Manually controlling a batch

Placing the mode of a step in MANUAL mode allows an operator to stop execution when the current subordinate step is complete. The operator can then click the AUTO button to allow the subordinate steps to continue according to the recipe, or execute an active step change to start the next (or any other) step at the same level.

For example, there is a problem with equipment related to the COOL phase in the MAKE_BASE operation of the Paint recipe. The operator and maintenance person decide that the best way to correct this is while the batch is in operation. This requires that the AGITATE phase (which runs in parallel with COOL phase) is stopped, and that the TEMP_TO_COOL parameter be changed several times while the phase is re-run.

After the batch is started and has reached the COOL phase (MAKE_BASE and MAKE_ADDITIVE are both active), the operator selects the MAKE_BASE operation and clicks the MANUAL button. This causes the procedure level of the recipe and the BASE unit procedure to go to MANUAL mode as well.

The ADDITIVE unit procedure goes to O-AUTO mode. The operator can choose to allow this to continue. He can select the MAKE_ADDITIVE operation and place it in MANUAL mode also.

With MAKE_BASE in MANUAL mode, the operator is able to independently select the AGITATE and the COOL phases and issue STOP, HOLD / RESTART, or ABORT commands. When they both reach a terminal state (Stopped, Aborted, or Complete), the operator selects the MAKE_BASE operation, and repeatedly does active step changes to repeat the COOL phase with changes to the TEMP_TO_COOL parameter. (This is done using the Parameters tab at the bottom of the screen.)

When changes are complete, the operator does a final active step change to the next (QA_TEST) phase, which puts it in Ready state. He then selects the MAKE_BASE operation, clicks the AUTO button to place the operation in O-AUTO mode, and then Clicks the Resume button to continue the unit operation at the QA_TEST phase. He then select the batch (procedure) level, and clicks the AUTO button to put the entire batch back in AUTO mode.