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Field Verification Test Matrix: CORE-08 Runtime, CORE-09 HMI/WebMI, and CORE-10 Soak

Document ID: CORE_08_09_10_FIELD_VERIFICATION_MATRIX
Milestone Scope: Plan v3 Post-Acceptance / Phase P7 Hand-off / Field Commissioning Sign-Off
Generated UTC: 2026-09-18T01:25:00Z
State Contract: STATE: CORE-08 CONFIG_AND_TEST_OK RUNTIME_PENDING_P7
Supervisor Offline Accepted: true (Signoff: 2026-09-17T14:20:00-07:00 in SUPERVISOR_OFFLINE_ACCEPTANCE.md)
Operational Mode: offline/DEV [PRODUCT_EVIDENCE] $\to$ P7_MANUAL (Field Manual Execution Only)
Target Controller: Horner APG XL4 Prime OCS (HE-XPCE2)
Programming Tool: Horner APG Cscape 10.2 (Build 10.2.751.4)
Active Project Container: TankLevel_P5_Dedicated.csp (Clean build: 0 errors, 0 warnings)
Safety & Lockout Policy: NO_PLC_DOWNLOAD_FAIL_CLOSED (Physical ports COM1..COM256, companion flash tools, Win32 32827/33149 locked fail-closed)
Live Telemetry Status: verified_live: false (Zero live PLC claims offline; field verification conducted manually by commissioning engineer)
Compiler Invariant: no_error_check_loop: true (Zero periodic polling loops)
Commissioning Engineer: Armando Silva (Lead Controls & Commissioning Engineer)

1. Scope & Execution Governance

This document establishes the definitive, point-by-point field verification test matrix for transitioning the accepted Plan v3 offline baseline into physical plant operation across three sequential field milestones:

  1. Milestone CORE-08 Runtime: Verification of live RS-485 half-duplex Modbus RTU telemetry on port MJ1 (Transmitters DEV_LT01, DEV_FT01, DEV_PT01).
  2. Milestone CORE-09 Physical HMI & WebMI: Verification of 3.5" TFT touchscreen display rendering, resistive touch navigation, alarm banners, and local LAN1 WebMI streaming.
  3. Milestone CORE-10 24-Hour Telemetry Soak: Continuous 24-hour dynamic hydraulic closed-loop pumping stability and communication reliability audit.
flowchart TD
    subgraph S0["Prerequisites (OFFLINE ACCEPTED)"]
        A1["TankLevel_P5_Dedicated.csp (CFBF Clean)"]
        A2["Pure ST POUs: FB_ModbusScaleQuality, TankLevelControl, TankLevelModbusBridge"]
        A3["Supervisor Sign-Off (2026-09-17)"]
    end

    subgraph S1["Gate P7 (Manual Load)"]
        P7["Manual Cscape Download (Ctrl+F9)\nArmando Silva (LOTO Verified)"]
    end

    subgraph S2["CORE-08 Runtime Field Matrix"]
        M1["RS-485 Physical Layer Check (120 Ohm / Vdiff > 200mV)"]
        M2["Slave Polling: DEV_LT01, DEV_FT01, DEV_PT01"]
        M3["Telemetry Quality & Scale Verification (%R101..%R105)"]
        M4["Watchdog Comm Loss & Fail-Safe Clamping Test"]
    end

    subgraph S3["CORE-09 HMI / WebMI Field Matrix"]
        H1["3.5' TFT LCD Screen Navigation (Screens 1..3)"]
        H2["Live Process Bar & Alarm Banners (%M1 High, %M2 Low)"]
        H3["Dual-Pen Real-Time Trend (PV vs SP)"]
        H4["WebMI WebSocket Streaming on LAN1 (192.168.254.128)"]
    end

    subgraph S4["CORE-10 24h Soak Field Matrix"]
        K1["24-Hour Uninterrupted Closed-Loop Pumping"]
        K2["> 864,000 Modbus Poll Cycles (< 0.01% Packet Loss)"]
        K3["Dynamic Thermal & Hydraulic Perturbation Stability"]
        K4["Physical Disconnect & Auto-Recovery Without PLC Restart"]
    end

    S0 ==> P7
    P7 ==> S2
    S2 ==> S3
    S3 ==> S4

    style S0 fill:#e8f5e9,stroke:#2e7d32,stroke-width:2px;
    style S1 fill:#fff3e0,stroke:#e65100,stroke-width:2px;
    style S2 fill:#e1f5fe,stroke:#0288d1,stroke-width:2px;
    style S3 fill:#ede7f6,stroke:#512da8,stroke-width:2px;
    style S4 fill:#fce4ec,stroke:#c2185b,stroke-width:2px;
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2. Milestone CORE-08 Runtime: Field Verification Matrix

2.1 Hardware Configuration & Bus Electrical Layer

  • Port: MJ1 (Modular 8-pin RJ45 on XL4 Prime HE-XPCE2).
  • Physical Standard: RS-485 Half-Duplex (2-wire + Common).
  • Pinout: Pin 4 = RS-485 Rx/Tx+ (Line B), Pin 5 = RS-485 Rx/Tx- (Line A), Pin 8 = Signal Ground.
  • Termination: 120 $\Omega$ 0.5W resistor installed between Pin 4 and Pin 5 at both physical bus extremities.
  • Protocol Driver: MJ1 CT RTU Modbus CMP v5.05 (CTRtu.dll v5.5.0.0, Modbus Master RTU).
  • Baud Rate: 19,200 bps | Data Bits: 8 | Parity: None | Stop Bits: 1.
  • Response Timeout: 250 ms | Retries: 3 | Inter-Frame Delay: $\ge 3.5$ char times ($&gt; 1.82\text{ ms}$).

2.2 Point-by-Point Test Cases (CORE-08)

Test ID Test Description Preconditions Injection / Procedure Expected Outcome Field Register State Result Sign-off
C08-T01 Bus Electrical Verification Power OFF, field wiring completed. Measure resistance between Lines A & B. Power ON, measure idle DC voltage. Resistance = $60\pm 5,\Omega$ (dual 120 $\Omega$ in parallel). Idle $V_{B-A} \ge +200\text{ mV}$. Line physical impedance nominal; zero ground loop offset. [ ] Pass
[ ] Fail		 AS / ______
C08-T02 DEV_LT01 Polling (Tank Level) Slave Addr 1 online; water level at 25.0%. Cscape Data Watch monitoring %AI1, %R101, %M10, %M11. Raw counts %AI1 reads $\approx 8000$. Pure ST bridge scales %R101 to $25.0% \pm 0.5%$. %AI1 $\approx 8000$
%R101 $= 25.0%$
%M10 $= 0$
%M11 $= 0$ 		[ ] Pass
[ ] Fail		 AS / ______
C08-T03 DEV_FT01 Polling (Inlet Flow) Slave Addr 2 online; feed pump active. Monitor %AI2, %R103, %M12, %M13. Raw counts %AI2 received. Scaled flow %R103 reads $0..500\text{ L/min}$ linearly. %AI2 within $[0..32000]$
%R103 scaled flow
%M12 $= 0$
%M13 $= 0$ 		[ ] Pass
[ ] Fail		 AS / ______
C08-T04 DEV_PT01 Polling (Discharge Press) Slave Addr 3 online; line pressurized. Monitor %AI3, %R105, %M14, %M15. Raw counts %AI3 received. Scaled pressure %R105 reads $0.0..10.0\text{ bar}$. %AI3 within $[0..32000]$
%R105 scaled press
%M14 $= 0$
%M15 $= 0$ 		[ ] Pass
[ ] Fail		 AS / ______
C08-T05 Underflow Quality Fault Check DEV_LT01 disconnected or sensor loop broken ($&lt;4\text{ mA}$). Disconnect signal loop to simulate transmitter underflow ($&lt;0\text{ counts}$). Sensor fault bit %M11 sets to 1 (BAD). %R101 clamps fail-safe to 0.0%. %AI1 $&lt; 0$
%R101 $= 0.0%$
%M11 $= 1$ (BAD)		 [ ] Pass
[ ] Fail		 AS / ______
C08-T06 Overflow Quality Fault Check DEV_LT01 over-range condition ($&gt;20\text{ mA}$). Inject $&gt;32000$ raw counts on Modbus register 40001. Sensor fault bit %M11 sets to 1 (BAD). %R101 clamps fail-safe to 100.0%. %AI1 $&gt; 32000$
%R101 $= 100.0%$
%M11 $= 1$ (BAD)		 [ ] Pass
[ ] Fail		 AS / ______
C08-T07 Comm Watchdog Trip & Pump Interlock System running in AUTO mode; feed pump %Q1 energized. Unplug MJ1 serial connector for $&gt; 2.0\text{ s}$. Watchdog timer trips: %M10 sets to 1 (Comm Fault). %M11 sets to 1. Pump %Q1 immediately de-energizes (0). %M10 $= 1$
%M11 $= 1$
%Q1 $= 0$ (OFF)
%R101 $= 0.0%$ 		[ ] Pass
[ ] Fail		 AS / ______
C08-T08 Auto-Recovery on Cable Reconnect System in comm fault state (%M10 = 1). Reconnect MJ1 serial connector. Within $500\text{ ms}$, Modbus frames resume. %M10 clears to 0. %M11 clears to 0. PV recovers cleanly without power cycle. %M10 $= 0$
%M11 $= 0$
%R101 valid PV		 [ ] Pass
[ ] Fail		 AS / ______

3. Milestone CORE-09 Physical HMI & WebMI: Field Verification Matrix

3.1 Display Specifications & Physical Architecture

  • Touchscreen: 3.5" Transflective TFT Color LCD (320x240 QVGA), 65,536 colors.
  • Digitizer: 4-wire analog resistive touch digitizer.
  • Ethernet Port: LAN1 (10/100 Mbps RJ45) configured with Static IP 192.168.254.128 (Subnet 255.255.255.0).
  • WebMI Server: Embedded Horner WebMI daemon running on ports 80 (HTTP) and 443 (HTTPS).

3.2 Point-by-Point Test Cases (CORE-09)

Test ID Test Description Preconditions Procedure Expected Outcome Sign-off
C09-T01 Touch Digitizer Calibration Controller powered ON; OCS System Menu accessible. Access System Menu $\to$ Touchscreen Calibration. Press the 4 calibration crosshairs in sequence. Crosshair coordinate delta $&lt; 2$ pixels. Touch target response accurate across all 4 display quadrants. [ ] Pass
[ ] Fail
AS / ______
C09-T02 Screen 1 Overview Display Controller in RUN mode. Default screen loaded. Visually inspect Screen 1: Title, System Status, Level Summary, and "Go to Control" button. No font clipping, color gradients render properly, jump button highlights on touch and transitions to Screen 2. [ ] Pass
[ ] Fail
AS / ______
C09-T03 Screen 2 Process Animation Screen 2 active; water level at 50.0%. Observe graphical vertical tank bar widget. Change level from 20% to 80%. Graphic tank bar smoothly animates fill height matching %R101. Digital readouts display PV: 50.0%, SP: 50.0%. [ ] Pass
[ ] Fail
AS / ______
C09-T04 High Alarm Banner Visual Audit Screen 2 active; water level $&lt; 75.0%$. Increase level past high limit ($&gt;75.0%$). %M1 sets to 1. Red alarm banner flashes on screen: "ALARM: TANK HIGH LEVEL". Audio beeper activates if enabled. [ ] Pass
[ ] Fail
AS / ______
C09-T05 Low Alarm Banner Visual Audit Screen 2 active; water level $&gt; 35.0%$. Decrease level below low limit ($&lt;35.0%$). %M2 sets to 1. Amber warning banner flashes: "WARNING: TANK LOW LEVEL". [ ] Pass
[ ] Fail
AS / ______
C09-T06 Alarm Acknowledge Pushbutton High or low alarm active. Press touch pushbutton "ACK ALARM" (%M3). Visual flashing transitions to solid steady illuminated banner. Alarm acknowledged flag registered in ST logic. [ ] Pass
[ ] Fail
AS / ______
C09-T07 Screen 3 Dual-Pen Trend Graph Controller in RUN mode; Screen 3 selected. Observe 60-second historical trend buffer with pens for PV (Red) and Setpoint (Green). Both pens scroll continuously at 100ms sample interval. Trend axes scale correctly from 0% to 100%. [ ] Pass
[ ] Fail
AS / ______
C09-T08 WebMI Remote Browser Mirroring PC connected to LAN1 (IP: 192.168.254.10). Open Chrome / Edge to http://192.168.254.128. Log in with authorized operator credentials. High-fidelity HTML5 / SVG screen mirror renders. Screen update latency $\le 250\text{ ms}$. Remote navigation works. [ ] Pass
[ ] Fail
AS / ______

4. Milestone CORE-10 24-Hour Telemetry Soak: Field Verification Matrix

4.1 Soak Environment & Dynamic Operating Profile

  • Continuous Duration: 24.0 consecutive hours (1,440 minutes).
  • Ambient Conditions: Operating temperature $15^\circ\text{C}$ to $40^\circ\text{C}$, relative humidity $10%$ to $85%$ non-condensing.
  • Actuator Load:
    • Feed Pump Contactor %Q1: 480VAC 3-phase motor, 15 HP, 18.5 FLA.
    • Drain Solenoid Valve %Q2: 24VDC pilot solenoid, 1.2A inrush, 0.4A holding.
  • Modbus Transaction Rate: 10 transactions/sec total (1 transaction per transmitter every 300 ms).
  • Target Transaction Count (24h): $\ge 864,000$ total poll cycles.

4.2 Point-by-Point Test Cases (CORE-10)

Test ID Test Description Evaluation Period Acceptance Criteria Measured Value Field Result Sign-off
C10-T01 Continuous Execution Stability Hours 00:00 to 24:00 (Full 24h) Zero CPU lockups, zero controller resets, zero unhandled task exceptions. Uptime: 24h 00m [ ] Pass
[ ] Fail		 AS / ______
C10-T02 Modbus RS-485 Frame Reliability Cumulative over 24 hours Total poll transactions $\ge 864,000$. Frame error / retry rate $&lt; 0.01%$ ($&lt; 86$ dropped packets). Total: ________
Errors: _______		 [ ] Pass
[ ] Fail		 AS / ______
C10-T03 Closed-Loop Level Regulation Hours 02:00 to 20:00 (Dynamic fill/drain) Process variable %R101 maintains setpoint within $\pm 2.5%$ under cyclic drain disturbances. Max Dev: $\pm$_____% [ ] Pass
[ ] Fail		 AS / ______
C10-T04 Thermal Drift & Sensor Invariance Monitored at $15^\circ\text{C}$, $25^\circ\text{C}$, $40^\circ\text{C}$ ambient Zero-point drift $&lt; 0.25%$ span. Gain drift $&lt; 0.50%$ span across ambient temperature excursions. Drift: ______% [ ] Pass
[ ] Fail		 AS / ______
C10-T05 Memory & Resource Leak Audit Monitored hourly via %SR registers Horner System Registers %SR33 (Scan Time) and %SR35 (Free Memory) show zero secular degradation. Scan: _____ ms
Free: _____ KB		 [ ] Pass
[ ] Fail		 AS / ______
C10-T06 Transient Noise Spike Immunity During large motor start / contactor cycling Contactor switching noise on adjacent wireways causes zero Modbus CRC errors or false alarm trips. CRC Errs: 0 [ ] Pass
[ ] Fail		 AS / ______
C10-T07 End-of-Soak Fail-Safe Trip Audit At Hour 24:00 Simulate e-stop / power interruption. Verify pump %Q1 and valve %Q2 return safely to de-energized state. Safe State Confirmed [ ] Pass
[ ] Fail		 AS / ______

5. Register Reference & Memory Map Summary

Register Type Tag Name Engineering Range Scaling Function Quality Bit Comm Alarm
%AI1 INT RawLevelCount $0..32000$ counts Modbus RTU 40001 (DEV_LT01) %M11 %M10
%AI2 INT RawFlowCount $0..32000$ counts Modbus RTU 40002 (DEV_FT01) %M13 %M12
%AI3 INT RawPressureCount $0..32000$ counts Modbus RTU 40003 (DEV_PT01) %M15 %M14
%R101 REAL TankLevelPV $0.0..100.0,%$ Linear Scale ($0..32000 \to 0.0..100.0$) N/A N/A
%R103 REAL InletFlowRate $0.0..500.0\text{ L/min}$ Linear Scale ($0..32000 \to 0.0..500.0$) N/A N/A
%R105 REAL DischargePressure $0.0..10.0\text{ bar}$ Linear Scale ($0..32000 \to 0.0..10.0$) N/A N/A
%R1 REAL TargetSetpoint $0.0..100.0,%$ Operator HMI Entry / Setpoint N/A N/A
%Q1 BOOL FeedPumpCommand FALSE / TRUE Discrete Output Relay (Pump 480VAC) N/A Interlocked %M10
%Q2 BOOL DrainValveCommand FALSE / TRUE Discrete Output Relay (Valve 24VDC) N/A N/A
%M1 BOOL AlarmHighLevel FALSE / TRUE Active when PV $&gt; 75.0%$ N/A Red Flash Screen 2
%M2 BOOL AlarmLowLevel FALSE / TRUE Active when PV $&lt; 35.0%$ N/A Amber Flash Screen 2
%M3 BOOL AlarmAckPB FALSE / TRUE Momentary HMI Ack Pushbutton N/A Clears Flashing

6. Autonomous Consortium Governance & Sign-Off

All test procedures above comply strictly with the governing safety rules:

  1. Zero PLC Download in Software: FastMCP servers and AI agents are permanently locked out fail-closed from physical COM ports and Win32 download command IDs (32827, 33149).
  2. Zero VERIFIED_LIVE Claimed Offline: Operational status remains strictly offline/DEV [PRODUCT_EVIDENCE] $\to$ P7_MANUAL.
  3. Single GUI Automation Owner: Exclusive interactive desktop access maintained on winsta0\Default (PID 12788).
  4. Compiler Watchdog Invariant: Zero periodic compiler polling loops (no_error_check_loop: true).

Multi-Agent Verification Consortium

Agent Role Responsibility Domain Audit Status Sign-off Date
Lead Orchestrator Critical path governance, gate discipline, evidence-based progression VERIFIED_OFFLINE 2026-09-18
PLC/IEC Specialist Pure ST AST validation, IEC 61131-3 conformance, ERR_LADDER_FORBIDDEN VERIFIED_OFFLINE 2026-09-18
Simulation Specialist In-memory cyclic emulation, register clamping, test vector assertion VERIFIED_OFFLINE 2026-09-18
Security & Safety Guard Fail-closed port lockout (COM1..256), download command interception (32827/33149) LOCKED_FAIL_CLOSED 2026-09-18
FastMCP Architect FastMCP JSON-RPC 2.0 tool suite (43 tools), 4-state contract integrity VERIFIED_OFFLINE 2026-09-18
GUI Automation Agent Single GUI owner (PID 12788), modal suppression, visible desktop boundary VERIFIED_OFFLINE 2026-09-18
Standards & Docs Agent Dual-root synchronization, documentation rigor, cryptographic audit VERIFIED_OFFLINE 2026-09-18

7. Field Sign-Off Certificate

(To be signed by Armando Silva upon completion of physical commissioning on-site)

Phase P7 Manual Download Completed: [ ] YES [ ] NO | Date: ____________ Signature: ____________________
CORE-08 Live Modbus Polling Accepted: [ ] YES [ ] NO | Date: ____________ Signature: ____________________
CORE-09 Physical HMI / WebMI Accepted: [ ] YES [ ] NO | Date: ____________ Signature: ____________________
CORE-10 24h Telemetry Soak Accepted: [ ] YES [ ] NO | Date: ____________ Signature: ____________________