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InfraStake Software Installation Guide – Allen Bradley Version

Original Instructions

Follow these instructions to knit the InfraStake software into your overall machine program. Follow the instructions in order, as some steps affect others. We recommend reading all of the instructions before beginning with implementation.

These instructions are intended for experienced controls engineers.

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PLC

Import program code

  • Import Infra_Main program into the MainTask
  • Determine whether the 31, 63, or 127 module version is required. A version with a higher module count than what is required may always be substituted, memory permitting.
  • The main InfraStake program will be imported as a separate program under the MainTask in Studio 5000. This program is comprised of two routines: The MainRoutine, which contains the add-on instructions to control the program, and the InputMapping routine, which maps real world inputs to the InfraStake program inputs.
  • There are four Controller-scope Tags which the Infra program uses:
    • Infra_User, which contains tags that you may want access to.
    • Infra_Constant, which contains tags that cannot be written to by the PLC.
    • Infra_Program, which contains tags that the program uses but are not useful to the user.
    • Infra_Cycle, which are used to control and monitor an Infra Cycle.

Map inputs

  • There is template code under the InputMapping routine to map Lamp Status, Punch Position (analog sensor only), Boss Presence (digital sensor only), and Full Stroke (digital sensor only) inputs to the relevant Infra_User tag arrays.
    • Module 1 corresponds to LampStatusInput_DINT[0].0.
  • The analog Punch Position input must be scaled to millimeters. The full range of the linear potentiometer is 12.7 mm (It does not span the full stroke of the punch cylinder).

Link control tags

  • Tie Infra_Cycle control tags to the main program. Make sure to do so for each Valve Group (zone) used. These include but are not limited to:
    • Start input
    • Abort input
    • Running indicator
    • PunchValve output
    • LowFlowCoolingAirValve output
    • HighFlowCoolingAirValve output

Configure security levels

  • If security levels are desired, link the Infra_User.HMI_Security_Level_Current to the main program security configuration.
    • Default security levels: 0 = Operator; 3 = Maintenance; 5 = Engineering.
    • The security levels for various groups of HMI objects can be edited from the tag Infra_Constant.HMI_Security_Level_Prog.
  • If security is not used, hard code this value to 5 or higher to access all features of the InfraStake software.
  • If FactoryTalk security is used, you will have to manually protect certain screens as you see fit for your application.

Configure HMI units

  • If applicable, tie the HMI_Units tag to the units switching function in the main program.
    • 0 = millimeters; 1 = inches.
    • Note that the units can also be switched from within the InfraStake program on the Information screen (‘i’ button in the upper left corner of each screen).

Link machine modes

  • Tie the Manual_Mode, and if applicable the Drycycle_Mode tags to the main program’s equivalent functions.
    • Manual mode allows access to the Manual screen functions and prevents an Infra Cycle from starting from the Start signal.
    • Dry cycle mode prevents the lamps from turning on when an Infra Cycle is run.

Set up lamp outputs

  • Create a new periodic Task, and configure it as follows:
    • This will be a separate periodic task that manages the lamp PWM output signals. Recommended task names are PWM, Infra_LampOutputs, etc.
    • The Period and Priority may be different depending on your application. For example, if your program has higher priority routines or needs a lower scan time for other tasks.
  • Import Infra_LampOutputs program to PWM periodic task.
    • Use the version matching the Module count chosen earlier.
    • Use the template code in the task’s program to map the PWM outputs to physical addresses.
      • Module 1 corresponds to LampOutput_DINT[0].0.
    • The PWM frequency should be set as high as possible while still allowing sufficient resolution of the PWM signal, accounting for scan times, report rates, latencies, etc.
      • A range of 4-10 Hz is recommended. Extol’s default is 5 Hz. The PM400 control card cannot accept PWM frequencies higher than 10 Hz.

Verify constant tag values

  • Fill/verify Infra_Constant tag values.
    • If imported correctly, all tag values should be populated already; you should not need to edit most fields for typical applications.
    • REQUIRED: Enter number of Valve Groups (zones) present. Maximum is 5 Valve Groups.

Reset the program

  • Switch to RUN mode.
  • With caution, while online with the PLC, toggle the Infra_User.Initialize bit (end of array structure). This resets the program to a factory default state. The bit automatically unlatches when the initialization is complete.
    • There is a five-second delay before initialization initiates. Reset the Initialize bit before then to abort.

Verify user tag values

  • Fill/verify whichever Infra_User tag values you desire to use in the main program.
    • The Infra_User UDT contains tags that that the integrator may want to access (versus the Infra_Program UDT, which the user will not need to access). However, in many applications, nearly all tags will not be used externally. Use caution if controlling these tags from the main program, as all valid-use conditioning is bypassed.
  • Fill/verify Infra_User.ValveGroup settings for each Valve Group (zone) used. Valve Group 1 corresponds to Infra_User.ValveGroup[1].
    • No valve properties are not configurable via the HMI, except the Punch Hold Time.
    • Valve[0] is not used.
    • The number of Valve Groups was determined when you set the Infra_Constant tag values.
    • While the default values will work in most applications, the values for High Flow Cooling Time and Cooling Air Timeout are the most likely to need modification.
    • If there is more than one Valve Group, rename Valve Groups to something meaningful. (If there is only one Valve Group the name is not used.)

HMI

Add displays

  • Add displays at the appropriate screen resolution. Right-click on the Displays item in the Application Explorer pane and select Add Components Into Application… Then browse to the Displays folder, select all and Open.
    • There are 14 displays.
      • 13 normal displays
        • 11 Replace
        • 2 On Top
      • 1 additional (On Top) display that contains items that you might use elsewhere. This should be deleted before compiling.
    • Display numbers may range from 1000 to 1099.

Add images

  • Add images with the appropriate screen resolution.
    • There are both BMP and PNG images, make sure to load both.

Note: The easiest way we’ve found to import BMPs and PNGs simultaneously is to type an asterisk ‘*’ into the File Name dialog, press Enter, and then select everything.

Add parameter file

  • Add parameter file.
    • If you’ve renamed the Infra tags or have a PLC shortcut other than “PLC”, change the placeholder shortcuts.

Modify Exit button

  • Open the Object Explorer ( icon) and browse to display 1000 Infra Home > Group4 > ExitInfraButton. Edit the Display field so that the button opens to the display of your choosing.

Update tag names

  • If the PLC Device Shortcut in RSLinx Enterprise Communication Setup is not “PLC” and/or the Infra_Program tag name has been changed, go into display 1031 Infra SPC Module > Group42 > MEChartControl and update the tag names on the Connections tab (Parameter usage in the MEChartControl ActiveX object is not possible).

Add objects to non-Infra displays

  • Add at least one Goto Display button somewhere in the parent application which links to the 1000 Infra Home display. This button must include the Infra parameter file.
  • If desired, add one or more of the items from the INFRA OBJECTS display to the parent applications. For example, to allow viewing/selection of the currently running Part(s) and current fault status from the parent application.
  • Make sure to include the Infra parameter file, or its contents, for all Goto Display Buttons that link to displays containing these objects; or replace the parameter placeholders for each object connection (Note that each item may be comprised of multiple objects).

Appendix

Default Tag Values

Find Infra_Constant default tag values (controller-scoped tag) in Appendix 1.

APPENDIX 1

SPC Data Organization

Learn how SPC data is stored on the PLC in Appendix 2.

APPENDIX 2

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