PLC Programming Notes SE

TM
PLC Programming Notes

Document: Document number goes here
Applies to: FUEL-FACS+ Facility Business System Standard Edition systems only
Authorized: FUEL-FACS+ Standard Edition Development Director
Coordinator: Director of Marketing Communications (written by Bob Curry)
Issued: dd-mmm-yyyy
Control Systems International, Inc.

8040 Nieman Road
Lenexa, Kansas 66214
Abstract
This document outlines the interaction between a FUEL-FACS+ Standard Edition (SE) system and PLCs used as
mechanical presets . This document is intended for CSI employees only.
Release Summary
dd-Mmm-yyyy MJK
Contents
Introduction......................................................................................................................................... 4
FUEL FACS+ S. E. for Truck Rack Installation with Manual Presets..............................................5
FUEL-FACS+ S.E. DDE Points Definition for Communication with Truck Rack Installation with
Manual Presets.............................................................................................................................. 6
Normal Completion Sequence (Sequence A)....................................................................................9
Abnormal Completion Sequence (Sequence B).............................................................................10
General PLC Programming Notes And Assumptions....................................................................11
PLC Logic Note And Definitions...................................................................................................... 12
Conditions to set the PLC FF OSR Preset X Begin Loading Bit....................................................13
Conditions to set the PLC Preset Enable Meter X Output.............................................................13
Conditions to set the Injector X Enable Mtr Y Inj Z Output............................................................13
Conditions to set the Preset Meter X Injector Failure Alarm Latch................................................13
Conditions to set the FUEL FACS+ S.E. DDE Preset Meter X Complete (PLC Buffer for FF DDE
Preset Complete Meter X) Bit................................................................................................. 14
Conditions to set Preset X Begin Loading Latch Bit Timer Bit.......................................................15
PLC Buffer for FF DDE Preset Meter Gross Meter X Register......................................................15
FF DDE Preset Meter Gross Meter X Register.............................................................................15
Preset Meter Gross Meter X Delta................................................................................................15
Conditions to Set the Preset Meter X “Flow” Bit............................................................................15
Conditions to Set the Detect “Unauthorized Flow” Preset Meter X Timer.....................................16
Conditions to Set the PLC “No Flow” Preset Meter X Timer........................................................16
Conditions to Latch the “Unauthorized Flow” Preset Meter X Bit..................................................16
Condition to Set the VRU Run Output........................................................................................... 16
VRU Operating Readback Input.................................................................................................... 16
Operation of the VRU Alarm Horn Delay Timer............................................................................16
Condition to Set the VRU Alarm Horn Output...............................................................................16
"Unauthorized Flow" Alarm Horn Output.......................................................................................17
Injector Failure Alarm Horn Output...............................................................................................17
FUEL FACS Comms Failure Alarm Horn Output...........................................................................17
Setup PLC for New Application bit................................................................................................ 17
Condition to Set the FF DDE Swing Arm Mtr X Right or FF DDE Swing Arm Mtr X Left Bits........17
FF DDE Meter X Blend %............................................................................................................. 17
RTD Temperature Measurement / RTD Module Set up Subroutine..............................................17
Table 2............................................................................................................................. 18
Average Temperature Calculation Subroutine (Temp. Sub.)........................................................18
Selectable Timed Interrupt (STI) Subroutine.................................................................................19
Injector Control Subroutine........................................................................................................... 20
Clear Application Subroutine......................................................................................................... 20
General Layout of the Main PLC Logic Program:..........................................................................20
General Layout of the Selectable Timed Interrupt (STI) Subroutine Ladder File 3........................23
General Layout of the Clear Previous Application Subroutine Ladder File 5.................................23
General Layout of the Injector Control Subroutine Ladder File 6..................................................24
General Layout of the Average Load Temperature Subroutine Ladder File 4...............................24
General Layout of the RTD Module Configuration Subroutine Ladder File 7................................25
PLC Programming Notes for FUEL FACS PLUS Standard Edition
PLC Configuration of Status Words for FUEL-FACS+ S. E............................................................26

Initial Setup of the PLC Program...................................................................................................... 29
Simulation Subroutine Uses............................................................................................................. 30
Subroutine 8 Simulate the Meter Pulse and Preset Meter Ready Inputs......................................30
Subroutine 9 Simulate FUEL FACS+ S.E. Inputs.........................................................................30
Subroutine 9 Simulate RTD Inputs................................................................................................ 30
PLC CPU Preparation........................................................................................................................ 32
Communication to FUEL FACS+ S.E...............................................................................................37
PLC Memory Map:............................................................................................................................. 46
Figures
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Tables
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/conversion/tmp/scratch/477939197.docx
Page 3 of 150
Introduction
The following is a general outline of the interaction of the FUEL FACS+ Standard Edition (S.E.)
for Truck Rack installation with manual presets and the Programmable Logic Controller (PLC).
This is not a detailed programming document, but a general overview. From this point on FUEL
FACS+ Standard Edition will be referenced as FUEL FACS+ S.E.
This assumes that the person using this will be familiar with the Rockwell software both the
installation and use of RSLinx and RSLogix.
This outline will begin with the general operations that are the basis for this document.
FUEL FACS+ S. E. for Truck Rack Installation

with Manual Presets
Following is the definition of the loading operation sequence, DDE points, and PLC interaction of
the FUEL FACS+ S.E. The assumed order of loading Mechanical Preset is as follows:
1. The driver arrives at a bay.
1. The driver makes all the proper connections to the trailer in preparation for loading
(ground, VRU, loading arm, etc.).
1. The driver will card in and select a dispatched order to load or enter a rack order to load.
1. The driver will start the load, select the compartment to load, select the mechanical preset
to use and begin loading.
1. When the driver completes filling this compartment, he may continue loading at this bay
or he may need to disconnect and move to another bay to complete his load. If he must
move to another bay, repeat steps 3 and 4 until he completes his load.
1. When the driver completes his loading, he will disconnect and leave the bay area.
Page 5 of 150
FUEL-FACS+ S.E. DDE Points Definition for
Communication with Truck Rack Installation with
Manual Presets
FUEL FACS+ S.E. has DDE points available for communication with the PLCs which are listed
in Table 1. These DDE points will be configured for each preset and meter in the system. Table 1
shows DDE point name, the location of the DDE point in the FUEL FACS+ S.E. configuration
screens or tabs (windows), if FUEL FACS+ S.E. will Read or Write the DDE point, the data type,
and the expected data range. These points are all pre-configured and are not available for change.
Table 1 contains only DDE points used by FUEL FACS+ S.E. For the FUEL FACS+ S.E. each
manual preset will have only one meter. Each meter may have up to three injectors.
DDE Points FUEL FACS+ Read Write Data Type Range of Data Word Range in
S.E. the PLC
Configuration
Location
Injector Enable Injector Detail Edit X Binary Set (1) Reset (0) B3:13 Through
B3:18
Meter Enable Meter Detail Edit X Binary Set (1) Reset (0) B3:09 Through
B3:10
Meter Gross Meter Detail Edit X Integer 0- Maximum load F11:00 Through
value quantity F11:31
(Double
precision
signed
32 bits)
Meter Blend % Meter Detail Edit X Integer Floating point N10:36 Through
value N10:67
(Double
precision Scaled by
signed
10
32 bits)
Whether this value
is truncated or not
depends on the
PLC point’s, Data
Type and the DDE
server.
DDE Points FUEL FACS+ Read Write Data Type Range of Data Word Range in
S.E. the PLC
Configuration
Location
Meter Meter Detail Edit X Integer Floating point N10:03 Through

Temperature value N10:34
(Double
precision Scaled by
signed
10
32 bits)
Whether this value
times 10 is truncated or not
depends on the
PLC point’s, Data
Type and the DDE
server
This is a WFA
temperature for the
quantity loaded.
Preset Complete Preset details Tab X X Binary Reset (0) if load is B9:00 Through
not completed and B9:01
Set (1) if load is
complete
Preset Quantity Preset Details Tab X Integer 0- Maximum load F11:33 Through
value quantity F11:64
(Double
precision
signed
32 bits)
Preset Start Preset details Tab X Binary Set (1) Reset (0) B9:11 Through
B9:12
Preset Right Preset Details Tab X Binary Set (1) Reset (0) B9:02 Through
Swing Arm B9:07
Preset Left Preset Details Tab X Binary Set (1) Reset (0) B9:02 Through
Swing Arm B9:07
There are two other DDE points that are assigned. These are points that are used to determine the
health of the communication link between the PLC and FUEL FACS+ S.E. One is the FF DDE
Health from the FF Server. This is an integer value sent to the PLC. It is a counter value sent at a
determined (set in FUEL FACS+ S.E.) internal so the PLC can determine the health of the
communication link. The other is the FF DDE PLC Health Bit (FF Read). This bit is used by
FUEL FACS+ S.E. to determine the health of communications with the PLC.
Page 7 of 150
This document will only deal with the points currently used with the mechanical presets.
The mechanical operational sequence begins with the driver card-in and the selection of the
mechanical preset device for loading. The valves and pumps are controlled by the PLC logic and
outside the scope of this document.
Once the mechanical preset has been selected, FUEL FACS+ S.E. will download the following
DDE points:
1. Meter Blend (0-1000)
1. Meter Enable (Set (1))
1. Injector Enable (Set (1) (If the recipe requires the additive)
1. Preset Quantity (how much to load)
1. Preset Start (Set (1))
1. Meter Blend % (if required by recipe, not used by current version)
FUEL FACS+ S.E. will immediately begin polling the DDE points Preset Complete and Meter
Gross Quantity. This polling will continue for the duration of the loading. These DDE points are
shown below:
 Preset Complete (Reset (0) if load is not completed and Set (1) if load is complete)
 Meter Gross Quantity
The PLC should delay three (3) seconds after receiving the Preset Start (Set) before commencing
loading. This three (3) second delay is needed to ensure that the PLC has all the above variables
(Items 1 through 6) in its memory. These loading variables must be in place to ensure the PLC
properly calculates and controls the mechanical preset loading.
Once the loading has begun, there are two sequences the PLC may use to complete loading. These
sequences will be referenced as Sequence A, normal completion and Sequence B, abnormal
completion.
After the three (3) second delay, loading will commence, FUEL FACS® + S.E. will continue
monitoring Preset Complete and Meter Gross Quantity every second (more or less depending on
network traffic). FUEL FACS+ S.E. monitors the Preset Complete point to determine if the PLC
has detected a load complete condition. Should FUEL FACS+ S.E. detect the Preset Complete
DDE point Set (1), this begins the Sequence A, normal completion sequence.
FUEL FACS+ S.E. monitors the Meter Gross Quantity to determine if a delta exists between the
current scan poll and the last time it polled these variables. If the Meter Gross delta equals zero
(0) for more than the time defined for the preset's NO FLOW timeout period in FUEL FACS+
S.E., a preset No Flow condition exists and Sequence B, abnormal completion begins.
The sequences are detailed below.

Normal Completion Sequence (Sequence A)

When Meter Gross Quantity is detected to be greater than or equal to the Preset Quantity or PLC
detects a fault condition with any of the given site/bay/preset permissives, it will set the Preset
Complete bit. This is the beginning of the normal load completion Sequence A.
When the FUEL FACS+ S.E. detects the Preset Complete bit is set, it will clear the following
DDE points:
 Meter Enable
 Injector Enable (If the recipe requires the additive)
 Preset Start
Once the FUEL FACS+ S.E. has cleared the bits above, it will then read the following DDE
points:
 Preset Quantity
 Meter Temperature
When the FUEL FACS+ S.E. has read the above Quantity, it will then clear the Preset Complete
point.
The PLC (upon detecting the Preset Complete transition from 1 to 0) clears the following to
prevent the FUEL FACS+ S.E. or the PLC from reading the old value on the start of a new load.
 Preset Quantity
 Meter Blend %
At this time the system is ready to process the next load.
Please note: If preexisting faults exist with the logic in the PLC (site permissives, VRU not
running, etc.), then sequence A is invoked immediately, appearing to FUEL FACS+ S.E. as if it
had completed the load immediately and loaded nothing.
Page 9 of 150
Abnormal Completion Sequence (Sequence B)
(FUEL FACS+ S.E. detects no flow or driver initiates shutdown. Same as Sequence A except for
the first FUEL FACS+ S.E. step)
FUEL FACS+ S.E. monitors the Meter Gross delta. If it is equal to zero (0), for greater than the
No Flow timeout period, (as determined by FUEL FACS+ S.E.) or a driver initiates a STOP
LOAD command from the DET, then FUEL FACS+ S.E. initiates the abnormal completion
sequence for the preset/meter in PLC.
This sequence begins when FUEL FACS+ S.E. clears the Preset Start.
The PLC is monitoring the Preset Start. If the Preset Start is cleared before the Preset Complete is
set, then the PLC will check to ensure no loading is taking place (pulses are not still being
counted). If no loading is taking place, then set the Preset Complete to 1.
FUEL FACS+ S.E. then waits for the PLC to set the Preset Complete to 1. This indicates the PLC
has detected the Preset Start clearing and completed or stopped the loading on the mechanical
preset.
FUEL FACS+ S.E. then clears the following DDE points:
 Meter Enable
 Injector Enable (If the recipe requires the additive)
Once FUEL FACS+ S.E. has cleared the bits above, it will then read the following DDE points:
 Preset Quantity
When FUEL FACS+ S.E. has read the above Quantity, it will then clear the Preset Complete
point.
The PLC (upon detecting the Preset Complete transition from 1 to 0) clears the following points to
prevent FUEL FACS+ S.E. or the PLC from reading the old value on the start of a new load.
 Preset Quantity
 Meter Blend %
At this time the system is ready to process the next load.

General PLC Programming Notes And

Assumptions
The following are the general assumptions used in the development of the PLC Code for FUEL
FACS+ S.E. These assumptions will be in the description of the action of the PLC program.
The final section will give the I/O descriptions and types, along with the memory map of the PLC
program.
For FUEL FACS+ S.E., the preset will have only one meter. The meter and preset numbers will
be the same (i.e. preset 1 will have meter 1 and preset 32 will have meter 32).
Each meter will be assigned three injectors. These injectors will be numbered and these numbers
will be assigned to a set meter (i.e. meter 1 will have injectors 1, 2, and 3 assigned to it, meter 2
will have injectors 4, 5, and 6 … meter 32 will have injectors 94, 95, and 96 assigned to it). These
assignments will not be changed.
Injector pacing will not be part of the PLC program. The PLC will set Injector X Enable Mtr Y
Inj Z output for the proper Injector. The Injector will then control the pacing of additive injection.
This PLC program assumes a K-Factor (pulses per unit of measure) for all meters to be 1 and the
Meter Factor to be 1. No provision for the calculation of the net quantity has been made.
The system’s design is for a meter delivery rate of 600 GPM. The system is designed for one
pulse per gallon. At this rate (10 gallons per second), the error in delivery caused by the PLC scan
would be + 1 gallon for every 100 ms of PLC scan time. The error caused by the one pulse per
gallon would be +/- 1 gallon.
The PLC will not control the pumps or valves to the preset. The preset will dispense only one
product and will not blend products in-line. Any blending will be on truck blending control by
FUEL FACS+ S.E. and accomplished by moving the truck to the presets with the products to be
blended.
The PLC will monitor a counter value from FUEL FACS+ S.E. This counter value will be used to
determine the state of the communication between the PLC and FUEL FACS+ S.E. If the PLC
detects the counter stopping, it will set an alarm bit. The PLC will allow the loading in progress to
complete normally. The loss of communication will inhibit the starting of new loads. When the
communication is reestablished, FUEL FACS+ S.E. will read the FF DDE Preset Complete Mtr X
bits and collect the proper data. The PLC will then complete the load. The main assumption for
loss of communication with FUEL FACS+ S.E. is that it will be lost in both directions. If the PLC
does not have communication with FUEL FACS+ S.E., then FUEL FACS+ S.E. does not have
communication with the PLC. FUEL FACS+ S.E will notify the operator of the loss of
communication. The loss of communication may also be an alarm horn output on the PLC.
Page 11 of 150
PLC Logic Note And Definitions
Input Marshaling
The real world inputs and inputs from FUEL FACS+ S.E. will be marshaled to internal bits. The
marshaling of inputs is done for the following reasons:
Logic maybe written before the actual input assignments are completed.
Logic may be written with a standard set of assumptions for input states (Real world input
conditions may be adjusted for in one place in the program rather than throughout the program.)
The state is maintained throughout the logic scan so all logic is serviced with the same state. Not
a problem for real world inputs of the SLC 505, but is a consideration for FUEL FACS+ S.E. and
other PLCs.
Allows the marshaled inputs to be logically grouped so matrices Boolean statement may be used
easily without placing undo constraints on the assignment of field inputs.
It allows for the easier disabling of the inputs by disabling the move commands for testing of the
logic.
It allows for the easier removal of unused input points by removing the Move statement containing
the addresses from the logic.
Output Marshaling
The real world outputs and outputs to FUEL FACS+ S.E. will be marshaled to internal coils or
bits. The marshaling of the outputs is done for the following reasons:
Logic maybe written before the actual output assignments are completed.
The state is maintained throughout the logic scan so all logic is serviced with the same state. Not a
problem for real world outputs of the SLC 505, but is a consideration for FUEL FACS+ S.E. and
other PLCs.
Allows the outputs to be logically grouped so matrices Boolean statement may be used easily
without placing undo constraints on the assignment of field outputs.
It allows for the easier disabling of the outputs by disabling the move commands for testing of the
logic.
It allows for the easier removal of unused output points by removing the Move statement
containing the addresses from the logic.
Conditions to set the PLC Preset Start Meter X Timer

The PLC Preset Meter Start Meter X Timer Done bit will set three (3) seconds after the PLC
Buffer for FF DDE Preset Meter Start Meter X has been set. This delay is there to allow for the
complete transfer of information from the FUEL FACS+ S.E. The PLC Preset Meter Start Meter
X Timer Done bit will be used in the place of PLC Buffer for FF DDE Preset Meter Start Meter X
in the program in order to allow for this delay.
Conditions to set the PLC FF OSR Preset X Begin Loading Bit

The PLC FF OSR Preset Begin Loading X Bit is used to determine the FUEL FACS+ S.E.
beginning of a load. This bit is only high for one scan. This is used to determine if the PLC
Buffer for FF DDE Preset Complete Meter X should be set at the beginning of a load. It is set
when it detects that the PLC Preset Meter Start Meter X and PLC Buffer for FF DDE Preset Meter
Enable Meter X are first set simultaneously.
Conditions to set the PLC Preset Enable Meter X Output

The PLC Preset Enable Meter X Output bit is used to start and stop the preset loading. The PLC
Preset Enable Meter X Output will be set to allow the preset to load. The PLC Preset Enable Meter
X Output will set when the following conditions are true:
1. The PLC Buffer for Preset Ready Meter X is set.
1. The PLC Buffer for FF DDE Preset Meter Enable Meter X is set.
1. The PLC Delay of Preset Start Meter X is set.
1. The PLC Buffer for FF DDE Preset Quantity Meter X is greater than zero.
1. The PLC “No Flow” Timer Meter X has not been set.
1. The PLC Buffer for FF DDE Preset Quantity Meter X is less than the PLC Buffer for FF
DDE Preset Meter X Gross.
1. The PLC Buffer for FF DDE Preset Complete Meter X is not set.
1. The Preset Meter 1 Injector Failure Alarm Latch is not set.
It’s reset when any of the conditions above are false.
Conditions to set the Injector X Enable Mtr Y Inj Z Output

The PLC will set the Injector X Enable Mtr Y Inj Z output when the PLC Buffer for Injector X
Enable Mtr Y Inj Z is set. The conditions to set the PLC Buffer for Injector X Enable Mtr Y Inj Z
are as follows:
1. The proper PLC Preset Enable Meter X output is set for the injector.
1. The Proper PLC Buffer for FF DDE Injector X Enable Mtr Y Inj Z is set.
1. The PLC Buffer for Injector X Alarm Mtr Y Inj Z alarm is not set.
It’s reset when any of the conditions above are false.
Conditions to set the Preset Meter X Injector Failure Alarm Latch

The PLC will set and latch the Preset Meter X Injector Failure Alarm Latch when the following
conditions are true:
1. The proper PLC Preset Enable Meter X output is set for the injector.
1. And any of the Following conditions are true:
Page 13 of 150
 The PLC Buffer for FF DDE Injector X Enable Meter Y Inj 1 is set and PLC
Buffer for Injector X Alarm Mtr Y Inj 1 is set.
 PLC Buffer for FF DDE Injector X Enable Meter Y Inj 2 is set and PLC Buffer
for Injector X Alarm Mtr Y Inj 2 is set.
 PLC Buffer for FF DDE Injector X Enable Meter Y Inj 3 is set and PLC Buffer
for Injector X Alarm Mtr Y Inj 3 is set.
This latch will be cleared when the PLC Buffer for FF DDE Preset Complete Meter X is cleared
and the PLC Preset Meter Start Meter X bit and the PLC Buffer for FF DDE Preset Meter Enable
Mtr X are not set.
Conditions to set the FUEL FACS+ S.E. DDE Preset Meter X Complete
(PLC Buffer for FF DDE Preset Complete Meter X) Bit
The PLC Buffer for FF DDE Preset Complete Meter X bit is set at the end of a preset loading.
This bit is set to notify FUEL FACS+ S.E. that the load is complete and FUEL FACS+ S.E.
should gather the data. This bit will only be set when a preset is in a loading configuration or at
the beginning on a load. The following conditions will set the PLC Buffer for FF DDE Preset
Complete Meter X:
1. If the PLC Buffer for FF DDE Preset Meter X Gross is equal to or greater than PLC
Buffer for FF DDE Preset Quantity Meter X. The PLC will then remove the PLC Preset
Enable Meter X output, any PLC Injector X Enable Inj output(s) for the preset and wait
until the PLC detects no flow for X seconds, then set the PLC Buffer for FF DDE Preset
Complete Meter X bit.
1. The PLC detects the loss of the Preset Ready Input. The PLC will then remove the PLC
Preset Enable Meter X output, any PLC Injector X Enable Inj output(s) for the preset and
wait until the PLC detect no flow for X seconds, then set the PLC Buffer for FF DDE
Preset Complete Meter X bit.
1. The PLC detects the clearing of the PLC Preset Meter Start Meter X bit (FUEL FACS+
S.E. has detected the operator has press stop or detected a “no flow” condition). The PLC
will then remove the PLC Preset Enable Meter X output, any PLC Injector X Enable Inj
output(s) for the preset and wait until the PLC detects no flow for X seconds, then set the
PLC Buffer for FF DDE Preset Complete Meter X bit.
1. The PLC detects an Injector Alarm for the preset. The PLC will then remove the PLC
Preset Enable Meter X output, any PLC Injector X Enable Inj output(s) for the preset and
wait until the PLC detects no flow for X seconds, then set the PLC Buffer for FF DDE
Preset Complete Meter X bit.
1. The PLC detects “no flow” condition for the meter for y seconds. The PLC will then
remove the PLC Preset Enable Meter X output, any PLC Injector X Enable Inj output(s)
for the preset then set the PLC Buffer for FF DDE Preset Complete Meter X bit.
1. The PLC detects the one shot event PLC FF OSR Preset Begin Loading X Bit setting and
the Preset Ready Mtr X is not set. This condition is tested before the PLC Buffer for FF
DDE Preset Complete Meter X bit.
1. The PLC detects the one shot event PLC FF OSR Preset Begin Loading X Bit setting and
the PLC Buffer for FF DDE Preset Quantity Meter X is zero (0). This condition is tested
before the PLC Buffer for FF DDE Preset Complete Meter X bit
Conditions to set Preset X Begin Loading Latch Bit Timer Bit

This bit is set to allow the PLC “no flow” Preset Meter X timer to monitor the flow condition. It
is also used to determine loading conditions. This bit will latch when the following conditions are
met:
1. The PLC Preset Meter Start Meter X bit and the PLC Buffer for FF DDE Preset Meter
Enable Mtr X are set for the beginning of the load.
The Latch is cleared when the PLC Buffer for FF DDE Preset Complete Meter X bit is cleared
PLC Buffer for FF DDE Preset Meter Gross Meter X Register

The PLC will keep a running total of the meter pulses (1 pulse equals a unit of measure). This
running total will be stored in the PLC Buffer for FF DDE Preset Meter Gross Meter X Register.
The pulses will be always be counted. This register will be cleared when the PLC Buffer for FF
DDE Preset Complete Meter X is cleared and the PLC Preset Meter Start Meter X bit and the PLC
Buffer for FF DDE Preset Meter Enable Mtr X are not set. It will also be cleared by the setting of
the PLC FF OSR Preset Begin Loading X Bit. This counting is always active to allow
determination of “unauthorized flow”.
FF DDE Preset Meter Gross Meter X Register

The PLC will move the PLC Buffer for FF DDE Preset Meter Gross Meter X Register value into
the FF DDE Preset Meter Gross Meter X Register. This move will always be executed after the
determination of the Delta. This is the value that FUEL FACS+ S.E. will use as the delivered
quantity. The move at this position sets the value to the current total and is to keep a record of the
last scan’s total for the next scan. This register will be cleared when the PLC Buffer for FF DDE
Preset Complete Meter X is cleared and the PLC Preset Meter Start Meter X bit and the PLC
Buffer for FF DDE Preset Meter Enable Mtr X are not set. It will also be cleared by the setting of
the PLC FF OSR Preset Begin Loading X Bit. This is the value used in conjunction with the FF
DDE Preset Meter Gross Meter X register to determine flow. This movement is always active to
allow determination of “unauthorized flow”.
Preset Meter Gross Meter X Delta
The PLC will compare the PLC FF DDE Preset Meter Gross Meter X Register to the
PLC Buffer for FF DDE Preset Meter Gross Meter X Register. If these registers are not
equal, then a count has occurred in the PLC FF DDE Preset Meter Gross Meter X
Register, and this is considered flow. This comparison is always preformed to allow
determination of “unauthorized flow”.
Conditions to Set the Preset Meter X “Flow” Bit

The PLC will monitor the Preset Meter Gross Meter X Delta condition. If a Preset Meter Gross Meter X Delta
exists (PLC FF DDE Preset Meter Gross Meter X Register and the PLC Buffer for FF DDE Preset Meter Gross
Meter X Register are not equal), then there is flow. The PLC will set the Preset Meter X “Flow” set. If there is no
Preset Meter Gross Meter X Delta (PLC FF DDE Preset Meter Gross Meter X Register and the PLC Buffer for FF
DDE Preset Meter Gross Meter X Register are equal), then there is “no flow” and the bit is cleared. This bit is used
in determining both “flow” and “unauthorized flow”.
Page 15 of 150
Conditions to Set the Detect “Unauthorized Flow” Preset Meter X
Timer
The PLC will monitor the PLC Preset Enable Meter X Output bit. If this bit is cleared then the
PLC will wait three (3) seconds and set the Detect “Unauthorized Flow” Preset Meter X Timer
Done Bit. The delay is to allow the “flow” of product through the preset meter to stop. This done
bit is used in determining “unauthorized flow”. This bit is cleared when the PLC Preset Enable
Meter X Output bit is set.
Conditions to Set the PLC “No Flow” Preset Meter X Timer

The PLC will monitor the PLC Preset Meter X “Flow” bit. If this bit does not set for seven (7)
seconds, then a “No Flow” condition exists and the PLC “No Flow” Preset Meter X Timer Done
bit will set. The PLC “No Flow” Preset Meter X Timer Done bit will clear when the Preset Meter
X “Flow” bit sets. The PLC “No Flow” Preset Meter X Timer is only active during loading or
when an “Unauthorized Flow” bit is latched.
Conditions to Latch the “Unauthorized Flow” Preset Meter X Bit

The PLC will monitor the Preset Meter X “Flow” bit. If this bit sets and the Detect “Unauthorized
Flow” Preset Meter X Timer Done Bit sets, then the “Unauthorized Flow” Preset Meter X Bit will
latch. This bit will unlatch when the “No Flow” Preset Meter X Timer Done bit sets.
Condition to Set the VRU Run Output

The PLC VRU output will be set whenever any PLC Buffer for FF DDE Preset Meter Enable Mtr
X bit is set. This bit will clear when none of these bits are set.
This is an optional point. It is not required for FUEL FACS+ S.E. operation. It is furnished for
the Customers convenience.
VRU Operating Readback Input

The VRU Operating Readback input is for the readback from the VRU to indicate that it is
operating. This is used in determining if there is a VRU Failure.
Operation of the VRU Alarm Horn Delay Timer

When the PLC detect the VRU Run Output set, it starts a delay timer. This timer will set a VRU
Alarm Horn Done bit XXX seconds after the VRU Run Output has set.
Condition to Set the VRU Alarm Horn Output

The VRU Alarm Horn output will be set whenever the VRU Alarm Horn Done bit has set and the
PLC VRU Operating Readback input is not set. This bit will clear when the VRU Alarm Horn
Done bit clears.
"Unauthorized Flow" Alarm Horn Output

The “Unauthorized Flow” Alarm Horn Output will be set whenever any “Unauthorized Flow”
Preset Meter X Bit is set. This bit will clear when none of these bits are set.
Injector Failure Alarm Horn Output

The Injector Alarm Horn Output will be set whenever any PLC Injector Alarm Inj X Bit is set.
This bit will clear when none of these bits are set.
FUEL FACS Comms Failure Alarm Horn Output

The FUEL FACS Comms Alarm Horn Output will be set whenever the PLC detects a
communication failure with FUEL FACS+ S.E. This bit will clear when communication is
restored.
Setup PLC for New Application bit

The PLC for New Application bit is set by the developer to allow the clearing of bits that may not
be served in the new application. It will also allow the developer to clear all buffers during
testing. This bit is set with the processor in the program mode. When the processor is set to the
run mode, the first scan bit will set and with the PLC for New Application bit set, the Clear
Application Subroutine is called and the buffer areas will be cleared.
The PLC for New Application bit will be unlatched at the end of the Clear Application Subroutine
scan.
Condition to Set the FF DDE Swing Arm Mtr X Right or FF DDE Swing
Arm Mtr X Left Bits
The PLC will monitor the condition of the Swing Arm Mtr X Input. If the input is set, the FF
DDE Swing Arm Mtr X Left is set. If the Swing Arm Mtr X Input is clear, then the FF DDE
Swing Arm Mtr X Right is set. FF DDE Swing Arm Mtr X Right is the default position (no input
wired).
FF DDE Meter X Blend %

This is a value sent to the PLC to form a calculation of the product recipe. It allows the PLC to
load blended products. This will not be used in the current version of FUEL FACS+ S.E. For this
version the Meter X Blend % is assumed to be 100%.
RTD Temperature Measurement / RTD Module Set up Subroutine

The RTD Module set up subroutine will only execute on the first scan. The Subroutine is Ladder
file 7 and is called ANASETUP.
Page 17 of 150
The PLC will use RTDs as the method to determine the product temperature. The following
assumptions have been made for the system:
1. The RTDs used will be the type 3916 Platinum 100 Ω RTD.
1. The value readback of the RTD will be the temperature value multiplied by ten (X 10).
i.e. a temperature of 60.5 º F will be 605.
1. Failure mode for a broken RTD is assumed to be the full down scale reading (–3280).
1. The selected scale is º F.
1. A 60 HZ filter will be used. A channel’s scan time is 55 ms per channel enabled.
1. All channels will be enabled on all installed RTD input modules. It will take a minimum
scan time of 220 ms for all channels to report temperature values.
1. The excitation for the RTD will be 2.0 mA
1. The RTD modules will be set to default scaling.
1. The bit setup of the Configuration word (decimal value of 3460) is as shown in the
following table (Table 2):
Table 2
Uses Unused Scaling Excitation Channel Filter Temperature Broken Data Format Input Type
Selection Current Enable Frequency Unit Input Selection Selection
Selection Selection Selection
Selection
Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Settings 0 0 0 0 1 1 0 1 1 0 0 0 0 1 0 0
10. All RTD channel configuration words will be moved to the proper channel configuration
output words on the PLC first scan.
1. RTD modules will only be installed in rack slots 5, 6, 7, 8, 9, 10 11, and 12.
10. The system will not be set up for auto configuration.
Average Temperature Calculation Subroutine (Temp. Sub.)

The temperature sent to FUEL FACS+ S.E. (FF DDE RTD Average Temperature (X 10) Mtr X)
will be an average temperature of the load. It is calculated in the Temp. Sub Subroutine.
The average temperature will be calculated by the TEM. SUB ladder file 4. This subroutine will
execute when the PLC Preset Enable Meter X Output bit is set. The average temperature is
calculated when the following conditions are met:
1. The PLC Preset Enable Meter X Output bit is set.

1. There is no alarm for the RTD channel, no broken input status bit, or no out of range bits
set.
If the above conditions are not met, then the system will not allow the calculations to take place.
The program will set the value of 600 (60.0˚) into the FF DDE RTD Average Temperature (X 10)
Mtr X register.
If items 1 and 2 above are met, then calculation of the average will be a running total stored in
PLC Buffer for RTD Mtr X Average Temperature Cal. Register. This total will be kept while the
calculation rung is enabled.
The PLC will also keep a total of the number of sums in the running total in the PLC Buffer for
RTD Mtr X Average Temperature Cal. Counter register. The average will be calculated by
dividing the running total PLC Buffer for RTD Mtr X Average register Temperature Cal by the
number of sums PLC Buffer for RTD Mtr X Average register Temperature CAL. Counter register.
The results are stored in FF DDE RTD Average Temperature (X 10) Mtr X register.
When the PLC Buffer for FF DDE Preset Complete Meter X is set but the FF DDE Preset
Complete Meter X is cleared, the following registers will be cleared:
1. The PLC Buffer for RTD Mtr X Average Temperature Cal.
1. PLC Buffer for RTD Mtr X Average Temperature CAL., Counter.
1. FF DDE RTD Average Temperature (X 10) Mtr X
When the PLC Preset Meter Start Meter X bit and the PLC Buffer for FF DDE Preset Meter
Enable Mtr X are not set it will also be cleared by the setting of the PLC FF OSR Preset Begin
Loading X Bit.
If the channel for the RTD is in alarm, then the Temperature average is not calculated but 60 (600)
is sent to FUEL FACS+ S.E.
Selectable Timed Interrupt (STI) Subroutine

The counting of the meter pulse will be done in a Selectable Timed Interrupt (labeled STI SUB
subroutine is ladder file 3). This STI SUB subroutine will be executed every 10 ms during the
logic scan.
The first rung in the STI will clear the B3 buffer word containing the first meter pulse bits PLC
Buffer for Pulse In Mtr X bits (meters 1 through 16). It will then perform an Immediate I/O
Update on the input module. Program will then move the input conditions into the PLC Buffer for
Pulse In Mtr X bits (the B3 word for meters 1 through 16).
The program will then test the conditions for the following:
 Clearing the meter 1 PLC FF DDE Preset Meter Gross Meter 1 Register
 Clearing the FF DDE Preset Meter Gross Meter 1 Register
 PLC Preset Enable Meter X Output bit should be set or cleared
 The requirement for injectors
The program will store any pulse detected in PLC FF DDE Preset Meter Gross Meter 1 Register
and compare the PLC FF DDE Preset Meter Gross Meter 1 Register with FF DDE Preset Meter
Gross Meter 1 Register to determine the delta, and meter flow conditions of meter 1.
Page 19 of 150
The program will then move the value in the PLC FF DDE Preset Meter Gross Meter 1 Register
into FF DDE Preset Meter Gross Meter 1 Register. The FF DDE Preset Meter Gross Meter 1
Register will serve as the last scan value for the program,
The program will repeat the above for meters 2 through 16.
The next section of the STI will repeat the above for the meters 17 through 32.
Injector Control Subroutine

This is the INJECTORS subroutine ladder file 6 that will control, monitor and set alarm conditions
of the Injectors. It will be called only when any of the following conditions exist:
 Any PLC Buffer for FF DDE Injector X Enable Mtr Y Inj Z is set.
 Any PLC Buffer for Injector X Enable Mtr Y Inj Z is set.
 Any Preset Meter X Injector Failure Alarm Latch is set.
This is done to reduce logic scan time when no injectors are required.
Clear Application Subroutine

This CLEAR SUB subroutine ladder file 5 is used to clear the PLC for a New Application. To
execute the subroutine the developer sets the New Application bit and then power cycles the PLC
to set the first scan in the PLC. This subroutine allows the clearing of bits that may not be served
in the new application. It will also allow the developer to clear all buffers during testing. This bit
is set with the processor in the program mode. When the processor is set to the run mode, the first
scan bit will set and with the PLC for New Application bit set, the Clear Application Subroutine is
called and the buffer areas will be cleared.
The PLC for New Application bit will be unlatched at the end of the Clear Application Subroutine
scan.
General Layout of the Main PLC Logic Program:

Areas:
1. Jump to the Clear Previous Application Subroutine ladder file 5 when the First Scan bit is set
and the Setup PLC for New Application bit are set.
1. Jump to the RTD Module set up subroutine will only execute on the first scan. The
Subroutine is Ladder file 7 and is called ANASETUP.
1. Marshal the main program inputs into the input buffer files.
1. Move Preset Ready Mtr (1 through 16) I:3 into B3:2 and Move Preset Ready Mtr (17
through 32) I:3.1 into B3:3 (May be removed if module is not used.)
2. Move Miscellaneous Inputs I:4 Into B3:4 (May be Removed if module is not used).
3. Move RTD Mtr (1 through 4) I:5.0, I:5.1, I:5.2, I:5.3 into N7:0 through N7:3 and Status
word for RTD Mtr (1 Through 4) I:5.4 through I:5.7 into N7:64 through N7:67 (May be
removed if module is not used.)
4. Move RTD Mtr (5 through 8) I:6.0, I:6.1, I:6.2, I:6.3 into N7:4 through N7:7 and Status
word for RTD Mtr (5 Through 8) I:6.4 through I:6.7 into N7:68 through N7:71 (May be
removed if module is not used.)
5. Move RTD Mtr (9 through 12) I:7.0, I:7.1, I:7.2, I:7.3 into N7:8 through N7:11 and
Status word for RTD Mtr (9 Through 12) I:7.4 through I:7.7 into N7:72 through N7:75
(May be removed if module is not used.)
6. Move RTD Mtr (13 through 16) I:8.0, I:8.1, I:8.2, I:8.3 into N7:12 through N7:15 and
Status word for RTD Mtr 13 through 16) I:8.4 through I:8.7 into N7:76 through N7:79
(May be removed if module is not used.)
7. Move RTD Mtr (17 Through 20) (21 through 24) I:9.0, I:9.1, I:9.2, I:9.3 into N7:16
through N7:19 and Status word for RTD Mtr (17 Through 20) I:9.4 through I:9.7 into
N7:80 through N7:83 (May be removed if module is not used.)
8. Move RTD Mtr (21 through 24) I:10.0, I:10.1, I:10.2, I:10.3 into N7:20 through N7:23
and Status word for RTD Mtr (21 through 24) I:10.4 through I:10.7 into N7:84 through
N7:87 (May be removed if module is not used.)
11. Move Swing Arm Mtr (1 through 16) I:13 into B3:5 and Move Swing Arm Mtr (17
through 32) I:13.1 into B3:6 (May be removed if module is not used.)
12. Move Injector Alarm Injector (1 through 16) I:14 into B3:7 (May be removed if module
is not used.)
13. Move Injector Alarm Injector (17 through 32) I:14.1 into B3:8 (May be removed if
module is not used.)
14. Move Injector Alarm Injector (33 through 48) I:15 into B3:9 (May be removed if module
is not used.)
15. Move Injector Alarm Injector (49 through 64) I:15.1 into B3:10(May be removed if
16. Move Injector Alarm Injector (65 through 80) I:16 into B3:11 (May be removed if
17. Move Injector Alarm Injector (81 through 96) I:16.1 into B3:12 (May be removed if
4. Marshal the FUEL FACS+ S.E. DDE points into the DDE buffer files.
1. Copy FF DDE Preset Meter Enable Mtr (1 through 32) B9:9 and B9:10 into B3:25 and
B3:26.
2. Copy FF DDE Preset Start Mtr (1 through 32) B9:11 and B9:12 into B3:27 and B3:28.
3. Copy FF DDE Injector Enable Inj (1 through 96) Mtr X Inj Y B9:13 through B9:18 into
B3:29 through B3: 34
4. Copy FF DDE Preset Meter Blend % Mtr (1 through 32) N10:25 through N10:57 into
N7:96 through N7:127.
Page 21 of 150
5. Copy FF DDE Preset Quantity Mtr (1 through 32) F11:33 through F8:64 into F8:32
through F8:63.
5. Logic for the preset meter 1 load permissives.
6. Determine the proper state for the PLC Buffer for FF DDE Preset Complete Mtr 1 and FF
DDE Preset Complete Mtr 1.
7. Determined if the following registers require reset:
 PLC FF DDE Preset Meter Gross Meter 1
 FF DDE Preset Meter Gross Meter 1
 PLC FF DDE Preset PLC Buffer for RTD Mtr 1 Average Temperature CAL.
 Counter Meter X Quantity, FF DDE Preset Meter 1 Quantity
 PLC Buffer for RTD Mtr 1 Average Temperature Cal.
 FF DDE RTD Average Temperature (X 10) Mtr 1
8. Determine the proper states for the PLC Buffer for Preset Enable Mtr 1
9. Repeat steps 5 through 8 for Meters 2 through 32.
10. Jump to Injector control subroutine if required.
11. Jump to Average Temperature subroutine if required.
12. Copy PLC Buffer for Preset Ready Mtr (1 through 32) B3:2 and B3:3 into B9:6 and B9:7 .
13. Logic for the FF DDE Swing Arm Meter (1 through 32) B9:1 through B9:5.
14. Logic for PLC Buffer for Run VRU B3:21/00.
15. Logic for PLC Buffer for VRU Alarm Horn B3:21/01.
16. Logic for PLC Buffer for “Unauthorized Flow” Alarm Horn B3:21/02.
17. Logic for PLC Buffer for Injector Failure Alarm Horn B3:21/03.
18. Logic for PLC Buffer for FUEL FACS Comms Failure Alarm Horn B3:21/04.
19. Marshal the main program output buffer file words into output words.
1. Move PLC Buffer for Miscellaneous Outputs (1 through 16) B3:21 into O:25 (Remove if
2. Move B3:13 PLC Buffer for Injector Enable Inj (1 through 16) into O:17 Injector Enable
Inj (1 through 16) (Remove if module is not used.)
3. Move B3:14 PLC Buffer for Injector Enable Inj (17 through 32) into O:18 Injector
Enable Inj (17 through 32) (Remove if module is not used.)
4. Move B3:15 PLC Buffer for Injector Enable (33 through 48) into O:19 Injector Enable
5. Move B3:19 PLC Buffer for FF DDE Preset Enable Mtr (1 through 16) into O:23 Preset
Enable MTR (1 through 16) (Remove if module is not used.)
8. Move B3:18 PLC Buffer for Injector Enable (33 through 48) into O:22 Injector Enable
9. Move B3:20 PLC Buffer for FF DDE Preset Enable Mtr (17 through 32) into O:24 Preset
Enable MTR (17 through 32) (Remove if module is not used.)
General Layout of the Selectable Timed Interrupt (STI) Subroutine

Ladder File 3
1. Clearing of the STI program input Buffer File PLC Buffer for Pulse in Meter (1 through
16) B3:0.
1. Immediate I/O update on I:1 Pulse In Meter (1 through 16) STI program inputs.
1. Move the Pulse In Meter (1 through 16) I:1 into B3:0.
1. Count pulses (add to PLC FF DDE Preset Meter Gross Meter 1).
1. Test for PLC Buffer for FF DDE Preset Meter Gross Meter 1 equal to or greater than FF
DDE Preset Quantity Meter 1.
1. Calculate PLC Preset Meter Gross Delta Meter 1. PLC Buffer for FF DDE Preset Meter
Gross Meter 1 equal FF DDE Preset Meter Gross Meter 1.
1. Test for “Flow”, “No Flow” and “Unauthorized Flow”.
1. Move PLC Buffer for FF DDE Preset Meter Gross Meter 1into FF DDE Preset Meter
Gross Meter 1.
1. Repeat Steps 4 through 8 for presets 2 through 16.
1. Clearing of the STI program input Buffer File PLC Buffer for Pulse in Meter (17 through
32) B3:1.
1. Immediate I/O update on I:2 Pulse In Meter (17 through 32) STI program inputs.
1. Move the Pulse In Meter (17 through 32) I:2 into B3:1.
1. Repeat Steps 4 through 8 for presets 17 through 32.
General Layout of the Clear Previous Application Subroutine Ladder

File 5
When the First Scan bit is set and the Setup PLC for New Application bit are set, the sub routine
will clear the following program area:
 PLC Buffer Files and Fuel Facs DDE areas B3:0 through B3:51
Page 23 of 150
 N7:0 through N7:127
 B9:0 through B9:18
 N10:0 through N10:67
 F11:0 through F11:64
 F8:0 through F8:159
 Clear I:4.0
 Clear I:3.0 through I:3.0
 Clear I:13.0 and I:13.1
 Unlatch PLC for New Application bit.
General Layout of the Injector Control Subroutine Ladder File 6

1. Logic for Preset Meter 1 injector permissive.
1. Logic for the Preset Meter 1 Injector Failure Alarms.
1. Determine the proper states for the PLC Buffer for Injector Enable Inj 1, 2, and 3.
1. Repeats steps 1 through 3 for meters 2 through 32.
General Layout of the Average Load Temperature Subroutine Ladder

File 4
Logic for calculation of Preset Meter X Average Load Temperature.
1. Determine if Meter 1 RTD has an alarm
1. If Meter 1 RTD has an alarm move 600 into the FUEL FACS RTD Average Temperature
(X10) Meter 1.
1. Allow Average load Temperature RTD Meter 1 Timer to run if the Alarm bit is not set
and the Preset Meter 1 is enabled.
1. Increment counter and calculate the average load temperature RTD meter 1 and store in
FUEL FACS RTD Average Temperature (X10) Meter 1, when the Average load
Temperature RTD Meter 1 Timer done bit is set.
1. Repeat steps 1 through 4 for RTD meters 2 through 32.
General Layout of the RTD Module Configuration Subroutine Ladder

File 7
1. Clear the output words O:5.0, O:5.1, O:5.2, O:5.3, O:6.0, O:6.1, O:6.2, O:6.3, O:7.0, O:7.1,
O:7.2, O:7.3, O:8.0, O:8.1, O:8.2, O:8.3, O:9.0, O:9.1, O:9.2, O:9.3, O:10.0, O:10.1, O:10.2,
O:10.3, O:11.0, O:11.1, O:11.2, O:11.3, and O:12.0, O:12.1, O:12.2, O:12.3.
1. Load the Configuration word into N32 through N7:63.
1. Move PLC Configuration for RTD Mtr (1 through 4) O:5.0, O:5.1, O:5.2, O:5.3 into N7:32
through N7:35. (May be removed if module is not used.)
1. Move PLC Configuration for RTD Mtr (17 Through 20) (21 through 24) O:9.0, O:9.1, O:9.2,
O:9.3 into N7:48 through N7:51. (May be removed if module is not used.)
1. Move PLC Configuration for RTD Mtr (21 through 24) O:10.0, O:10.1, O:10.2, O:10.3 into
N7:52 through N7:55. (May be removed if module is not used.)
1. Move PLC Configuration for RTD Mtr (25 through 28) O:11.0, O:11.1, O:11.2, O:11.3 into
N7:56 through N7:59 (May be removed if module is not used.)
1. Move PLC Configuration for RTD Mtr (29 through 32 O:12.0, O:12.1, O:12.2, O:12.3 into
N7:60 through N7:63. (May be removed if module is not used.)
Page 25 of 150
PLC Configuration of Status Words for FUEL-
FACS+ S. E.
The PLC status words will be setup when the system is original configured. There will be two (2)
section. One is the standard STI section and I/O section that will not change and the I/O section
that will changed based on the I/O module installed.
The STI Section will consist of the Status words and bit S:30, S:31 and S:2/1. The Status words
for the I/O modules that will not change are for slots 0 CPU always installed and 26 through 31
(these slots will never have any I/O modules installed in them. Table 3 shows the setting for these
words and bits.
Table 3
STI and Constant I/O Status Word Setup
Status Word Description Settings

Address
S:30 Setpoint (X10 ms) (STI) 1
S:31 File Number (STI) 3
S:2/1 Enable (STI) 1
S:11/00 I/O Slot Enable 0 (CPU) 1
S:27/00 I/O Slot Interrupt Enable Slot 0 (CPU) 1
S:12/10 I/O Slot Enable 26 0
S:28/10 I/O Slot Interrupt Enable Slot 26 0
The PLC will configured base on the installed I/O modules. The configuration is setup by the
status words.
Table 4
I/O Status Word Setup
Slot Description I/O Slot I/O Slot Module P/N

Enable Interrupt
Address Status Enable
word set to Status
1 if module word set
is present to 1 if
and set to module is
0 if not present
and set to
0 if not
0 CPU-32 K Memory OS501 S:11/00 S:27/00 1747-l552
1 Pulse In Meter 1 Through 16 S:11/01 S:27/01 1746-ITB16
2 Pulse In Meter 17 Through 32 S:11/02 S:27/02 1746-ITB16
3 Preset Ready Meter 1 Through 32 S:11/03 S:27/03 1746-IB32
4 Miscellaneous Inputs S:11/04 S:27/04 1746-ITB16
5 RTD Meter 1 Through 4 S:11/05 S:27/05 1746-NR4
13 Swing Arm Meter 1 Through 32 S:11/13 S:27/13 1746-IB32
14 Injector 1 Through 32 Alarm Meter 1 S:11/14 S:27/14 1746-IB32

Through 11
15 Injector 33 Through 64 Alarm Meter S:11/15 S:27/15 1746-IB32

11 Through 22
16 Injector 65 Through 96 Alarm Meter S:12/00 S:28/00 1746-IB32

22 Through 32
17 Injector 1 Through16 Enable Meter 1 S:12/01 S:28/01 1746-0W16

Through 6
Page 27 of 150
Table 4
I/O Status Word Setup
Slot Description I/O Slot I/O Slot Module P/N

Enable Interrupt
Address Status Enable
word set to Status
1 if module word set
is present to 1 if
and set to module is
0 if not present
and set to
0 if not
18 Injector 17 Through 32 Enable Meter S:12/02 S:28/02 1746-0W16

6 Through 11
19 Injector 33Through 48 Enable Meter S:12/03 S:28/03 1746-0W16

11 Through 16

17 Through 22
21 Injector 65Through 80 Enable Meter S:12/05 S:28/05 1746-0W16

22 Through 27

27 Through 32
23 Preset Enable Meter 1 Through 16 S:12/07 S:28/07 1746-0W16
24 Preset Enable Meter 17 Through 32 S:12/08 S:28/08 1746-0W16
25 Miscellaneous Outputs VRU Start S:12/09 S:28/09 1746-0W16

and Miscellaneous Horns
Failure to set these Status words and bits correctly will cause a malfunction of the PLC. These
values must be set correctly before the PLC is placed in run mode.
Initial Setup of the PLC Program

To set the PLC program for a new site you should do the following:
1. Bring the Basic program up offline.
1. Do a Save as to store the program as the site-specific program.
1. Modify the saved program’s Status words to enabled the installed I/O modules and
disable the I/O modules that are not installed. Please note the PLC will fault if proper
rack configuration is not present.
1. Set the Setup PLC for New Application bit (B3:47/0.)
1. Connect the Programmer to the SLC500 505 and put the key switch in program.
1. Download the site-specific program and go online.
1. Move the key switch into run and insure the PLC runs and does not fault.
1. Move the key switch into program.
1. Upload the program form the PLC (this should save the site-specific program.
1. Move the key switch to run and then to remote. The PLC is now ready for test.
Page 29 of 150
Simulation Subroutine Uses
The PLC has three Simulation subroutines. These are Lad 8 PLC SIMULA, LAD9 FFSIMULAT,
and LAD 10 SIM RTD. These subroutines are used to simulate the real world condition.
Subroutine 8 (Lad 8 PLC SIMULA) simulates the pulse inputs and the Preset Ready field inputs.
Subroutine 9 (LAD9 FFSIMULAT) simulates the inputs from FUEL FACS+ S.E. Subroutine 10
(LAD 10 SIM RTD) simulates the RTD inputs to the PLC.
Subroutine 8 Simulate the Meter Pulse and Preset Meter Ready Inputs
Subroutine 8 is accessed by setting the B3:47/04 (Allow the access to the PLC Simulation of Pulse
inputs of Subroutine 8) bit. When this bit is set the PLC will execute the subroutine for the PLC
meter pulse inputs simulation.
This Subroutine will generate simulated meter pulse inputs for all enabled preset meter. It will
also generate a Preset Meter Ready input for all FUEL FACS enabled meter.
This subroutine should only be used will the input modules for the meter pulses and meter ready
are not installed.
Subroutine 9 Simulate FUEL FACS+ S.E. Inputs

Subroutine 9 is accessed by setting the B3:47/05 (Allow the access to the FF Simulation of the
Subroutine 9) bit. When this bit is set the PLC will execute the subroutine for the FUEL FACS+
S.E. inputs simulation.
This subroutine will move the PLC Buffer FUEL FACS DDE Preset Meter Enable Meter 1
through 32 bits into the FUEL FACS DDE Preset Meter Start Meters 1 Through 32 bits.
Setting the proper PLC for FUEL FACS DDE Preset Meter Enable Meter X bit simulates
transactions. Setting this bit will set the FUEL FACS DDE Preset Meter Start bit for the meter bit
and load a preset of 2500 for the meter. The load will begin three (3) second after the start bit sets.
The subroutine will clear the transaction ten (10) seconds after the complete bit sets.
The subroutine includes special function bits. These are as follows:
1. The Setting this bit Will set the FUEL FACS DDE Enable Bits for Meters 1 through 32
bit (B3:47/10.) Toggle this bit on then off will start transactions on all meter.
1. The Setting this bit Will clear the FUEL FACS DDE Enable Bits for Meters 1 through 32
bit (B3:47/11.)
1. The Setting this bit Will clear the FUEL FACS DDE Enable Bits for Meters 1 through 32
bit (B3:47/12.) Toggle this bit on then off will clear the complete bit for all the
transactions.
1. Setting the Set the Transactions to Run sequentially (B3:47/13) bit will allow a
transaction to run every 240 second. The transactions will move through the meters
sequentially.
This subroutine should only be used for testing when FUEL FACS server is not available.
Subroutine 9 Simulate RTD Inputs

Subroutine 10 is accessed by setting the Allow the access to the RTD Simulation of the Subroutine
10 bit (B3:47/06).
This subroutine will set the Channel Enable on all RTD channels so the PLC will execute the
Temperature averaging calculation when the RTD modules are not installed. It will also generate
count up and count down values from 600 to 800 values for RTD values.
This subroutine should only be used when the RTD modules are not installed.
Page 31 of 150
PLC CPU Preparation
To setup the SLC-5/05 CPU for uses you must do the following steps:
1. Plug battery into J5 red wire to the edge of the board.
1. Ensure what the jumper on J4 is in the top position top (the two (2) pins furthest from the
edge of the board (bottom).)
1. Ensure the power is disconnected from the rack and plug the CPU into slot 0) of the first
rack.
1. Turn the key to the program mode.
1. Connect the power to the rack.
1. Ensure that RSLinx has both the DF-1 and Ethernet drivers installed, configured, and
running (see Figure 1.)
Figure 1
7. Ensure that RSLogix is setup for DF-1 communication (see Figure 2.)
Figure 2
8. Ensure that the Program to be loaded has the proper communication configuration (see
figures 3,4, and 5.)
Figure 3
Page 33 of 150
Figure 4
Figure 5
9. Connect serially to the CPU and download the base program.
10. Place the Programmer online.
11. Ensure the base program has loaded the IP address as 204.120.169.231 (See Figure 6.).
Figure 6
12. Set the I/O status words are set for the proper installed modules(see Figure 7.) (Failure to
set the proper I/O status will cause the CPU to fault.)
Figure 7
13. Turn the key to the run and then back to remote.
14. Ensure that the Programmer display remote run.
Page 35 of 150
15. Ensure that the Program has loaded the proper communication configuration (see figures
3,4, and 5.)
16. Set the communication to the Ethernet mode (see Figure 8.)
Figure 8
17. Disconnect the serial communication and establish the Ethernet mode.
Communication to FUEL FACS+ S.E.

The PLC will communicate to FUEL FACS+ S.E. using DDE. The FUEL FACS+
S.E. server will have Rockwell software RSLinx installed on it. This software will have the
software key installed. This is not the RSLinx Lite version. The RSLinx Lite version will not
support DDE.
This assumes the RSLinx is already installed on the FUEL FACS+ S.E. server and the key has
been installed (the DDE driver will not operate with RSLinx Lite.)
The Rockwell RSLinx will be set up to communicate to the PLC through the Ethernet connection.
The following is the setup steps for the Ethernet communication through RSLinx:
1. Start RSLinx and choose the configure driver (see Figure 9.)
2. Select the driver Ethernet to PLC-5/SLC-5820-E and Add New
3. AB_ETH-1 should display in the Configured Drivers list. (see Figure 10.)
4. Select the AB_ETH-1 driver and then select configure.
5. In the current Mapping list select node one (1) an enter the PLC’s IP address
(204.120.169.231 is the default any node and IP address compatible to the installation is
acceptable.) (See Figure 11.)
6. Accept the node one (1) address and return to the main window.
18. Do a RSWho and double click on the AB_ETH-1 Ethernet. (See Figure 12.)
7. Right click on the 204.120.169.231 SLC-5/05. (See Figure 13.)
8. Select Configure New DDE/OPC Topic. (See Figure 14.)
9. Enter the topic name of CSI-SLC505. (See Figure 15.)
10. Select Done and close RSLinx.
Page 37 of 150
Figure 9
Figure 10
Figure 11
Page 39 of 150
Figure 12
Page 41 of 150
Figure 13
Figure 14
Figure
Figure 15
Page 43 of 150
The above should allow the FUEL FACS+ S.E. server to communicate with the PLC via DDE
through the RSLinx server and the topic CSI-SLC505.
Document number goes here - FUEL-FACS+ dd-mmm-yyyy 29-May-2020 3:19 A5/P5 PRELIMINARY Page 45 of 150
This document is for internal use by CSI personnel only. Any unauthorized use or distribution will subject you to possible termination, injunctive relief, and all other rights provided by law to CSI.
01PLC Programming Notes
PLC Memory Map:

The following tables are the assignment of PLC’s memory map.
Digital Input I: Table
Table 5
Digital Input
Address Description PLC B3 PLC B3 Module P/N
Buffer File Buffer

File
by word
by bits
I:1/00 Pulse In Meter 1 B3:0/00 B3/00 1746-ITB16
Document number goes here - FUEL-FACS+ dd-mmm-yyyy 五/二十九/二〇三:一九二十九五/P 五 PRELIMINARY Page
46 of 150
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
I:3/00 Preset Ready Meter 1 B3:2/00 B3/32 1746-IB32
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
I:3.1/00 Preset Ready Meter 17 B3:3/00 B3/48 1746-IB32
48 of 150
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
I:4.1/00 VRU Operating Readback B3:4/00 B3/64 1746-ITB16
I:4.1/01 Misc. Input # 2 B3:4/01 B3/65 1746-ITB16
I:13/00 Swing Arm Meter 1 B3:4/00 B3/64 1746-IB32
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
I:13.1/00 Swing Arm Meter 17 B3:6/00 B3/96 1746-IB32
50 of 150
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
I:14/00 Injector 1 Alarm Meter 1 Injector 1 B3:7/00 B3/112 1746-IB32
I:14.1/00 Injector 17 Alarm Meter 6 Injector 2 B3:8/00 B3/128 1746-IB32
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
52 of 150
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
54 of 150
Table 5
Digital Input
Buffer File Buffer

File
by word
by bits
Digital Output O: Table
Table 6
Digital Output

File by File by
word bits
O:17/00 Injector 1 Enable Meter 1 Injector 1 B3:13/00 B3/208 1746-0W16
Table 6
Digital Output

File by File by
word bits
56 of 150
Table 6
Digital Output

File by File by
word bits
Table 6
Digital Output

File by File by
word bits
58 of 150
Table 6
Digital Output

File by File by
word bits
Table 6
Digital Output

File by File by
word bits
O:23/00 Preset Enable Meter 1 B3:19/00 B3/304 1746-0W16
60 of 150
Table 6
Digital Output

File by File by
word bits
O:25/00 Run VRU B3:21/00 B3/336 1746-0W16
O:25/01 VRU Alarm Horn B3:21/01 B3/337 1746-0W16
O:25/02 "Unauthorized Flow" Alarm Horn B3:21/02 B3/338 1746-0W16
O:25/03 Injector Failure Alarm Horn B3:21/03 B3/339 1746-0W16
O:25/04 FUEL FACS Comms Failure Alarm Horn B3:21/04 B3/340 1746-0W16
O:25/05 Misc. Output # 6 B3:21/05 B3/341 1746-0W16
O:25/06 Misc. Output # 7 B3:21/06 B3/342 1746-0W16
O:25/07 Misc. Output # 8 B3:21/07 B3/343 1746-0W16
O:25/08 Misc. Output # 9 B3:21/08 B3/344 1746-0W16
O:25/09 Misc. Output # 10 B3:21/09 B3/345 1746-0W16
O:25/10 Misc. Output # 11 B3:21/10 B3/346 1746-0W16
Table 6
Digital Output

File by File by
word bits
O:25/11 Misc. Output # 12 B3:21/11 B3/347 1746-0W16
O:25/12 Misc. Output # 13 B3:21/12 B3/348 1746-0W16
O:25/13 Misc. Output # 14 B3:21/13 B3/349 1746-0W16
O:25/14 Misc. Output # 15 B3:21/14 B3/350 1746-0W16
O:25/15 Misc. Output # 16 B3:21/15 B3/351 1746-0W16
Analog Input Table
Table 7
Analog Input
Address Description PLC Module P/N Status Configuration Channel

Buffer Word Word
File by
word
I:5.0 RTD Meter 1 N7:00 1746-NR4 I:5.4 O: 6.0 0
I:5.1 RTD Meter 2 N7:01 1746-NR4 I:5.5 O: 6.1 1
I:5.2 RTD Meter 3 N7:02 1746-NR4 I:5.6 O: 6.2 2
I:5.3 RTD Meter 4 N7:03 1746-NR4 I:5.7 O: 6.3 3
I:6.0 RTD Meter 5 N7:04 1746-NR4 I:6.4 O: 7.0 0
I:6.1 RTD Meter 6 N7:05 1746-NR4 I:6.5 O: 7.1 1
I:6.2 RTD Meter 7 N7:06 1746-NR4 I:6.6 O: 7.2 2
I:6.3 RTD Meter 8 N7:07 1746-NR4 I:6.7 O: 7.3 3
I:7.0 RTD Meter 9 N7:08 1746-NR4 I:7.4 O: 8.0 0
I:7.1 RTD Meter N7:09 1746-NR4 I:7.5 O: 8.1 1

10
62 of 150
Table 7
Analog Input

Buffer Word Word
File by
word
I:7.2 RTD Meter N7:10 1746-NR4 I:7.6 O: 8.2 2

11
I:7.3 RTD Meter N7:11 1746-NR4 I:7.7 O: 8.3 3

12
I:8.0 RTD Meter N7:12 1746-NR4 I:8.4 O: 9.0 0

13
I:8.1 RTD Meter N7:13 1746-NR4 I:8.5 O: 9.1 1

14
I:8.2 RTD Meter N7:14 1746-NR4 I:8.6 O: 9.2 2

15
I:8.3 RTD Meter N7:15 1746-NR4 I:8.7 O: 9.3 3

16
I:9.0 RTD Meter N7:16 1746-NR4 I:9.4 O: 10.0 0

17
I:9.1 RTD Meter N7:17 1746-NR4 I:9.5 O: 10.1 1

18
I:9.2 RTD Meter N7:18 1746-NR4 I:9.6 O: 10.2 2

19
I:9.3 RTD Meter N7:19 1746-NR4 I:9.7 O: 10.3 3

20
I:10.0 RTD Meter N7:20 1746-NR4 I:10.4 O: 11.0 0

21
I:10.1 RTD Meter N7:21 1746-NR4 I:10.5 O: 11.1 1

22
I:10.2 RTD Meter N7:22 1746-NR4 I:10.6 O: 11.2 2

23
I:10.3 RTD Meter N7:23 1746-NR4 I:10.7 O: 11.3 3

24
I:11.0 RTD Meter N7:24 1746-NR4 I:11.4 O: 12.0 0

25
I:11.1 RTD Meter N7:25 1746-NR4 I:11.5 O: 12.1 1
Table 7
Analog Input

Buffer Word Word
File by
word
26
I:11.2 RTD Meter N7:26 1746-NR4 I:11.6 O: 12.2 2

27
I:11.3 RTD Meter N7:27 1746-NR4 I:11.7 O: 12.3 3

28
I:12.0 RTD Meter N7:28 1746-NR4 I:12.4 O: 13.0 0

29
I:12.1 RTD Meter N7:29 1746-NR4 I:12.5 O: 13.1 1

30
I:12.2 RTD Meter N7:30 1746-NR4 I:12.6 O: 13.2 2

31
I:12.3 RTD Meter N7:31 1746-NR4 I:12.7 O: 13.3 3

32
FUEL FACS+ S.E. DDE Bit File B9 Table
Table 8
B9 FUEL FACS+ S.E. DDE Bit File
PLC B9 PLC B9 Description To FF From

File by File by FF
word bits
B9:0/00 B9/00 FUEL FACS DDE Preset Complete Meter 1 X X
64 of 150
Table 8

File by File by FF
word bits
Table 8

File by File by FF
word bits
B9:2/00 B9/32 FUEL FACS DDE Swing Arm Meter 1 Right X
B9:2/01 B9/33 FUEL FACS DDE Swing Arm Meter 1 Left X
66 of 150
Table 8

File by File by FF
word bits
Table 8

File by File by FF
word bits
B9:6/00 B9/96 FUEL FACS DDE Preset Ready Meter 1 X
68 of 150
Table 8

File by File by FF
word bits
Table 8

File by File by FF
word bits
B9:8/00 B9/128 FUEL FACS DDE PLC Health Bit (FUEL FACS X
Read)
B9:8/01 B9/129
B9:8/02 B9/130
B9:8/03 B9/131
B9:8/04 B9/132
B9:8/05 B9/133
B9:8/06 B9/134
B9:8/07 B9/135
B9:8/08 B9/136
B9:8/09 B9/137
B9:8/10 B9/138
B9:8/11 B9/139
B9:8/12 B9/140
B9:8/13 B9/141
B9:8/14 B9/142
70 of 150
Table 8

File by File by FF
word bits
B9:8/15 B9/143
B9:9/00 B9/144 FUEL FACS DDE Preset Meter Enable Meter 1 X
Table 8

File by File by FF
word bits
B9:11/00 B9/176 FUEL FACS DDE Preset Start Meter 1 X
72 of 150
Table 8

File by File by FF
word bits
B9:13/00 B9/208 FUEL FACS DDE Injector 1 Enable Meter 1 Injector X

1

2
Table 8

File by File by FF
word bits

1

2

3

1

2

3
B9:13/09 B9/217 FUEL FACS DDE Injector 10 Enable Meter 4 X

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2
74 of 150
Table 8

File by File by FF
word bits
Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2
Table 8

File by File by FF
word bits
Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2
76 of 150
Table 8

File by File by FF
word bits
Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2
Table 8

File by File by FF
word bits
Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2
78 of 150
Table 8

File by File by FF
word bits
Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2

Injector 3

Injector 1

Injector 2
Table 8

File by File by FF
word bits
Injector 3

Injector 1

Injector 2

Injector 3
FUEL FACS+ S.E. DDE Integer File N10 Table
Table 9
N10 FUEL FACS+ S.E. DDE Integer File
Integer Description To FF From FF

Files
N10:0 FUEL FACS DDE Health From the FUEL FACS Server X
N10:1
N10:2
N10:3 FUEL FACS DDE RTD Average Temperature (X 10) Meter X

1

2

3

4

5
80 of 150
Table 9

Files

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21
Table 9

Files

22

23

24

25

26

27

28

29

30

31

32
N10:35
N10:36 FUEL FACS DDE Preset Meter Blend % Meter 1 X
82 of 150
Table 9

Files
Table 9

Files
N10:68
FUEL FACS+ S.E. DDE Floating Point F11 File Table
Table 10
F11 FUEL FACS+ S.E. DDE Floating Point File
Floating Description To FF From FF

Point
Files
F11:0 FUEL FACS DDE Preset Meter Gross Meter 1 X
84 of 150
Table 10

Point
Files
F11:32
F11:33 FUEL FACS DDE Preset Quantity Meter 1 X
Table 10

Point
Files
86 of 150
Table 10

Point
Files
PLC Timer File 4 Table
Table 11
PLC Timer File
Address Description
T4:0 PLC FUEL FACS Communication Timer
T4:1 PLC Preset Start Delay Meter 1 Timer
Table 11
PLC Timer File
Address Description
T4:33 PLC "No Flow" Preset Meter 1 Timer
88 of 150
Table 11
PLC Timer File
Address Description
T4:65 “Unauthorized Flow” Preset Meter 1 Timer
Table 11
PLC Timer File
Address Description
90 of 150
Table 11
PLC Timer File
Address Description
T4:97 Average Load Temperature RTD Meter 1 Timer
Table 11
PLC Timer File
Address Description
T4:129 PLC Start Delay VRU Timer
PLC Floating Point F8 File Table
Table 12 PLC
Floating Point File
Floating Description Source

Point or
Files Destinatio
n
F8:0 PLC Buffer For FUEL FACS DDE Preset Meter Gross Meter 1 F11:0
92 of 150
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n
F8:32 PLC Buffer For FUEL FACS DDE Preset Quantity Meter 1 F11:33
94 of 150
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n
F8:64 PLC Buffer for RTD Meter 1 Average Temperature Calculation

Counter

Counter

Counter

Counter

Counter
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n
Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter
96 of 150
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter

Counter
F8:95 PLC Buffer for RTD Meter 32 Average Temperature Calculation.

Counter
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n
98 of 150
Table 12 PLC
Floating Point File

Point or
Files Destinatio
n
PLC Integer N7 Files Table
Table 13
PLC Integer Files
PLC Description Source or

INTEGER Destination
File
N7:0 PLC Buffer for RTD Meter 1 I:5.0
100 of 150
Table 13
PLC Integer Files

INTEGER Destination
File
N7:32 PLC Configuration for RTD Meter 1 O:5.0
Document number goes here - FUEL-FACS+ dd-mmm-yyyy 29-May-2020 3:19 A5/P5 PRELIMINARY Page 101 of
150
Table 13
PLC Integer Files

INTEGER Destination
File
N7:64 PLC Status Word for RTD Meter 1 I:5.4
102 of 150
Table 13
PLC Integer Files

INTEGER Destination
File
B3:80 PLC Status Word for RTD Meter 17 I:9.4
150
Table 13
PLC Integer Files

INTEGER Destination
File
N7:96 PLC Buffer for FUEL FACS DDE Preset Meter Blend % Meter 1 N10:36
104 of 150
Table 13
PLC Integer Files

INTEGER Destination
File
N7:128 N10:68
N7:129 PLC Buffer for FUEL FACS DDE Health From the FF Server N10:00
PLC Binary B3 Files Table
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:0/00 PLC Buffer for Pulse In Meter 1 I:1/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
106 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:2/00 PLC Buffer for Preset Ready Meter 1 I:3/00
B3:3/00 PLC Buffer for Preset Ready Meter 17 I:3.1/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:4/00 PLC Buffer for VRU Operating Readback I:4/00
B3:4/01 PLC Buffer for Misc. Input #2 I:4/01
108 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:5/00 PLC Buffer for Swing Arm Meter 1 I:13/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:6/00 PLC Buffer for Swing Arm Meter 17 I:13.1/00
B3:6/16 PLC Buffer for Injector 1 Alarm Meter 1 Injector 1 I:14/00
110 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:6/32 PLC Buffer for Injector 17 Alarm Meter 6 Injector 2 I:14.1/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
112 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:13/00 PLC Buffer for Injector 1 Enable Meter 1 Injector 1 O:17/00
114 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
116 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
118 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:19/00 PLC Buffer for Preset Enable Meter 1 O:23/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:21/00 PLC Buffer for Run VRU O:25/00
B3:21/01 PLC Buffer for VRU Alarm Horn O:25/01
B3:21/02 PLC Buffer for "Unauthorized Flow" Alarm Horn O:25/02
B3:21/03 PLC Buffer for Injector Failure Alarm Horn O:25/03
B3:21/04 PLC Buffer for FUEL FACS Comms Failure Alarm Horn O:25/04
B3:21/05 PLC Buffer for Misc. Output #6 O:25/05
120 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:22/00
B3:22/01
B3:22/02
B3:22/03
B3:22/04
B3:22/05
B3:22/06
B3:22/07
B3:22/08
B3:22/09
B3:22/10
B3:22/11
B3:22/12
B3:22/13
B3:22/14
B3:22/15
B3:23/00 PLC Buffer for FUEL FACS DDE Preset Complete Meter 1 B9:0/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
122 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:25/00 PLC Buffer for FUEL FACS DDE Preset Meter Enable Meter 1 B9:9/00
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:27/00 PLC Buffer for FUEL FACS DDE Preset Start Meter 1 B9:11/00
124 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:29/00 PLC Buffer for FUEL FACS DDE Injector 1 Enable Meter 1 Injector B9:13/00
1
2
3
1
2
3
1
2
3
B3:29/09 PLC Buffer for FUEL FACS DDE Injector 10 Enable Meter 4 B9:13/09
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
126 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
128 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
130 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
Injector 1
Injector 2
Injector 3
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
Injector 1
Injector 2
Injector 3
B3:35/00 PLC FUEL FACSOSR Preset 1 Begin Loading One Shot
132 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:37/00 PLC FUEL FACSOSR Preset 1 Begin Loading Bit
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:39/00 Preset 1 Begin Loading Latch Bit
134 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:41/00 One Shot for Pulse In Meter 1
136 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:43/00 Preset Meter 1 Injector Failure Alarm Latch
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
138 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:45/00 Unauthorized Flow Preset Meter 1 Latch
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:47/00 Setup PLC for New Application
B3:47/01
B3:47/02
B3:47/03
B3:47/04 Allow the access to the PLC Simulation of Pulse inputs of

Subroutine 8
B3:47/05 Allow the access to the FF Simulation of the Subroutine 9
B3:47/06 Allow the access to the RTD Simulation of the Subroutine 10
B3:47/07
B3:47/08 Target for minimum Scan jump Must not be removed
B3:47/09
B3:47/10 Setting this bit Will set the FUEL FACS DDE Enable Bits for Meters
140 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
1 through 32
B3:47/11 Setting this bit Will clear the FUEL FACS DDE Enable Bits for
Meters 1 through 32
B3:47/12 Setting this bit Will clear the FUEL FACS DDE Enable Bits for
Meters 1 through 32
B3:47/13 Set the Transactions to Run sequentially
B3:47/14 Always False instruction (never set High)
B3:47/15
B3:48/00 PLC Delay of Preset Start Meter 1
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:50/00 Preset 1 Begin Loading Permissive
142 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:52/00
B3:52/01
B3:52/02
B3:52/03
B3:52/04
B3:52/05
B3:52/06
B3:52/07
B3:52/08
B3:52/09
B3:52/10
B3:52/11
B3:52/12
B3:52/13
B3:52/14
B3:52/15
B3:53/00 PLC has detected an Injector 1 - 96 enabled by FUEL FACS
B3:53/01 PLC has detected a Injector 1- 96 enabled by the PLC
B3:53/02 PLC has detected a Preset Meter 1- 32 Injector Failure Alarm
B3:53/03
B3:53/04
144 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:53/05
B3:53/06
B3:53/07
B3:53/08
B3:53/09
B3:53/10
B3:53/11
B3:53/12
B3:53/13
B3:53/14
B3:53/15
B3:54/00 Preset 1 Has Reached PLC Buffer for Preset Quantity Meter 1
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:56/00 PLC Preset Complete One Shot Meter 1
146 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Table 14
PLC Binary Files

Buffer Destination
File by
word
B3:58/00 No Flow Preset Meter 1 Latch
148 of 150
Table 14
PLC Binary Files

Buffer Destination
File by
word
150
Notice
All procedures, data, information, drawings, specifications or other material, whether
accompanying this document or separately supplied in furtherance of this document, contain
confidential and proprietary information which (i) is the property of Control Systems
International, Inc. (“CSI”), (ii) is disclosed by CSI only in confidence, and (iii) except as CSI may
otherwise permit in writing, is to be used, disclosed or copied only to the extent necessary for the
evaluation and use thereof by the recipient. The foregoing shall not apply to any such material to
the extent that the contents (i) are now or subsequently become available to the public without
payment, (ii) were previously known to the recipient, or (iii) subsequently become otherwise
known to the recipient without restriction.
This document is based on information available at the time of its publication. While efforts have
been made to be accurate, the information contained herein does not purport to cover all details or
variations in hardware and software, nor to provide for every possible contingency in connection
with installation, operation and maintenance.
The information contained in this document is subject to change, without notice, at any time and
should not be used as a specification for any FUEL-FACS product nor for any particular FUEL-
FACS project.
CSI makes no representation or warranty, either expressed or implied, with respect to, and
assumes no responsibility for, the accuracy, completeness, or sufficiency of the information
contained herein. No warranties of merchantability or fitness for a particular purpose shall apply.
This document takes precedence over and supersedes in their entirety all previous versions or
revisions.
VXL, FUEL-FACS, UCOS, and the CSI logo are registered marks of Control Systems
International, Inc. Control Systems International, CSI, and FUEL-FACS+ are trademarks of
Control Systems International, Inc. UCOS U.S. Pat. 5,812,394.
All other product and company names/logos mentioned in this document are trademarks and/or
registered trademarks of their respective holders.
Copyright © Control Systems International, Inc. 2000. All Rights Reserved.
8040 Nieman Road, Lenexa, KS 66214-1523 USA
Telephone: 913-599-5010 Facsimile: 913-599-5013
http://www.csiks.com email: mktg@csiks.com
CSI Document No. Document number goes here
CSI Form No. K-9906-DOT-2-MKTG-23031999-MJK
150 of 150

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PLC Programming Notes

Authorized: FUEL-FACS+ Standard Edition Development Director

Coordinator: Director of Marketing Communications (written by Bob Curry)

Control Systems International, Inc.

PLC Configuration of Status Words for FUEL-FACS+ S. E............................................................26

FUEL FACS+ S. E. for Truck Rack Installation

1. The driver arrives at a bay.

Meter Meter Detail Edit X Integer Floating point N10:03 Through

1. Meter Blend (0-1000)

1. Meter Enable (Set (1))

1. Preset Quantity (how much to load)

1. Preset Start (Set (1))

1. Meter Blend % (if required by recipe, not used by current version)

 Meter Gross Quantity

The sequences are detailed below.

Normal Completion Sequence (Sequence A)

 Injector Enable (If the recipe requires the additive)

 Meter Gross Quantity

 Meter Gross Quantity

At this time the system is ready to process the next load.

FUEL FACS+ S.E. then clears the following DDE points:

 Injector Enable (If the recipe requires the additive)

 Meter Gross Quantity

 Meter Gross Quantity

At this time the system is ready to process the next load.

General PLC Programming Notes And

Conditions to set the PLC Preset Start Meter X Timer

Conditions to set the PLC FF OSR Preset X Begin Loading Bit

Conditions to set the PLC Preset Enable Meter X Output

1. The PLC Buffer for Preset Ready Meter X is set.

1. The PLC Delay of Preset Start Meter X is set.

1. The Preset Meter 1 Injector Failure Alarm Latch is not set.

It’s reset when any of the conditions above are false.

Conditions to set the Injector X Enable Mtr Y Inj Z Output

It’s reset when any of the conditions above are false.

Conditions to set the Preset Meter X Injector Failure Alarm Latch

1. And any of the Following conditions are true:

Conditions to set Preset X Begin Loading Latch Bit Timer Bit

PLC Buffer for FF DDE Preset Meter Gross Meter X Register

FF DDE Preset Meter Gross Meter X Register

Preset Meter Gross Meter X Delta

Conditions to Set the Preset Meter X “Flow” Bit

Conditions to Set the PLC “No Flow” Preset Meter X Timer

Conditions to Latch the “Unauthorized Flow” Preset Meter X Bit

Condition to Set the VRU Run Output

VRU Operating Readback Input

Operation of the VRU Alarm Horn Delay Timer

Condition to Set the VRU Alarm Horn Output

"Unauthorized Flow" Alarm Horn Output

Injector Failure Alarm Horn Output

FUEL FACS Comms Failure Alarm Horn Output

Setup PLC for New Application bit

FF DDE Meter X Blend %

RTD Temperature Measurement / RTD Module Set up Subroutine

1. The selected scale is º F.

1. A 60 HZ filter will be used. A channel’s scan time is 55 ms per channel enabled.

1. The excitation for the RTD will be 2.0 mA

1. The RTD modules will be set to default scaling.

10. The system will not be set up for auto configuration.

Average Temperature Calculation Subroutine (Temp. Sub.)

1. The PLC Preset Enable Meter X Output bit is set.

1. The PLC Buffer for RTD Mtr X Average Temperature Cal.