I/O
signals.
The following configuration of the Unity controller illustrates a suggested
configuration:

Figure 1 Unity Memory Configuration

The above configuration allocates the following addresses:

Digital Output (0x): %M1 – 2048

Digital Input (1x): %I1 – 2048
Analog Input (3x): %IW1 -512
Other purposes (3x): %IW513 - 1024
Analog Output (4x): %MW1 - 512
Other purposes (4x): %MW513 – 1994
ECS Data exchange (4x): %MW2000 – 63200

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 5

 The data area allocated for data exchange with ECS is divided as shown below:

Type No. Of Size in NO. of Start End

units Words words Addr Addr
PLC set time 1 5 5 1995 1999
Watch Dog 1 1 1 2000 2000
Address
ECS Commands 100 3 300 2001 2300
MSW Group 50 2 100 2301 2400
MSW Route 50 2 100 2401 2500
MSW Units 300 2 700 2501 3100
Spare 3101 3200
MSW Select 100 2 200 3201 3400
MSW Alarm 300 2 600 3401 4000
MSW Analog 300 4 1200 4001 5200
MSW PID 50 2 100 5201 5300
Interlock 400 0,0625 25 5301 5325
Indication 400 0,0625 25 5326 5350
Operator Set Point 100 2 200 5351 5550
Totalizer 100 2 200 5551 5750
PID SPA+SPM 50 4 200 5751 5950
Faceplate Group 50 15 750 5951 6700
Faceplate Route 50 10 500 6701 7200
Faceplate Select 100 5 500 7201 7700
Faceplate Alarm 300 15 4500 7701 12200
Faceplate Analog 300 60 18000 12201 30200
Faceplate PID 50 60 3000 30201 33200
Faceplate Units 300 100 30000 33201 63200
Figure 2 ACESYS Memory Layout

The above memory allocation can be changed but the following part of the
documentation will refer to this layout.

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 General Elementary Variables
A number of elementary variables have to be created for general use. Create the
following variables:

Figure 3 Elementary Variables

Watchdog
The purpose of this variable is to monitor the communication between the PLC and
ECS. For further information see “Master Block” on page 17 and “General
Configuration” on page 24.

ECS_CMD
The purpose of this array is to receive department commands from ECS. For
information about the PLC program for the department see “Department Block” on
page 19 and for the ECS configuration see “Department Configuration” on page 28.
The data array contains the information shown below:

Figure 4 Department Variables in PLC

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 MSW_GROUPS
This array contains the Machine Status Word (MSW) and timestamp for all group
objects for monitoring actual state on ECS. For further information about groups
see chapter “Group”.

Figure 5 Group MSW array

MSW_ROUTES
This array contains the Machine Status Word (MSW) and timestamp for all route
objects for monitoring actual state on ECS. For further information about routes see
chapter “Route”.

Figure 6 Route MSW array

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 MSW_UNITS
This array contains the Machine Status Word (MSW) and timestamp for all unit
objects (unimotor, bimotor, motorgate, valve, positioner, extended motor, extended
gate and extended valve) for monitoring actual state on ECS. For further
information about units see the appropriate chapter for the unit type.

Figure 7 Unit MSW array

MSW_SELECT
This array contains the Machine Status Word (MSW) and timestamp for all select
objects for monitoring actual state on ECS. For further information about routes see
chapter “Select”.

Figure 8 Select MSW array

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 MSW_ALARMS
This array contains the Machine Status Word (MSW) and timestamp for all digital
alarm objects for monitoring actual state on ECS. For further information about
routes see chapter “Alarm”.

Figure 9 Alarm MSW array

ANALOG_ALARMS
This array contains the actual analog value, Machine Status Word (MSW) and
timestamp for all analog measuring objects for monitoring actual state on ECS. For
further information about routes see chapter “Alarm”.

Figure 10 Analog MSW array

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 MSW_PID
This array contains the Machine Status Word (MSW) and timestamp for all PID
objects for monitoring actual state on ECS. For further information about routes see
chapter “PID”.

Figure 11 PID MSW array

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ACESYS Installation

After installation of the CD “ACESYS V7.04 for Unity” two libraries have to be
installed. By default the ACESYS installation will copy files to
“C:\ACESYS\v7.0.4”:

Figure 12 ACESYS Installation Destination

After installation of the ACESYS CD two folders containing libraries exist:

Libraries to
be installed

The “PLC Library” contains the ACESYS standard function block library and data
types, and the “SIM Library” contains functions for writing to physical input for
Device Simulation purpose.

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 Install the libraries using the program from the Unity software package “Types
Library Update”:

Figure 13 Unity Types Library Update

Please note that the “Unity Pro XL” software must not be started during the library
installation.
Browse to the PLC Library (default stored in “C:\ACESYS\v7.0.4\Unity\PLC
Library”) pick select the FAMILY.DSC and select open:

Figure 14 PLC Library Locations

Select Install Family:

Figure 15 PLC Library Installations

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 A successful installation will give the following message:

Figure 16 Installation Succeeded

Afterward browse to the SIM Library (default stored in

“C:\ACESYS\v7.0.4\Unity\SIM Library”) pick select the FAMILY.DSC and select
open:

Figure 17 SIM Library Locations

Install this library the same way as the PLC Library.

If the library to be installed already exists on the system a message similar to the
following message will be shown:

Figure 18 Library Update Message

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ACESYS Implementation

The following section describes how the ACESYS standard has been implemented
in the Unity Controller, in respect to the controller functionality.

Program Organizing
The program structure can be displayed in Functional or Structural view
The structural view is shown below:

Figure 19 Structural View

The execution order of the program is equal to the section order in the structural
view.

The functional view is shown below:

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 Figure 20 Functional View

Swapping between the two views is done by clicking the two icons shown below:

Right-clicking on a section allows linking to a functional section:

Figure 21 Linking Sections to Functional Module

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 Master Block
The first block to be inserted in the PLC-program is the Master Block:

To Department
FBs

The purpose of the master block is:

 Monitor the communication with ECS
 Launch Master Stop when communication with ECS fails
 Make flash slow/fast pulses
 Enable Device Simulation
 Show actual PLC scan time
 Adjust PLC clock from ECS

Watchdog
If the input “WatchDog_Enable” is set to high, the master block will monitor the
communication with ECS. If a high signal is not received on the in-/output
“WatchDog_ECS” within the time defined on the input “WatchDog_Time” a
master stop command will be launched. The master block will automatically clear
the in-/output “WatchDog_ECS” after receiving a high signal.
The remaining time before a master stop is launched can be monitored on the
output “WatchDog_Elap”.
See “General Elementary Variables” on page 7 for declaring of the variable
“WATCHDOG”.

Scan Time
The actual scan time for the PLC can be monitored on the output “ScanTime_ms”
in milliseconds.

Enable Device Simulation

The Device Simulation can be enabled for the PLC by setting the input
“SIM_Enabled” to high.

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 17

 Master Link
The output “MASTER_Link” is of the type “ACESYS_MASTER_LINK” and has
the following structure:

Figure 22 Master Link Structure

This output is linked to all department objects.

PLC Clock
The in-/output “Time_Set” is used to adjust the PLC system date and time from
ECS. The actual time will be send from ECS in the format DT (Data & time). After
the PLC has adjusted the PLC clock the in-/output “Time_Set” will be reset to
“DT#2000-01-01-12:00:00”. Any new values will trig a new adjusting of the PLC
system date and time.

18 · Introduction (Unity) Copyright © FLSmidth Automation. All rights reserved.

 Department Block
For each department represented in the PLC a department object has to be assigned:

From Master FB

To Group FBs

See “General Elementary Variables“ on page 7 for declaring of the variable

“ECS_CMD[x]”.
The department FB will reset the commands launched from ECS after launching the
command on the output “DEPT_CMD”.

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 19

 Manipulating with Group/Route Command
Normally the command from the parent object (group/route) is linked directly to the
unit:

Figure 23 Direct link of parent command

Some time it can be necessary to manipulate with this command for a single unit.
Since the CMD is a structure a new variable can be created of the type
“ACESYS_CMD”:

In the PLC-program the originally is copied to this new variable. Now it is possible
to make logic for each item in the structure, and link the new variable to the unit:

Figure 24 Manipulated Commands to Unit

In the above the Group Select command is not passed to the unit, but all other
commands are passed.

20 · Introduction (Unity) Copyright © FLSmidth Automation. All rights reserved.

 ACESYS Library
The ACESYS library contains a number of function blocks and data types.

Function Blocks
The following Derived FB Types are included in the ACESYS standard:

Figure 25 ACESYS FB Library

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 Data Types
The following Derived Data Types are included in the ACESYS standard:

Figure 26 ACESYS Data Types

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ECS Configuration

The following sections describes configuration of the ECS system for proper
communication with the Unity. The examples will use the memory layout shown in
Figure 2 ACESYS Memory Layout page 6, and are based on Ethernet
communication. Parameters to pay special attention are marked with a circle.

Common Configuration
The Common configuration is valid for all PLCs configured. Two parameters have
to be configured different from the default value:
Max. Holding Register: 64000
Max Input Register: 64000
These figures have to match to the memory allocation shown Figure 2 ACESYS
Memory Layout page 6.
Furthermore server to synchronize system clocks in the PLCs has to be selected.
The possible options are No, From Server 1, From Server 2 or From Both:

Figure 27 Unity Server Common Configuration

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 23

 General Configuration
In the following example a redundant Ethernet configuration is configured on a
Unity PLC.
The watchdog addresses and T.O.D. Register have to match to the memory
allocation shown Figure 2 ACESYS Memory Layout page 6. The watchdog period
has to be smaller than the time configured in the PLC-program for automatic
execution of master stop when communication timeout.

Figure 28 Unity Server General Configuration

Please note the length of the T.O.D. Register doesn’t matter when Unity PLC is
selected because the time and date is always send in the PLC format DT which
allocate 4 words.

24 · Introduction (Unity) Copyright © FLSmidth Automation. All rights reserved.

 The actual communication status can be monitored for the PLC and each network.
For this purpose create B-point tags using the algorithm 13 and the Interface type
Modicon.

Figure 29 Point Configuration Status Points

The addresses configuration for these status points using algorithm 13 has to be left
blank:

Figure 30 Address Configuration Status Points

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 Link Configuration
Each of the links has to be configured with the appropriate net address:

Figure 31 Unity Server Link Configurations

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 Status
For each of the configured link the status can be monitored:

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 27

 Department Configuration
The department commands addresses have to match to the memory allocation
shown Figure 2 ACESYS Memory Layout page 6.

Figure 32 Department Configuration

In the above example department 1 is configured, using MW2001-2003.

Department commands: Department 1 MW2001-2003

Department 2 MW2004-2006
….
Department 100 MW2298-2300

The bit addresses are always as shown in the example.

28 · Introduction (Unity) Copyright © FLSmidth Automation. All rights reserved.

PLC Configuration

The following sections describe basic configurations for settings up a Unity PLC-
project.

Project Settings
Select Tools  Project Settings in the menu:

Figure 33 Unity Project Settings

Set the parameter “Variables not used” in the Warning during analyses. This will
ensure that you get a warning if you have defined variables which are not used.
Select the parameter Include Upload Information. This makes it possible to make an
upload a complete PLC-program without having an offline program. It is
recommended to use the option to ensure the possibility to upload the complete
program, including variables adjusted from the faceplates. Using the option will
require more memory in the PLC

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 29

 Connecting to the PLC
Configure the IP-address on the PLC by using the push buttons on the CPU.
To establish the communication to the PLC from the Unity Pro XL software
package select PLC  Select Address from the menu:

Figure 34 Unity Set Address

Select TCPIP and the correct IP-address.

Afterwards select PLC  Connect from the menu.

When the connection is established it is possible to transfer the project to the PLC:

Figure 35 Unity PLC menu

Transferring requires a stop of the PLC.

Another option is to compare the project with the PLC:

Figure 36 Unity PLC comparison

30 · Introduction (Unity) Copyright © FLSmidth Automation. All rights reserved.

 The project can be transferred to the PLC or the PLC can be transferred to the
project.

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 31

 Ethernet Configuration
In the communication create a net network by right-click at the Networks folder:

Figure 37 Unity Network definition

Select Ethernet and choose a proper name:

Figure 38 Unity Add Network

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 Afterwards double-click at the new created network to configure the network:

Figure 39 Unity Net Configurations

Enter the correct IP address and sub network mask.

The parameter Model Family is very important to configure correct.

If the connection is the on board port on the PLC it is has to be “TCP/IP 10/100
Extended connection”. A normal 140 NOE 771 01 Ethernet 10/100 module has to
be configured as a “TCP/IP 10/100 Regular connection”.

After the network has been configured the network has to be linked to the Ethernet
card or on-board Ethernet port on the CPU. Select the Ethernet port in the hardware
configuration:

Figure 40 Unity Select of Ethernet Port

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 Double-click at the Ethernet port and select the network:

Figure 41 Unity Assigning Network to Ethernet Port

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 Memory Consumption
The actual use of memory in the PLC can be monitored by selecting PLC 
Memory Consumption in the Menu.
The memory usage screen of a PLC with memory card and data storage is shown
below. If the PLC does not have a memory card, only the information relating to
the internal memory is displayed:

Figure 42 Unity Memory Consumptions

During program editing (online or offline) it is a good idea to bring this menu up
from time to time and press the push button “Pack”. This function will make a
memory re-organization.

Copyright © FLSmidth Automation. All rights reserved. Introduction (Unity) · 35

Device Simulation
An optional package to the ACESYS standard library offers a set of function blocks
for simulation of I/O signal is supported.
Implementation of the individual simulation functions will be documented in the
following chapters for the specific functions.
The following characteristics are covered by the PLC I/O simulation:
 The simulation can be en/disabled by manipulating with an input on
the ACESYS_MASTER block (see Enable Device Simulation on page
17).
 By keeping the simulation for all units in one program it is easy to
delete the internal PLC I/O simulation.
 The simulation code is not infiltrated in the basic PLC-code, but kept
in separate function blocks.

It is recommended to gather the simulation code in one section:

Figure 43 Device Simulation Program Section

It the above example the device simulation is programmed in Structured Text (ST).

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