SOP M4 Beta Test

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Standard Operating Procedure
Subject:
SOP For Testing M4 Beta Versions
Author:
Troy Humphrey
Approved by:
Don Warf

Contents

Objective

The objective of this SOP is to provide the reader a step-by-step process for setting up a test of M4 using the standard equipment all field maintenance employees should be familiar with in conjunction with the Control Logix PLC, Emulator and Logixscraper.

Scope

The scope of this SOP is limited to M4, LogixScraper and Control Logix functions. It assumes the user is knowledgeable in other areas such as how to clear a buffer in a transceiver or how to setup and start the test wheel.

Responsibilities

PSMFC Kennewick staff will be responsible for testing new versions of M4.

Procedure

Determine the type of test you wish to run

  1. Baseline
    • Description: Send tags to M4 on all 64 ports. No database is used. All tags will be ignored. Increase tag frequency until data is lost.
    • Goal: To establish a baseline frequency at which the system starts to lose data.
    • Check: Compare the list of tags sent to M4 with M4’s output.
    • Failure Condition: Not all tags were received.
  2. Identification
    • Description: Send tags to M4 at baseline frequency. All tags are found in the data base. All tags are monitored.
    • Goal: To check that all tags are identified and monitored at baseline frequency.
    • Check: Compare input tags with M4 output file.
    • Failure Condition: Not all tags are received or identified.
  3. Speed Test
    • Description: Send tags to M4 at baseline frequency. All tags are found in the database. All tags generate the divert command.
    • Goal: To check that all tags are identified and generate the divert command at baseline frequency.
    • Check: Compare input tags with M4 output file.
    • Failure condition: Not all tags are received, identified, or generate the divert command.
  4. Gate latency test
    • Description: Send tags to M4 at baseline frequency. One monitor will be removed from Simulator setup. This monitor will be the actual transceivers in the lab. All tags will generate the divert command. Time from the moment the tag is read by the transceiver to the moment PLC sends the divert command will be measured.
    • Goal: Measure M4 latency from receiving a tag to the PLC sending the command to the gate.
    • Check: Use Logixscraper to analyze the data.
    • Failure condition: The latency is greater than 100 milliseconds or there are large number of outliers.



Set up the test wheel

  1. Place the tags on the wheel in accordance to the type of test you wish to run.
  2. Set the speed and revolutions on the HMI and reset the counter from any previous test.
  3. Place the monitors in the appropriate position for the type of test you wish to run.
    • You may have to put the monitors as close together as possible or separate them as much as possible depending on what type of test you wish to run.



Set up transceivers

  1. Ensure that each transceiver used in the test has the appropriate firmware version otherwise you the 'gate out' will not follow the unique on/off rules.
  2. Place the transceiver you want to use into ‘scan’ and put the transceivers you don’t want to use into ‘standby’.



===Set up the Emulator=== (when used for testing)

  1. Open the Emulator Program
  2. For each COM port assign a Device ID and a Tag Rate
    • Example
      • Device ID: 21 (use Hex id's)
        • Note what ID you assigned to what port so you can correlate that when setting up M4.
      • Tag Rate: 1000 (milliseconds at which this port will send tag codes)
  3. Click on the top icon in the tree.
  4. Fill in the "Tag Properties' fields.
    • Feed type:
      • Options
        • Automatic
        • Manual
        • Random
      • Select 'Automatic'
    • Tag Source:
      • Options
        • User defined
        • OS Ticks
        • Random
        • Sequence
        • Tag File
      • Select 'Sequence'.
    • Number of Tags:
      • Enter number of tags you want for the type of test you are running. The number of tags and the tag rate determine the length of the emulation.
    • Start At:
      • The tag code you wish to start at.
  5. Fill in the 'Device Properties' fields.
    • Type:
      • Options
        • FS2001F
        • FS1001
        • FS1001A
        • FS1001M
        • FS1001G2
        • GPS
        • None
      • Select 'FS1001'
    • Protocol:
      • Options
        • ASCII
        • Binary
        • NMEA
      • Select 'ASCII'
    • Baud Rate:
      • Options
        • 9600
        • 14400
        • 19200
        • 38400
        • 57600
        • 115200
        • 128000
        • 115200
        • 128000
        • 256000
      • Select '115200'
  6. Click the 'Play' button to connect to the Device Masters.
    • Top tool bar, single arrow.
  7. Click the 'Go' button to start the emulation.
    • Top tool bar, arrow with bar to the left of it.
  8. Click the 'Stop' button to stop the test.
    • Top tool bar, square.
  9. Click the 'Pause' button to pause the emulation.
    • Top tool bar, parallel bars.



Set up M4

Need John and Nadia's input.

Set up Contrologix

  1. Ensure that RSLinx is running and that the Control Logix Ethernet card is communicating with the PC that you are working on.
  2. Start RSLogix5000 and open the Sequence of Events program and go online.
  3. Expand the I/O Configuration folder in the project tree and double click on [2] 1756-IB16ISOE Sequence_Of_Events.
  4. Under the ‘Configuration’ tab set up the type of events that you want the SOE module to record. Under the heading ‘Enable CST Capture’ there is two columns with check boxes for each Event Point.
    • The left column is for recording the time stamp when the Event Point goes from OFF to ON. This should be checked for all event points that are involved in the test including any test points (Event Points 10 & 11)
    • If you check the top box it will automatically fill in the rest of the boxes with checks.
      • The right column is for recording the time stamp when the Event Point goes from ON to OFF. For most tests these boxes will be un-checked.
  5. If you un-check the top box it will automatically un-check the rest of the boxes.
  6. Refer to the table below to determine what each Event Point relates to:
Event Point
Description of Event Point
5
Transceiver 01 Gate Out pulse
6
Transceiver 02 Gate Out pulse
7
Transceiver 03 Gate Out pulse
8
Transceiver 04 Gate Out pulse
10
Test Box toggle switch
11
Test Box toggle switch
12
A Gate Solenoid
13
B Gate Solenoid
14
C Gate Solenoid
15
D Gate Solenoid

Set up Logixscraper

  1. Start LogixScraper
  2. Click on the ‘connect’ button
  3. Using the Test Box, test Event Points 10 & 11 by using the toggle switches. Note if LogixScraper is recording data and if it is recording ‘on-to-off’ events, or ‘off-to-on’ events or both.
    • If no data is being recorded then refer to the troubleshooting tips section of this SOP.
    • If data that is not relevant to the test you are running is being recorded refer to Section 10 Setting up Contrologix, and turn off the Event Points you are not interested in.
    • If data is missing that you need for the test ensure that the Event Points are turned on in the Sequence of Events Module. Refer to Section 10 Setting up Contrologix.
  4. Use the SLC5/05 test box to test each gate Event Point.
  5. Rotate the wheel by hand to test each transceiver Event Point.
  6. If you are doing latency testing you will want to make sure that the gates configured in your M4 setup are sending divert requests to the appropriate gate in the SLC5/05. Refer to the chart above to determine what each Event Point relates to.
    • If you expect A Gate to open when you read a tag on Transceiver 01 you should see an Event Point 5 followed by an Event Point 12.
  7. Running a report in Logixscraper is addressed in Section 14 Analyzing the Results.



Test setup

  1. Rotate the belt by hand and check the following.
    • Does the tag data read on all the transceivers that are in ‘scan’?
    • Does the tag data record in M4 properly?
    • Does the counter on the HMI increment by one when the flag passes by the sensor?
    • Do the counters increment in the SLC5/05 if you are doing gate latency testing?
    • Does Logixscraper record the appropriate Event Points?
  2. If the answer is yes to all of the above questions proceed to the next step. If the answer is no to any of the questions refer to the troubleshooting tips section of this document.
  3. Set the counter to 2 revolutions an start the belt. The wheel should rotate the belt two revolutions and stop. Repeat step 12.1.i-v.



Run test

  1. You now need to ensure everything is in place to start the test. At this point:
    • The tags should be on the wheel and the proper distance apart for the type of test you are running.
    • The transceivers involved in the test should be in scan and the ones that are not in standby.
    • The revolutions and belt speed should be set.
    • M4 should be configured correctly and communicating to the PLC if you are performing gate latency testing.
  2. Take the following steps before resetting the SOE module.(You have to reset the module so that the ‘Event Number’ starts at 0.)
    • Set the wheel in place with the flag just above the sensor.
    • Reset the revolution counter on the HMI.
    • Clear the transceiver buffers.
    • Clear M4 Counters.
    • Clear the counters on the SLC5/05 if performing gate latency testing.
    • Clear the SOE Module by toggling the ‘clear’ switch on the Test Box.
      • Zero’s should fill the fields on LogixScraper
  3. Using RSLogix5000 reset the SOE Module
    • Expand the I/O Configuration folder in the project tree and double click on [2] 1756-IB16ISOE Sequence_Of_Events.
    • Under the ‘Module Info’ tab click on ‘Reset Module’.
    • Watch the messages in the lower left corner and wait until the module status returns to ‘running’.
  4. Click ‘Disconnect’ in LogixScraper.
  5. At this point you could enter in the test parameters into Logixscraper or wait until the test is finished and you are ready to run a report.
  6. Click ‘Connect’ in Logixscraper to start a new file.
  7. Start the wheel.
  8. When the test is complete click on the ’Disconnect’ in Logixscraper to close the file.



Analyze the results

  1. When the test is done and you have clicked on ‘Disconnect’ in Logixscraper to close the file you will need run a report.
  2. In Logixscraper, expand the ‘Report’ tree
  3. Click on Test and fill in the following:
    • Test Number
    • Test Name
      • Example: M4 Alpha Gate Latency test
    • Tester
      • Your name
  4. Click on ‘Application’ and fill in the following:
    • Application name
      • Example: M4
    • Application version
      • Example: M4 Alpha
    • Running as
      • Example: Service or Application
    • Database size
    • Diversion units
    • Tags to divert
  5. Click on ‘Lab Belt’ and fill in the following:
    • Tags on the belt
    • Distance apart
    • Set revolutions
    • Actual revolutions
    • Belt speed
  6. Click on ‘Emulator’ and fill in the following:
    • Number of ports
    • Tag rate
    • Tag count
      • You will have to go to the Emulator and record how many tags it delivered to M4.
  7. Click on ‘Transceivers’ and fill in the table.
    • You will have to retrieve buffer data from the transceivers.
    • You will have to retrieve PLC data from the SLC5/05 counters.
    • You will have to retrieve application data from M4.
  8. Click on ‘PLC’ and fill in the following:
    • Program name
    • Number of rungs
  9. Click on ‘Report Wizard’
  10. Select the file you want to run the report on.
    • The file name is the timestamp of when ‘Connect’ was clicked.
  11. Review the Event Points captured in the file you have selected. Each Event Point should have it’s description to the left of it. If you want to change the description simply erase the description in place and enter in a new one. The descriptions should not have to be changed however. At this point in running the report you should ensure that all the Event Points you would expect to see are actually there. If they are not click ‘Cancel’ and ensure that you have the appropriate file selected to run the report on.
  12. Pair up the Event Points you want to know the difference between.
    • If you want to know the difference in time from Event Point 5 and Event Point 12 you would select Event Point 12 first and then Event Point 5. Logixscraper will then subtract the timestamp of each Event Point 12 from the proceeding Event Point 5’s timestamp.



Troubleshooting

  1. Tag data doesn't read on all the transceivers that are in ‘scan’.
    • Check the tuning of the transceivers.
    • Try a different tag.
    • Check the cables.
  2. Tag data doesn't record in M4 properly.
    • Check cabling.
    • Check topology setup.
  3. The counter on the HMI doesn't increment by one when the flag passes by the sensor.
    • Check the sensor alignment.
    • Replace the white tape.
  4. The counters don't increment in the SLC5/05 when you are doing gate latency testing.
    • Check M4 topology setup.
    • Ping the PLC from the PC that M4 is running on.
    • Check that RSLogix is online with the PLC.
  5. Logixscraper doesn't record the appropriate Event Points.
    • Check the SOE Module Configuration in Contrologix to ensure that the Event Points are turned on or off.
  6. No information is being displayed in Logixscraper.
    • Try to ping the PLC from the PC that Logixscraper is running.
    • Check cableing and IP addresses.
    • Check that the message instruction in the Contrologix program is pointing to the IP address of the PC that Logixscraper is running on.
      • If you are not familure with Contrologix ask for assistance.
    • If the previous methods don't resolve the issue contact Troy or Nadia for help.
  7. Emulator locks up.
    • Capture message and email to Nadia.



References

Write references here.

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