SOP M4 Test Setup

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	Standard Operating Procedure
Subject:	SOP M4 Test Setup
Author:	Troy Humphrey
Approved by:	Don Warf

Contents 1 Objective 2 Scope 3 Responsibilities 4 Procedure 4.1 Determine the type of test you wish to run 4.2 Set up the test wheel 4.3 Set up the transceivers 4.4 Set up the Emulator 4.5 Set up M4 4.6 Set up Contrologix 4.7 Set up Logixscraper 4.8 Test setup 4.9 Run test 4.10 Set up the Logixscraper Report Tool and analyze the data. 4.11 Troubleshooting 4.11.1 Logicscraper Doesn't Connect 4.11.2 Tag data doesn't read on all the transceivers that are in ‘scan’ 4.11.3 Tag data doesn't record in M4 properly 4.11.4 The counter on the HMI doesn't increment by one when the flag passes by the sensor 4.11.5 The counters do not increment in the SLC5/05 when you are doing gate latency testing 4.11.6 Logixscraper doesn't record the appropriate Event Points 5 References

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.

Scope

The scope of this SOP is limited to 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.

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 the transceivers

1. Place the transceiver you want to use into ‘scan’ and put the transceivers you don’t want to use into ‘standby’.
2. If the monitors were moved or the coils moved in the previous step the tune of the transceivers could be affected. Check the tune of each transceiver.

Set up the Emulator

If you are not using the Emulator skip this step

THIS PART OF THE PROCEEDURE WILL BE COMPLETED WHEN A WORKING MODEL OF THE EMULATOR IS AVAILABLE.
Troy 11:38, 4 June 2007 (PDT)CURRENTLY THE EMULATOR WILL LOCK UP AT TIMES.

Set up M4

REFER TO THE FOLLOWING SOP

Set up Contrologix

1. Ensure that RSLinx is running and that the ControLogix 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 unchecked.
     • If you uncheck the top box it will automatically uncheck the rest of the boxes.
5. 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 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 Event of Module. Refer to Setting up Contrologix.
4. Use the SLC5/05 test box to test each gate Event Point.
5. Rotate the wheel by hand to 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 Set up the Logixscraper Report Tool and analyze the data.

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 speed for the test you want to run.
4. Set the counter to 2 revolutions and start the belt. The wheel should rotate the belt two revolutions and stop. Repeat step 1.

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.
   • 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
   • You have to reset the module so that the ‘Event Number’ starts at 0.
   • 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.

Set up the Logixscraper Report Tool and analyze the data.

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 preceding Event Point 5’s timestamp.
13. Compare the test result to the test criteria to determine if the test was a success or not.

Troubleshooting

Logicscraper Doesn't Connect

1. Open RSLogix5000
2. Find the message instruction
   • Compare the following Tabs to the following graphics.

IT IS VERY IMPORTANT THAT THE IP ADDRESS MATCHES THE ADDRESS OF THE MACHINE THAT LOGIXSCRAPER IS RUNNING ON!!!

Tag data doesn't read on all the transceivers that are in ‘scan’

1. Check the cabling from the transceiver to the antenna.
2. Check the tune of the transceiver.
3. If Unique is 'ON' try a different tag.
   • Unique should be on.

Tag data doesn't record in M4 properly

1. Refer to the M4 setup and ensure that all cabling is correct.

The counter on the HMI doesn't increment by one when the flag passes by the sensor

1. Make sure the flag (usually a white piece of tape) is clean.
2. Place flag in front of sensor and ensure that at least 3 lights come on.
   • If at least 3 lights don't come on turn the small switch to + sensitivity and press the button on the sensor until 3 lights come on.
3. Run the flag by the sensor several time to ensure that it is counting in the HMI.
   • If the lights on the sensor are lighting up properly but the HMI isn't counting, check the PLC program to ensure the appropriate counter in the PLC is incrementing.
     • If the PLC counter is incrementing but the HMI counter is not check the RSView program and ensure that the 'target' under RSLinx Enterprise is set to the correct device. ie.LABNET being the PLC's name that controls the wheels.

The counters do not increment in the SLC5/05 when you are doing gate latency testing

1. Use M4's manual toggle of the gates to ensure that the RTO (Request To Open) bit is being set in the PLC.
2. Make sure the RTO bit increments the proper counter in the PLC.

Logixscraper doesn't record the appropriate Event Points

1. Open the Contrologix program and ensure that the Event Points you are looking for are turned on and the one's you don't need are turned off.
2. Make sure you are recording OFF-ON states and not ON-OFF unless the test you are running requires an ON-OFF time stamp.

References

Contact PSMFC at (509) 735-2773

Name	Extension
Don Warf	1
Scott Livingston	2
Darren Chase	3
Alan Brower	4
Troy Humphrey	5

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