BRAUMAT compact
V3.0 SP1
Engineering Manual
09/2012
A5E02608507B-02
General
GeneralGeneral
General
1
11
1
Installation
InstallationInstallation
Installation
2
22
2
Demo
DemoDemo
Demo
Project
ProjectProject
Project
3
33
3
System
SystemSystem
System
Overv
OvervOverv
Overview
iewiew
iew
4
44
4
Create
CreateCreate
Create
New
NewNew
New
Project
ProjectProject
Project
5
55
5
Excel
ExcelExcel
Excel
Addin
AddinAddin
Addin
6
66
6
Trending
TrendingTrending
Trending
7
77
7
Recipe
RecipeRecipe
Recipe
Configuration
ConfigurationConfiguration
Configuration
8
88
8
Scheduler
SchedulerScheduler
Scheduler
9
99
9
Batch
BatchBatch
Batch
Data
DataData
Data
Export
ExportExport
Export
a
aa
and
ndnd
nd
Report
ReportReport
Report
10
1010
10
Technologi
TechnologiTechnologi
Technological
calcal
cal
Hierarch
HierarchHierarch
Hierarchy
yy
y
11
1111
11
Connection
ConnectionConnection
Connection
of
ofof
of
CFC
CFCCFC
CFC
Pl
PlPl
Plans
ansans
ans
12
1212
12
Control
ControlControl
Control
Modules
ModulesModules
Modules
13
1313
13
User
UserUser
User
Archives
ArchivesArchives
Archives
14
1414
14
Expanded
ExpandedExpanded
Expanded
Functionalities
FunctionalitiesFunctionalities
Functionalities
15
1515
15
Plant
PlantPlant
Plant
-
--
-
distribution
distributiondistribution
distribution
on
onon
on
various
variousvarious
various
c
cc
controllers
ontrollersontrollers
ontrollers
16
1616
16
Redundant
RedundantRedundant
Redundant
Server/Client
Server/ClientServer/Client
Server/Client-
--
-System
SystemSystem
System
17
1717
17
Redundant
RedundantRedundant
Redundant
Single
SingleSingle
Single
Station
StationStation
Station
18
1818
18
Restart
RestartRestart
Restart
After
AfterAfter
After
CPU
CPUCPU
CPU
Stop
StopStop
Stop
19
1919
19
Web
WebWeb
Web
20
2020
20
Further
FurtherFurther
Further
Information
InformationInformation
Information
in
inin
in
dealing
dealingdealing
dealing
with
withwith
with
BRAUMAT
BRAUMATBRAUMAT
BRAUMAT
compact
compactcompact
compact
21
2121
21
Do
DoDo
Document
cumentcument
cument
Cross
CrossCross
Cross
Reference
ReferenceReference
Reference
22
2222
22
Engineering Manual, 06/2010, A5E02608507B-02 Page 2
Safety guidelines
Safety guidelinesSafety guidelines
Safety guidelines
This manual contains notices which you should observe to ensure your own personal safety, as well as to protect
the product and connected equipment. These notices are highlighted in the manual by a warning triangle and are
marked as follows according to the level of danger.
Danger
DangerDanger
Danger
indicates that death, severe personal injury or substantial property damage will result if proper precautions are
not taken.
Warning
WarningWarning
Warning
indicates that death, severe personal injury or substantial property damage can result if proper precautions are
not taken.
Caution
CautionCaution
Caution
indicates that minor personal injury or property damage can result if proper precautions are not taken.
Attention
AttentionAttention
Attention
draws your attention to particularly important information on the product, handling the product, or to a particular
part of the documentation.
Qualified personnel
Qualified personnelQualified personnel
Qualified personnel
Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined
as persons who are authorized to commission, to ground, and to tag circuits, equipment, and systems in
accordance with established safety practices and standards.
Correct usage
Correct usageCorrect usage
Correct usage
Note the following:
Warning
WarningWarning
Warning
This device and its components may only be used for the applications described in the catalogue or the
technical
descriptions, and only in connection with devices or components from other manufacturers which have
been approved or recommended by Siemens.
This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and
operated and maintained as recommended.
Brands
BrandsBrands
Brands
SIMATIC®, SIMATIC HMI®, SIMATIC NET® und SENTRON® are Brands of SIEMENS AG.
Some other designations used in these documents are also brands; the owner's rights may be violated if they are
used by third parties for their own purposes.
Disclaimer of liability
Disclaimer of liabilityDisclaimer of liability
Disclaimer of liability
We have checked this manual to ensure that its contents are correct and applicable in relation to the hardware
and software it describes. Despite all our endeavours, however, discrepancies cannot be wholly excluded and so
we cannot guarantee complete correctness and applicability. However, the data in this manual are reviewed
regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are
welcomed.
Siemens AG
Industry Sector
Postbox 48 48
90327 NUREMBERG
GERMANY
Ⓟ 06/2010
Copyright © Siemens AG 2009.
Technical data subject to change
Contents BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 1
Contents
CONTENTS 1
1 GENERAL 8
1.1
System Requirements 8
1.2
Hardware Configurations 8
1.2.1
Bundle SIMATIC PCS 7 Box RTX 8
1.2.2
Bundle AS416-2 Single OS 9
1.2.3
Bundle AS416-3 Redundant Single OS 9
1.2.4
Bundle 416-3 OS-Server/Client 10
1.3
Engineering Requirements 10
1.3.1
Excel Version for BRAUMAT compact engineering 10
1.3.2
Excel Version for batch data 10
1.3.3
Name Conventions 10
1.3.4
Engineering Conventions 11
1.3.5
Time Setting 12
1.3.6
Path Definitions 13
1.4
Quantity Structure 13
1.5
Resource usage 14
1.6
Projectable Quantity Structure 15
2 INSTALLATION 16
2.1
Requirements for SIMATIC PCS 7 Standard 16
2.2
BRAUMAT compact Installation 16
2.3
Expanded Standard Installation 17
2.4
Installation Demo Project and Control Module Library 17
2.5
Needed Licenses: 17
3 DEMO PROJECT 19
3.1
Configurations 19
3.1.1
SIMATIC S7 Hardware Configuration 19
3.1.2
SIMATIC S7 Netpro-Configuration 19
3.1.3
Configuration Station Configuration Editor 19
3.2
S7 Compile and Load Program 19
3.3
Generate OS 19
4 SYSTEM OVERVIEW 20
BRAUMATcompact Contents
Engineering Manual, 06/2010, A5E02608507B-02 Page 2
4.1
System Plan
Unit Sequence 20
4.1.1
System Plan 20
4.2
Unit Plan 23
4.2.1
Unit Control module (Partition A , B , C and D) 23
4.2.2
Unit Parameter (Partition E) 29
4.2.3
Unit Number 30
4.3
Unit Sequence
Text Allocation 30
4.3.1
Unit Sequence Recipe Configuration 30
4.3.2
Scheduler Unit 31
4.4
Sequencer with Status Diagram 32
4.4.1
Status Transition Idle Starting 34
4.4.2
Status transition Starting Running 34
4.4.3
Status transition Running ready to complete 34
4.4.4
ready to complete Completing 34
4.4.5
5 Completing Completed 34
4.4.6
Completed Idle 34
4.4.7
Running Holding 34
4.4.8
Holding Held 34
4.4.9
Held Resume 35
4.4.10
 Resume Running 35
4.4.11
 Abort 35
4.4.12
 Aborting Aborted 35
4.4.13
 Aborted Idle 35
4.4.14
 Stopping 35
4.4.15
5 Stopping Stopped 35
4.4.16
 Stopped Idle 35
4.5
Options of step behavior 36
4.5.1
Behavior at the command Resume after Hold 36
4.5.2
Reset of the Aggregates 36
5 CREATE NEW PROJECT 37
5.1
General 37
5.1.1
SIMATIC Manager 38
5.1.2
Create user text library 38
5.1.3
HW Configuration 38
5.1.4
Netpro 38
5.2
Technological Hierarchy 38
5.3
CFC Plans 39
5.3.1
System Charts 41
5.3.2
Unit 42
5.3.3
Link the Units Together 43
5.4
WinCC Engineering 44
5.4.1
Project-Specified Configuration 44
5.4.2
Runtime Configuration 60
5.5
Control modules 67
5.5.1
Insert and connect control modules 67
5.5.2
Connection / Import via IEA-Assistant 67
Contents BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 3
6 EXCEL ADDIN 68
6.1
General 68
6.1.1
Requirements 68
6.1.2
Development Environment 68
6.1.3
General Settings in order to work with the Workbooks 69
6.1.4
Online - / Offline - Mode 70
6.1.5
Workbook - 01_TextLib_General.xls 73
6.1.6
Workbook - 01_TextLib_ Recipetypes.xls 74
6.1.7
Workbook - 01_TextLib_RecName_for_Rectype1.xls 75
6.1.8
Workbook 2 - 02_TextLib_Unit.xls 76
6.1.9
Workbook 3 - 03_Archive_Unit_Para.xls 78
6.1.10
Workbook 4 - 04_Archive_Unit.xls 80
6.1.11
Possible Error Sources 85
7 TRENDING 86
8 RECIPE CONFIGURATION 87
8.1
Recipe configuration 87
8.2
Recipe Types 87
8.3
Start units with different recipes 88
8.4
Different recipe types in the brewery 89
8.4.1
Assign recipe type to unit 89
8.4.2
Start unit with different recipe type 90
9 SCHEDULER 91
9.1
CFC Plan 91
9.2
WinCC Engineering 92
10 BATCH DATA EXPORT AND REPORT 94
10.1
Batch Export 94
10.2
Batch Report 95
11 TECHNOLOGICAL HIERARCHY 97
12 CONNECTION OF CFC PLANS 99
12.1
Connection via Process Object View 99
12.1.1
Unit 99
12.1.2
Aggregates 100
12.1.3
Use of Configuration Text Data 102
12.2
“Manual“ Connection of Aggregate 104
13 CONTROL MODULES 107
BRAUMATcompact Contents
Engineering Manual, 06/2010, A5E02608507B-02 Page 4
13.1.1
List of the Templates (acc. Master Plans) 107
13.1.2
Functionality 107
13.1.3
CM Info 110
14 USER ARCHIVES 111
14.1
Archives 111
14.2
Contents and Settings 112
14.3
Backup and Recovery User Archives 113
15 EXPANDED FUNCTIONALITIES 115
15.1
Shared Use of Aggregates / Units 115
15.1.1
Aggregates : BRC_MUX (CM multiplexer FB1105) 115
15.1.2
Units: BRC_USTA: (TA starter FB1108) 116
15.2
Unit Multiplexer 123
15.2.1
General 123
15.2.2
CFC BRC_UMX 123
15.2.3
User Interface 124
15.3
Expanded Synchronisation 126
15.4
Standardisation concept in BRAUMAT compact 129
15.4.1
Overview 129
15.4.2
Set Parameter for Standardisation 131
15.4.3
Configure Recipe Quantity 132
15.4.4
Start Batch with a Quantity 132
15.4.5
Runtime Events in the Environment Standardisation 133
15.5
Master Unit- Configure Referencing Unit 134
15.5.1
General 134
15.5.2
CFC Plans 135
15.5.3
WinCC Engineering 138
15.5.4
Online Engineering 139
15.5.5
Expansion 140
15.6
Set Point Trends 140
15.6.1
(BRC_SPT: BRAUMAT compact setpoint trend ) – Line Archive 140
15.6.2
(BRC_SPTX: BRAUMAT compact set point trend ) – Trend Archive 142
15.7
Operating Locking 144
15.8
Open User Specified Expansion 146
15.9
Step Counter and Sum Counter 147
15.10
Time Step Monitoring 148
15.10.1
Temporal Step Monitoring 149
15.10.2
Step Time in Minutes 150
15.11
Projection 60 Units 151
15.11.1
New CFC – chart 151
15.11.2
Install additional „BRC_BAID“ 151
15.11.3
Install additional „FB_RECM“ 152
Contents BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 5
15.11.4
Install additional „FB_ARCHM“ 153
15.11.5
Create new raw data variables 153
15.11.6
Skripting 154
15.12
Update Group Display 156
15.13
Automatic Jump 157
15.13.1
Jump Coordinator 157
15.13.2
Jump with recipe set point 161
15.13.3
Combination Jump via Recipe Set Point with Jump Coordinator. 163
15.14
Condition based operator request 164
15.14.1
Automatic Operator Request Reset 164
15.14.2
Operator request OR Signal as move net step condition 167
15.15
Encode / Decode for CM_Info 169
15.15.1
Encode CM_INFO 169
15.15.2
Decode CM_INFO 170
15.16
Free Batch Name 171
15.17
Locking of Step Change 171
15.17.1
AS - Configuration 171
15.17.2
OS – Konfiguration 172
15.17.3
Recipe Configuration 173
15.17.4
Runtime Events 173
15.18
Change of the Set value at Running Recipe 176
15.19
Set Value Adoption in the Runtime 177
15.20
Batch data export and supervision of the batch archive 181
15.20.1
Functionality 181
15.20.2
AS-Configuration 181
15.20.3
OS-Configuration 182
15.20.4
OS – Further functions 184
15.21
Export und import of recipes 186
15.21.1
Functionality 186
15.21.2
AS-configuration 186
15.21.3
OS- Configuration 187
16 PLANT - DISTRIBUTION ON VARIOUS CONTROLLERS 190
16.1
System configuration 1 190
16.1.1
Structure of the project 190
16.1.2
Multi project 191
16.2
System configuration 2 192
16.2.1
Structure of the project 192
16.2.2
Multi project 193
16.3
Equipment ID 193
16.3.1
System configuration 1 193
16.3.2
System configuration 2 193
16.4
Recipe type 194
16.4.1
System configuration 1 194
BRAUMATcompact Contents
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16.4.2
System configuration 2 194
16.5
CFC - Typical ‚SYSTEM 194
16.6
CFC - Typical ‚SCHEDULER’ 195
16.7
Scripting 196
16.8
Unit - Start via U_A_NEXT / U_A_PREV 198
16.9
Unit start via function block USTA 199
16.10
Shared Equipment 199
17 REDUNDANT SERVER/CLIENT-SYSTEM 201
17.1
Network Structure 201
17.2
Engineering in SIMATIC Manager 202
17.2.1
Hardware Configuration 202
17.2.2
Install Netpro 203
17.2.3
Other Configuration 204
17.3
Engineering in WinCC 206
17.3.1
Install Master-Server 206
17.3.2
Install Standby-Server 207
17.3.3
Install Client 207
17.3.4
Use of „make“ 208
18 REDUNDANT SINGLE STATION 210
18.1
Minimal Configurations – An Oververiew 210
18.2
ES/OS-Master und OS-Standby (Single Station Redundancy) 210
18.2.1
Configuration Description 210
18.2.2
Paticularities / restrictions 211
19 RESTART AFTER CPU–STOP 213
19.1
AS - Configuration 213
19.2
Functioning 213
20 WEB 215
20.1
Braumat compact Web Components 215
20.2
Restricted functionality of BRAUMAT compact on Web Clients 216
20.2.1
Editor Recipe names 217
20.2.2
Batchreport 217
20.2.3
Save Data: Export / Import UserArchive data 217
20.2.4
Manage Batchdata 218
21 FURTHER INFORMATION IN DEALING WITH BRAUMAT COMPACT 219
Contents BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 7
21.1
Consequences of the over-all Translation 219
21.2
Packed ET200S Addresses 219
21.3
Recommendation Time Synchronisation 219
21.4
Use of the ISO Protocol 219
21.5
Scheduler 220
22 DOCUMENT CROSS REFERENCE 221
BRAUMATcompact General
Engineering Manual, 06/2010, A5E02608507B-02 Page 8
1 General
BRAUMAT compact is a library to PCS 7, which is exclusively applicable with the
released BRAUMAT compact version of SIMATIC PCS 7.
The structure as well as the installation of the system software is explained in the PCS
7 documentation.
1.1 System Requirements
The current system requirements are documented in the readme file on the installation
CD.
1.2 Hardware Configurations
BRAUMAT compact is available in different bundled systems.
These Bundles will be installed fully and delivered accordingly with a license. For the
AS-Systems, there is the option of either a 24V DC or 120V/230V AC power supply.
The OS-Systems will be configured in different language options.
Further information can be retrieved from the read-me file or from the different
reference numbers.
1.2.1 Bundle SIMATIC PCS 7 Box RTX
The SIMATIC Box PC is equipped with a Software Controller WinAC RTX.
General BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 9
1.2.2 Bundle AS416-2 Single OS
The Bundle 416-2 Single OS consists of the following components:
1 x AS 416-2 with the option of either a 24V or 120/230V power supply with
license 500 PO
1 x SIMATIC PCS 7 Industry-PC as OS Single-Station 1000 PO with Multi-VGA
1.2.3 Bundle AS416-3 Redundant Single OS
The Bundle AS416-3 Redundant Single OS consists of the following components:
1 x AS 416-3 with the option of either a 24V or 120/230V power supply with
license 500 PO
2 x SIMATIC PCS 7 Industry-PC as OS Single-Station 1000 PO with Multi-VGA
with redundancy comparison.
BRAUMATcompact General
Engineering Manual, 06/2010, A5E02608507B-02 Page 10
1.2.4 Bundle 416-3 OS-Server/Client
The Bundle Server-Client consists of the following components:
1 x AS 416-3 with the options power supply with license 500 PO
1 x SIMATIC PCS 7 Industry-PC as OS-Server 1000 PO
1 x SIMATIC PCS 7 Industry-PC as OS-Client
1.3 Engineering Requirements
1.3.1 Excel Version for BRAUMAT compact engineering
The BRAUMAT compact engineering is generated and imported by Excel. BRAUMAT
compact is released with MS Excel 2003, 2007 and 2010.
MS Excel has to be installed on the SIMATIC PCS 7 Engineering Station.
1.3.2 Excel Version for batch data
The batch data are exported in Excel via an export function.
BRAUMAT compact is released with MS Excel 2003, 2007 and 2010.
MS Excel must be installed on the computer, on which the export process should be
carried out.
1.3.3 Name Conventions
The following length conventions are to be considered for the name allocation.
Referring to the length, average texts are accepted. Names with a high percentage of
long letters (e.g. M, W, m, w) could possibly not be displayed entirely. Texts with a high
percentage of short letters (e.g. e, t, i, l) possibly enable the display of longer texts.
General BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 11
Object Valid max. Length
Unit name 24
Recipe type name 24
Recipe name 24
Step name 40
Operator request 40
Name of Control Module 40
Parameter name 40
Unit of measurement 5
Name of analogue value 24
Logic name 24
Prefix order in the Scheduler 19
Prefix charge in the Scheduler 19
1.3.4 Engineering Conventions
For creating a new project the text library must be installed on the engineering station
(ES), (see chapter 6 Excel Addin).
The CFC plan name has the following structure <unit name>_PHCON the unit name,
however, can be chosen freely.
Example for the unit Mill:
CFC – Plan: Mill_PHCON
BRAUMATcompact General
Engineering Manual, 06/2010, A5E02608507B-02 Page 12
1.3.5 Time Setting
BRAUMAT compact expects that the AS is set on UTC. The time difference between
AS and local PC/Server must be configured correctly via the SIMATIC Manager.
The following example shows the setting for the Central European Time (Winter).
Image 1: Time setting
General BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 13
1.3.6 Path Definitions
BRAUMAT compact needs different paths in the data system
1. Export / Import of the User Archives (Backup)
The entire User Archive can be exported to „c:\backup“ (Standard setting) resp.
reimported from there. This directory is optional and can be configured resp.
altered to runtime in the Engineering Display. The therefore needed path must
be set up.
2. Automatic Export of the Archive Data
The archive data are exported circular and then deleted. The data are exported
to c:\export\ua. This directory needs to be set up.
3. Export of the Batch Reports
The batch reports are exported in a directory that is configured in the data
XLS2UA.ini (directory BRAUMAT in the OS Project). This directory must be set
up.
4. Excel Addin
The directory EXCEL_ADDIN must be copied from the directory
…\Programme\Siemens\WINCC\BRAUMAT_compact into the respective OS
project directory, e.g. …\BRC_Prj\wincproj\OS.
1.4 Quantity Structure
Requirements
Bundle SIMATIC S7-416-2 Single OS
Quantity Structure
180 valves
25 pumps
50 analogue values
20 units
30 other blocks
The stated quantity structure specifications are standard values, which function with
the stated memory expansion of the PLC and with the licenses.
The limits are not defined and can be exceed partially. Thereby, the limits for the PLC
storage as well as for the server license are to be considered.
BRAUMATcompact General
Engineering Manual, 06/2010, A5E02608507B-02 Page 14
1.5 Resource usage
Function Process
Objects (AS)
Process
Objects (AS
and OS)
Tags
(OS)
PBK
(AS)
Basic System 3
3
96
33
Unit without Control
Module 3
3
531
7
Scheduler 1
1
435
3
Valve (Feedback
close) 1
1
53
1
Motor (runs with
Feedback) 1
1
53
1
Pump 1
1
53
1
PID Controller 1
1
285
2
The consumption of resources shows an approximate indication. An accurate storage
occupancy, runtime analysis, and consumption of process object must be determined
in particular case. The stated values vary according to the selected CFC template.
Remark:
The method of counting process objects in PCS7 V7.1 is described in FAQ 38855207.
http://support.automation.siemens.com/WW/view/de/38855208
General BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 15
1.6 Projectable Quantity Structure
The following quantity structure is available in BRAUMAT compact:
Components/Subset Quantity
Description
Number of the dynamic
units 20 A dynamic unit is a unit with several recipe
switches within a couple of hours
Number of units in the
system unit 50 A system unit contains the operating area e.g.
brewery, cellar, or filtration.
Number of units maximal
99 Thereby additional units are allowed to the
dynamic units, which execute few recipe
switches (e.g. fermentation tank)
Recipe types 10 A recipe type is a group of similar recipes
Recipe per recipe type 32 A recipe is the brackets of homonymous
sequences per unit
Steps per sequence 64 One sequence describes the cycle of exactly one
unit.
Control module per unit 128 Per unit 128 control modules (Valves, motors,
pumps,…) can be held in the connection of the
sequence.
Parameter types per unit 24 A parameter type describes a parameter with
diagram, Min, Max, Hysteresis and type (Timer,
counter, set point / actual value comparison)
Parameter per step 24 Each parameter type can be configured with
another set point per each step.
Logic per unit 32 The logic enables an expanded forward condition
resp. an Or connection.
Maximal one logic can be used per control
module
Analogue value per unit 16 16 analogue values can be used as set point-
actual value comparison per unit
Orders per scheduler 22 On each scheduler a maximum of 22 orders is
configurable
BRAUMATcompact Installation
Engineering Manual, 06/2010, A5E02608507B-02 Page 16
2 Installation
2.1 Requirements for SIMATIC PCS 7 Standard
The installation of BRAUMAT compact requires a prior successful and complete
installation of SIMATIC PCS 7 V7.0 incl. all required licenses.
BRAUMAT compact bundles are preconfigured.
2.2 BRAUMAT compact Installation
The installation of the setup is started by the file Setup.exe on the delivered Installation
CD. After selecting the language and confirming the license agreement, the selection
of the target system (ES, OS, OS-Client) that should be installed is to be carried out as
follows:
Image 2: Target systems that are to be installed
A successful installation will be confirmed by the following message:
Image 3: Completing the Installation
Installation BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 17
2.3 Expanded Standard Installation
MS Excel must be installed. MS Excel is not scope of delivery and has to be provided
by the user.
The batch data can be exported to an Excel sheet. MS Excel will then be used to
generate the batch report.
This function is usable only with MS Excel installed.
The BRAUMAT compact engineering will be executed with Excel on the SIMATIC PCS
7 engineering station.
If MS Excel 2007 or higher is used VBA for Excel must be activated explicitly.
If MS Excel 2007 or higher is used the active x controls must be released in the
security centre of Excel.
Notes on installation of Microsoft Excel
When using BRAUMAT compact Microsoft Excel can be installed after PCS7.
2.4 Installation Demo Project and Control Module Library
The Setup installs an entire brewery sample project in the following PCS 7 path:
…\Siemens\STEP7\EXAMPLES_MP\BRC_DEMO.zip.
Alongside the BRAUMAT compact Control Module Library (CM) is installed in the
Standard Step 7 directory …\Siemens\STEP7\S7LIBS.
2.5 Needed Licenses:
The BRAUMAT compact Runtime Bundles are already preinstalled and licensed
accordingly:
Bundle PCS7 Box RTX Single Station Single Station
redundant Server - Client
AS Lizenzen 1 x RUNTIME
LICENSE AS
(PO 100)
5 x RUNTIME
LICENSE AS (PO
100)
5 x RUNTIME
LICENSE AS (PO
100)
5 x RUNTIME
LICENSE AS
(PO 100)
OS Lizenzen
WINCC/USER
ARCHIVES
PCS 7 BOX
RTX OS
RUNTIME
(WINAC
RTX2010) (250
PO)
Braumat
compact
WINCC/USER
ARCHIVES
SINGLE STATION
V7.1 (PO 1000)
Braumat compact
2 x WINCC/USER
ARCHIVES
SINGLE STATION
REDUNDANCY V7.1
(PO 1000)
2x Braumat compact
WINCC/USER
ARCHIVES
SERVER V7.1
(PO 1000)
CLIENT V7.1
Braumat compact
BRAUMATcompact Installation
Engineering Manual, 06/2010, A5E02608507B-02 Page 18
Notes on license
In addition licenses for the WinCC User Archives are required; they are contained on
the license key memory stick as well.
The license according to the General License Conditions for Software Products for
Automation and Drives for Customers with a Seat or Registered Office in
Germany/outside Germany (hereinafter each "License Conditions") allows the use of
the User Archives only within the use of the product BRAUMAT compact according to
license. Siemens is not liable for any use over and beyond this limitation. Transfer of
license to a third party is not permitted as independent transaction but only within
transfer of rights according to the License Conditions of the product BRAUMAT
compact.
Missing Licenses:
Microsoft Excel
Web Client
PCS7 Engineering Licenses
Microsoft Excel must be installed and licensed by the user for exporting the batch data
and for the engineering of BRAUMAT compact.
Demo Project BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 19
3 Demo Project
Retrieve it under …\Siemens\STEP7\EXAMPLES_MP\BRC_DEMO.zip. with the
SIMATIC Manager and save it in the project directory e.g. in SIMATIC S7 project
directory (S7Prj).
Open the demo project in SIMATIC Manager.
3.1 Configurations
3.1.1 SIMATIC S7 Hardware Configuration
Open the HW-Configuration and adjust the hardware to the hardware on hand.
Compile the alteration and reload the CPU.
3.1.2 SIMATIC S7 Netpro-Configuration
Open Netpro and adjust the network addresses to their conditions.
3.1.3 Configuration Station Configuration Editor
Use the Station Configuration Editor to enter the different components in the same manner as
in the demo project (see HW configuration).
3.2 S7 Compile and Load Program
Open an arbitrary CFC chart and compile the entire program.
3.3 Generate OS
Compile the entire OS with master reset. After that start the OS runtime.
Per each unit in OS runtime must
1.) The control matrix Engineering Faceplate be opened and the data of the user
archive be read. After that the control matrix data must be written to the PLC.
2.) The button Parameter is to be pushed once for each unit. In the parameter type
dialogue the data must be read from the archive first and then written. Thereby the
parameter type data is transferred to the control.
The demo should be executable now. Start a recipe e.g. Pils on the mill.
BRAUMATcompact System Overview
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4 System Overview
4.1 System Plan
Unit Sequence
4.1.1 System Plan
The CFC plan system is available for an installation as central component, containing
several units. The system plan contains 3 blocks. Each of these blocks is connected to
a block of the unit. Each of the blocks provides a central service.
4.1.1.1 Recipe Manager (FB_RECM):
Image 4: Recipe Manager Block
The recipe manager block (RECIPE of Type BRC_REC) of every unit requests the
recipe parameter at a recipe start from the user archive ARCH_1<EQM_ID><Recipe
type> (e.g. ARCH_10401 for parameter archive for unit 04 (=EQM_ID) with recipe type
01). As soon as the data are received, they are provided at the output REC_ST.
The recipe manager is triggered by the corresponding unit (output REQ_ST at the
recipe block BRC_REC)) at the recipe start on the input REQ0<EQM_ID>_S.
The inputs REC_REQ (=Request active) and REC_FIN (=Request completed) show
the current hand shake state with the OS server.
Maximal 99 units can be connected.
System Overview BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 21
The recipe manager is also used for loading the set points. Therefore the inputs
REQ_100_S and greater are used (see chapter 15.4 Master Unit- Configure
Referencing Unit).
4.1.1.2 BatchID-Generator (BRC_BAID):
Image 5: BatchID-Generator Block
The BatchID-Generator generates an unique batch number beyond all connected
systems.
The BatchID-Generator is triggered by the corresponding unit (output QREQBAID at
the unit manager block SB_IF)) at the recipe start (via Scheduler, Start button of unit)
at the input REQ0<EQM_ID>_ST.
The batch number is provided at the output BAID_ST. Thereby the batch number
consists of the value at the input AS_NO and 5 digit of a consecutive number.
The next used batch number will be displayed at the input COUNT.
The current value for the next batch number is set via the input START_PV and a
positive edge at the input SET.
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4.1.1.3 Archive Manager (FB_ARCHM):
Image 6: Archive Manager Block
The archive manager block writes the recipe archive data of the batch in the user
archives ARCH_<EQM_ID> and ARCH_2<EQM_ID>. Thereby the archive manager of
each unit is triggered via the inputs REQxxx_S. The archive manager receives for each
unit 2 data types.
1. Header Data:
The header data are provided per each unit by the block ARCH_HEAD. Thereby
the header data are transferred by the block ARCH_HEAD once at the recipe
start (starting time) and once at the recipe end (ending time). The archive
manager writes these data on a data record in the user archive
ARCH_2<EQM_ID> via the data server.
2. Step Data:
The step data are provided per each unit by the block ARCH_STEP. Thereby
the step data are transferred after 18 consecutive steps and at the end of the
unit by the ARCH_STEP block to the archive manager. The archive manager
writes these data via the OS server on a data record in the user archive
ARCH_<EQM_ID>.
System Overview BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 23
4.2 Unit Plan
The unit plan or Sequence plan processes exactly one unit. The Sequence plan
consists of 6 partitions
1. Partition A:
Connection of the first 32 Control Modules and basic configuration of the unit
2. Partition B:
Connection of the second 32 Control Modules
3. Partition C:
Connection of the third 32 Control Modules
4. Partition D:
Connection of the fourth 32 Control Modules
5. Partition E:
24 Parameter blocks for the set point handling
6. Partition F:
controls the recipe on the unit and consists of the sequence control (1), the
interface blocks to the system plan (4,5) and interface blocks to the parameters
(2,3).
4.2.1 Unit
Control module (Partition A , B , C and D)
The Control Modules are connected to the unit in the Partition A, B ,C and D. Thereby
4 connection blocks are available.
There is also a connection block available for the analogue values of the unit in
partition F (2,3).
Each Control Module receives internally a virtual ID between
1 and 32 (first 32 Control Modules)
or between 65 and 96 (second 32 Control Modules)
or between 97 and 128 (third 32 Control Modules).
or between 129 and 160 (fourth 32 Control Modules).
These virtual Control Module ID is used for defining the input resp. output on the 4
connection blocks.
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4.2.1.1 Feedback (FB_CM , FB_CMY ,FBc_CMW , FBd_CMZ)
Image 7: Connection Feedback Control Module
The feedback output of the control module is connected to the feedback blocks. This is
QOPENED for a valve, QRUN for a motor, or Q for a sensor.
System Overview BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 25
4.2.1.2 Manual/Automatic Response (FB_AUTO , FB_AUTOY , FBc_AUTOW ,
FBd_AUTOZ)
Image 8: Connection Feedback Control Module
On the manual/automatic respond blocks the manual/automatic response of the control
modules is connected. This is QMAN_AUT for a valve or motor. In case of a sensor
this access remains idle.
BRAUMATcompact System Overview
Engineering Manual, 06/2010, A5E02608507B-02 Page 26
4.2.1.3 Interlock Response (FB_LOCK , FB_LOCKY , FBc_LOCKW ,
FBd_LOCKZ)
Image 9: Connection Interlock Control Module
The interlock response of the control module is connected at the interlock response
blocks. This is V_LOCK for a valve and LOCK for a motor. In case of a sensor this
access remains idle.
System Overview BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 27
4.2.1.4 Triggering (CMD , CMDY , cCMDW , dCMDZ)
Image 10: Connection Triggering Control Module
The triggering of the control modules is connected to the trigger blocks. This is
AUTO_OC for a valve and for a motor. In case of a sensor this access remains idle.
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4.2.1.5 Analogue Values (Input AVxx on U_U_SYN)
Image 11: Connection Analogue Values
Analogue values are linked to the unit via the unit interface block (U_U_SYNC).
System Overview BRAUMAT compact
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4.2.2 Unit
Parameter (Partition E)
For each unit are 24 parameter blocks available. During the runtime the parameter
blocks evaluate the certain parameterized function step-respectively (actual value >=
set point, actual value = set point, time expired, counted measured reached, ...)
compared to the set point.
Image 12: Parameter Block
The set point is transferred to the parameter block (SP_VAL_A) with every step switch
via the recipe block RECIPE. As soon as the current data are available at the
parameter block, a positive edge is generated at REC_OKP, thereby SP_VAL_A is
written on Q_SP_VAL and evaluated. If the parameter is a counter or timer, the
counting /timing process is started via the input TIME_REL. Thereby the use of the
parameter (=Starting process) is configured in the recipe.
The current analogue value for comparison is available at the input for the comparison
set point with analogue value.
Q_RESULT shows if the parameter conditions are fulfilled (=1) or not (=0). This value
will be evaluated as forward condition.
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4.2.3 Unit Number
A basic component of BRAUMAT compact is that every unit must receive a unique ID
(EQM_ID). This will be
1. Entered at the unit interface block U_U_SYNC at the input EQM_ID.
2. In the text library (Worksheet 2) of the EXCEL ADDIN 02_TextLib_Unit.xls.
3. Used in the archive configuration for different archives (see 5.4.1.2 File WinCC
User Archive)
Via the unit number the texts are read from the text library during runtime. Thereby the
EQM_ID is multiplied by 1000. The step names, logic names, operating requests,
parameter names including the dimension and the name of the analogue values follow
after the complete 1000th entry in the text library.
The user archives for the batch data and set points contain each the EQM_ID in their
name. (ARCH_<EQM_ID>, ARCH_2<EQM_ID>, ARCH_1<EQM_ID><recipe type>.
The proper allocation between user archive and unit is made via the naming and
EQM_ID.
The EQM_ID serves as key in the user archive BRC_UNI_PARAMETER and
BRC_UNIT.
4.3 Unit Sequence
Text Allocation
All texts for the step names, logic names, operating requests, parameter names
including the dimension and the names of the analogue values are entered for each
unit in an available Excel file e.g.MK_TextLib_Unit.xls.
When opening the control matrix Engineering Faceplate (Step sequences
configuration), the according configuration display is opened and the texts are read and
written in the text library. This process is carried out only for the currently active
language.
4.3.1 Unit Sequence
Recipe Configuration
Up to 32 recipes can be defined in the WinCC Runtime. Thereby each recipe receives
a internally unique ID between 1 and 32.
Step sequences (1 to 32) are configured for each unit. Whereas the first step sequence
is allocated to the 1
st
recipe, the 2
nd
step sequence to the 2
nd
recipe etc, i.e. the recipe
consists of the step sequences of the involved units.
All step sequences are stored in the PLC and in the user archive. In order that the
recipe data are available also after a complete loading, they have to be read back in
the CFC plan via the plan read back (Designated Parameters).
System Overview BRAUMAT compact
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4.3.2 Scheduler
Unit
Image 13: CFC Scheduler
The scheduler plan contains a block (BRWP) centrally, which contains and controls all
orders. A batch is started to each order via the START block.
Thereby a scheduler is always connected to exactly one unit (the so called start unit of
a brew line). That way the scheduler starts exactly this unit. All following units are
started via a running unit depending on the recipe.
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4.4 Sequencer with Status Diagram
The following image shows the status diagram of the sequencer
Image 14: Status diagram Sequencer Control
The initial position of each sequencer of each unit is the idle state.
Status transitions with Self completing (sc) and Continuous as known from the
SIMATIC Batch are not available in the BRAUMAT compact.
System Overview BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 33
The state of the status diagram can be changed by the user, by application and the
BRAUMAT compact library.
Image 15: User interface status diagram
Image 16: Application interface status diagram
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4.4.1
Status Transition Idle
Starting
The status transition Idle Starting is carried out via
The operator prompt when the user pushes start
The application in the P_UINT.Start is equal TRUE (e.g. Scheduler or USTA
FB)
The application sets U_A_PREV.Start or U_B_PREV.Start equal TRUE.
The batch ID and the parameters are read, before the unit transfers from idle into
starting.
4.4.2
Status transition Starting
Running
The status transition Starting –> Running is carried out automatically by the BRAUMAT
compact blocks as soon as the sequencer Starting finished its last step.
The sequencer for Starting is carried out in the status Starting.
4.4.3
Status transition Running
ready to complete
The status transition Running –> ready to complete is carried out automatically by the
BRAUMAT compact blocks as soon as the sequencer Running finished its last step.
The sequencer for the recipe is carried out in the status Running.
4.4.4
ready to complete
Completing
The status transition Ready to Complete –> Completing is carried out automatically by
the BRAUMAT compact blocks.
The status Ready to Complete is pending only for one cycle.
4.4.5 5
55
5 Completing
Completed
The status transition Completing –> Completed is carried out automatically by the
BRAUMAT compact blocks, as soon as the sequencer Completing finished its last
step.
The sequencer for Completing is carried out in the status Completing.
4.4.6
Completed
Idle
The status transition Completed –> Idle is carried out automatically by the BRAUMAT
compact blocks.
4.4.7
Running
Holding
The status transition Running Holding is carried out by
The operator prompt when the user pushes Hold
The application sets the input connector I_HOLD at the block
4.4.8
Holding
Held
The status transition Holding –> Held is carried out automatically by the BRAUMAT
compact blocks, as soon as the sequencer Holding finished its last step.
The sequencer for holding is carried out in the status holding.
System Overview BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 35
4.4.9
Held
Resume
The status transition Held Resume is carried out by
the operator prompt when the user pushes Resume
the application sets the input connector I_RESUME at the block
4.4.10

Resume
Running
The status transition Resume –> Running is carried out automatically by the
BRAUMAT compact blocks, as soon as the sequencer Resume finished its last step.
The sequencer for Resume is carried out in the status Resume.
4.4.11

Abort
The status transition … Abort is carried out by
The operator prompt when the user pushes Abort
The application sets the input connector I_ABORT at the block
The input connector I_ABORT operates only in Starting, Running, Holding,
Held, Resume, and Completing.
4.4.12

Aborting
Aborted
The status transition Aborting –> Aborted is carried out automatically by the BRAUMAT
compact blocks, as soon as the sequencer Aborting finished its last step.
The sequencer for Aborting is carried out in the status Aborting.
4.4.13

Aborted
Idle
The status transition Aborted –> Idle is carried out automatically by the BRAUMAT
compact blocks.
4.4.14

Stopping
The status transition … Stopping is not addressable in the BRAUMAT compact.
4.4.15
5
55
5 Stopping
Stopped
The status transition Stopping Stopped is carried out automatically by the
BRAUMAT compact blocks, as soon as the sequencer Stopping finished its last step.
The sequencer for Stopping is carried out in the status Stopping.
4.4.16

Stopped
Idle
The status transition Stopped –> Idle is carried out automatically by the BRAUMAT
compact block.
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4.5 Options of step behavior
4.5.1 Behavior at the command Resume after Hold
Via the input connector I_RESMODE at the block U_U_SYN you can configure
between two versions at the command Resume. If the input is configured on 1, the
previous function will be continued after the Resume command. If a 0 is configured at
the input, the step sequence starts from the beginning.
4.5.2 Reset of the Aggregates
At the step switch can basically 2 modes per unit be configured. All aggregates remain
in the state of the previous step at a step switch, or are reset.
The according behaviour is set in the CFC plan of the according unit in the A5 at the
block U_U_SYN at the input I_TRNSMDE (1= reset all aggregates, 0=all aggregates
remain in the state of the previous step. Thereby aggregates are switched shock-freely,
when they are accessed in two consecutive steps.
Image 17: PhaseCon settings
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5 Create New Project
Basic knowledge in SIMATIC PCS 7 is required for this chapter. Therefore SIMATIC
PCS 7 offers a training (SYSTEM course) as well as a starter documentation like e.g.
Getting Started.
5.1 General
A ready to use demo project is installed on each bundle
Basically the filing of a project is carried out via the PCS 7 usual standard. It is
recommended to use the PCS 7 assistant “New Project“.
Three levels should be used for the technological hierarchy in the PCS 7 wizard “New
Project“. SFC plan objects are not used.
Image 18: Configuration of PCS 7 Assistant “New Project“
The message numbers are recommended unambiguously in the entire CPU.
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5.1.1 SIMATIC Manager
Name the PC station after your computer name.
5.1.2 Create user text library
The text library with the corresponding message texts must be copied from BRAUMAT
compact Library in the user project. The following steps are to be followed:
1. Open the BRAUMAT compact Library CM_Vxx in the SIMATIC Manager via :
File>Open> Select Tab Libraries > CM_Vxx
2. Select the folder text libraries and copy the entire folder in the S7-Program-
Container of your user project.
5.1.3 HW Configuration
In the HW Configuration the communication data like IP address of the CP are to be
carried out at the corresponding network (is newly generated with this configuration),
possibly the DP address of the CPU and if requested in the project, further
configurations like time synchronisation.
Compile and load the configuration.
5.1.4 Netpro
Insert the corresponding communication card (already carried out automatically at Box
PC) for the PC station in the Netpro and set up the network address at the
corresponding network.
A connection must be inserted for the WinCC application, if not already existing.
Compile and load of the configuration.
5.2 Technological Hierarchy
The automatically generated names are to be adjusted in the plant view. They should
be renamed as follows:
System(1) e.g. brew house or cellar
Unit(1) e.g. lauter tub
Function(1) Sequence
Parallel to the hierarchy file Sequence a hierarchy file CM is generated for the control
module. Further information to the structure of the system hierarchy are in the chapter
“7 Trending“.
The technological hierarchy should be filed completely at the beginning of the project.
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5.3 CFC Plans
In the following subchapters the generating of a unit and the BRAUMAT compact
system-depending plans are described. Thereby this unit has no control modules yet.
Those are explained later in the chapter “13 Control Modules“.
Miscellaneous basic settings referring the storage assignment of the CPU and the
compile process of the CFC plans are needed for a BRAUMAT compact application.
The Compiler settings are opened via the menu Options Customize
Compile/Download… .
Image 19: Open Compile Options CFC
In the following dialogue “Settings for Compilation/Download“ the settings for the “FC
numbers from:“ are to be adjusted on 1 to 1100.
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Image 20: Compiler Settings CFC
The local data memory of the CPU must possibly be adjusted as well. The needed
storage allocation can be determined via the plan reference data dialogue in the
display local data.
Image 21: Local data
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If the local data need is higher than the offline projected storage memory, then the
settings in the HW Configuration are to be adjusted in the tab Memory in the properties
dialogue of the CPU.
Image 22: Memory Adjusting of the CPU
5.3.1 System Charts
First a BRAUMAT compact application needs comprehensive plans, which are used
over all units.
The CFC plans and pictures are loaded from the BRAUMAT compact library. This is
visible the best from the plant view.
Next to the CFC plans SYSTEM and SCHEDULER the engineering picture
(Engineering.pdl) is copied from the library. A possible existing picture in the hierarchy
file of the system must be deleted.
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Image 23: Filing of SYSTEM CFC Plans
5.3.1.1 System
The CFC plan SYSTEM will be filed in the hierarchy folder of the system e.g. brew
house.
The CFC plan SYSTEM contains the archive manager, the recipe manager, and the
BATCH-ID generator for this system and is used centrally by all units. The connecting
is carried out later via the unit.
5.3.1.2 Scheduler
The CFC plan SCHEDULER will be filed in the hierarchy file of the system e.g. brew
house.
The CFC plan SCHEDULER contains the scheduler and the start switch of the first
unit, which should be started from the scheduler. The connecting is carried out later via
the unit.
5.3.2 Unit
In order to include an unit in BRAUMAT compact, the CFC plan UNIT_PHCON from
the BRAUMAT compact library of the hierarchy file Sequence will be copied in the
hierarchy file Sequence of the unit. Possibly existing pictures, reports and/or CFC
plans must be deleted.
The CFC plan is renamed in e.g. unit abbreviation + Seq, e.g. ML_SEQ for the unit
mill.
See also Chapter “7 Trending“.
The connection of the unit with the system plans is carried out via the process object
view. The text file Unit_2_System_Connection is used as template data.
The CFC plan of the unit is opened in the process object view with the tab Parameter.
By means of the text file Unit_2_System_Connection the connections are edited.
The detailed process with the configuration of the connections via the process object
view is explained in the chapter “12.1 Connection via Process Object View“.
In the Sequence Control CFC plan on page A5 the number of the unit must be entered
on the input ”EQM_ID“ at the block “U_U_SYN“. This must be unambiguous and
correspond with the unit number of the Excel sheet 2 02_TextLib_Unit.xls (see chapter
“5.4.1.6 Adjust Configuration Picture“)
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Image 24: Unit number in the CFC plan
5.3.3 Link the Units Together
The units must be linked together. These connections are realized via the block
“U_U_SYN“ in the sequence control CFC plan.
The inputs “U_A_PREV“ / “U_B_PREV“ establish the connection to the up streaming
and the outputs “U_A_NEXT“ / „U_B_NEXT“ to the following units.
Image 25: Connection Predecessor and Successor Units
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At the block of the “first“ unit the output “U_B_NEXT“ is connected firmly on the own
input “U_A_PREV“ / “U_B_PREV“.
At all other units, which do not have two predecessors, the parameter “U_B_NEXT“ is
connected firmly on the own not used inputs “U_A_PREV“ / “U_B_PREV“.
Image 26: Short of the Predecessors Internal Connect
The following picture shows an example for the connection of the units.
Image 27: Example Connection of Units
5.4 WinCC Engineering
The WinCC Configuration is divided in two parts. The first part must be executed each
time when generating a new project. The second part is executed in the project for
each system, unit, aggregate, … .
5.4.1 Project-Specified Configuration
5.4.1.1 General Configuration
Adjustment by the user ES/OS
OS-
Client
1. Copy the file
…\Siemens\WinCC\BRAUMAT_compact\ScriptAct with the
files DateTime.act, SetDateTime.act and SetUserMachine
in your OS project directory …\wincproj\OS\ScripotAct.
2. Copy the folder Braumat from the directory
…\Siemens\WINCC\BRAUMAT_compact\ in your OS-Project
directory …\wincproj\OS\.
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3. Edit the file BRC_UA2XLS.ini (contained in the Braumat folder)
and enter the path to your batch export directory at the
parameter Path=… It must be a valid directory.
4. Copy all picture files (*.pdl) from the directory
…\Siemens\WINCC\BRAUMAT_compact\GraCS in your OS
project directory …\wincproj\OS\ GraCS
-
5. Copy all picture files (@*.pdl) from the directory
…\Siemens\WINCC\BRAUMAT_compact\GraCS in your OS-
project directory …\wincproj\OS\ GraCS
6. In case you want to use trend pictures with a 1600x1200
resolution, copy all picture files (@*.pdl) from the directory
…\Siemens\WINCC\BRAUMAT_compact\GraCS\1600x1200
in your OS project directory …\wincproj\OS\ GraCS
BRAUMAT compact provides an application to an automatic generating of the needed
internal variable and the row data variable per unit and function.
These variables are configured in the data file BR_TAGGEN.ini. The tag generator
application (BRC_TagGen.exe) should be configured in the start-up of the WinCC
project, so that the needed variables are generated automatically.
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Image 28: Configure Tag Generator in WinCC Start-up
5.4.1.2 File WinCC User Archive
The User Archive must be selected in the feature dialogue of the computer under the
Tab start-up.
Image 29: Activate User Archive for OS
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5.4.1.3 Starting BRAUMAT compact Table Generator
After installation of BRAUMAT compact is placed a symbol in the WinCC Explorer.
Through right mouse click, is opening following selection.
Image 30: Start Table Generator
It is possible to choose between 2 sheet “User Archives” and “Excel Addin”.
Image 31: Table Generator – Selection “Excel Addin”
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Image 32: Table Generator – Selection “User Archives”
Button “Fill / Clear” Recipe Head Parameter: Each recipe can consist of up to 10
recipe types. Via this action the head parameter for each recipe type are generated
only once. At the moment only the recipe type 1 is supported. If it becomes necessary
to use further recipe types (see 8.2 Recipe Types), this step must be carried out for
each recipe type. Enter the recipe type number in this line to create the recipe head
parameter archive.
Button “Fill / Clear” Recipe Data: Herewith a table (e.g. 10801 for the unit 8 recipe type
1) is generated once in the user archive for the stated unit and for the stated recipe
type. If the table is already existing, the action is stopped with an error. The entered
recipe values are stored in these archives.
This step must be executed for each unit with corresponding unit number.
If it becomes necessary to use further recipe types (see 8.2 Recipe Types), the
corresponding units must be generated with the assigned recipe type number. A unit
can only be connected with a recipe type number.
Additionally recipe data must be generated for the import and export handling.
Therefore the unit 0 and the recipe type 0 must be used and the recipe data must be
generated with these values. As result the archive ARCH_10000 is created. This
archive is used for importing recipes only.
Button Batch Data / Batch Head Parameter: For each unit a archive must be filed
once for each batch and batch head parameter.
This step must be executed for each unit with corresponding unit number.
Button Units / PHCON Tables / Unit Parameter / Set point Trends / User Table /
Redundancy: These actions must be executed only once at the generating of the
project.
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The archive for redundancy cannot be generated until the redundancy is activated in
the WinCC explorer.
The archive names are each generated automatically after the entry in the white arrays
and updated in the according grey text array (in the middle of the image). Furthermore
the status of the archive is controlled and displayed in the colored array to the right.
The colouring should communicate fast and easily to the setter as well as the operator,
if a user archive is generated correctly.
The following states are possible:
0 (red)
Archive does not exist, but is needed for the correct operation of the BRAUMAT
compact. Therefore the corresponding button is released and generates after operating
this, archive and if necessary pre allocated data sets.
1 (yellow/green)
Archive exists, however does not contain data sets. This is required for the following
archives, and therefore displayed in green:
-
The remaining receive in this case a yellow status symbol, i.e. the pre allocated data
sets are missing in this archive. Therefore the corresponding button is released and
must be operated.
2 (green)
Archive exists and contains data sets. Nothing needs to be done, therefore the
corresponding button is deactivated.
The following archives are generated as result. Here on the example for 7 units.
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Image 33: User Archive for 7 units
The report data in the user archives (ARCH_<UnitID> and ARCH_2<UnitID) are
archived automatically. For further information please refer to chapter 15.20 Batch data
export and supervision of the batch archive.
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5.4.1.4 Adjust Engineering Picture
The objects are filed in a own Typical.PDL with the name “@BRC_Typicals.PDL“.
The objects are copied from here in the picture “Engineering.PDL“ and connected with
the Dynamic Wizard “Connect Picture Block with Test Point“.
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Image 34: Unit configuration
For the connection of the picture objects to the structure variable the CFC plan of the
unit is selected under Sequence in the variable dialogue of the Dynamic Wizard. The
procedure and run-time picture object is connected to the variable PL and the
information picture object to the variable U_U_SYN and for jump set point to the
variable PL_JP.
5.4.1.5 Project Process Picture
The aggregates as well as pipelines and tank of the current unit are in the process
picture. These are placed there and connected with the known methods.
Furthermore, it is recommended to set up a status resp. operating bar for the current
unit on the upper picture margin. Moreover, the status bars of the up resp. down
streaming unit(s) can be set up there.
The objects are filed in a own Typical.PDL with the name “@BRC_Typicals.PDL“.
From there the objects are copied in the corresponding process picture and connected
with the Dynamic Wizard.
Image 35: Status bar for current on unit
In order to connect the picture object on the structure variables the CFC plan of the unit
is selected under Sequence in the variable dialogue of the Dynamic Wizards and linked
on the variable PL.
A block view of the unit is available as a further object, which is generated and linked
identically to the status bar.
*_SEQ/PL
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Image 36: Example for a Unit Block
A further object for the unit is available with this recipe display. In this object the recipe
steps are displayed at a running recipe. Should there be more steps projected than
shown in the unit recipe block, the current step (with a green background) is displayed
in the visible array. The unit recipe block scrolls automatically.
The number of visible lines can be adjusted via the property „LineNumbers“ between
10 and 32.
Image 37: Example for an Unit Recipe Block
5.4.1.6 Adjust Configuration Picture (Excel Addin – 02_TextLib_Unit.xls)
In the sheet 02_TextLib_Unit.xls of the unit are the texts filed, which appear later in the
parameter dialogue.
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Image 38: Text Configuration for Unit
In general there are some “special signs“ resp. expansions to be considered:
Expansion Name Description
,se Sensor Panels of the type Sensor can only be enquired.
An installation of the sensor is not possible.
,- Isolator / Reserve
This line is shown in the dialogue unlike ,hide,
however cannot be operated.
,hide Invisible This panel is not shown in the dialogue.
,ac Actuator Panels of the type actuator can only be set. An
enquiry of the result is not possible.
,timer Time Reserved for later version.
,< Group Start Start of the group. Is written behind the first
element of the group. Can be combined with + and
–.
,< Group End End of a group. Is written behind the last element
of the group. Cannot be combined with + and –.
,<+ Grouped Start of the group. Is written behind first element of
the group. Group is closed at the opening of the
dialogue.
,<- Open Group Start of group. Is written behind the last element of
the group. Group is opened at the opening of the
dialogue.
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The number (TA-No.:) and the text (Name_ in the title panel of the configuration picture
define the unit with unit number and in the clear text. Thus the text also appears in the
dialogues. The number of the unit is entered in the CFC plan of the unit (under
Sequence) in FB U_U_SYN on the Parameter EQM_ID.
Image 39: Excel Addin – Sheet 2
All aggregates of this unit are listed in the panel Control Modules. The sequence and
position of the texts must correspond to the sequence of the connection on the
sequence control blocks (FB_CM).
Image 40: Aggregate Text
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In the panel Units Before / After the units are entered, which are connected with the
block “U_U_SYN“ in the sequence control CFC.
Image 41: Text Configuration Predecessor and Successor of a Unit
A successive unit is started automatically via the connection with entry in 37 resp. in
39. Via the entries in 38 resp. 40 the units can be synchronized additionally. Thereby
the units are always connected in pairs e.g. entry 37 / 38 with 35 / 36 of the successive
unit.
Unit after (Entry 37 resp. 39) Unit before (Entry 33 resp. 35)
Icon
Meaning Icon
Meaning
Start of the successive unit Confirm running of unit
Start of the successive unit and
check that this has started
Check that successive unit has
started.
Unit after (Entry 38 resp. 40) Unit before (Entry 34 resp. 36)
Icon
Meaning Icon
Meaning
Report reaching of the
synchronisation point to
successive unit
Report reaching of synchronisation
point to prior unit
Report reaching of
synchronisation point to
successive unit and wait for
feedback.
Waiting for reaching of the
synchronisation point of the prior
unit and then report this one back
Check if successive unit reached
the synchronisation point and
report
Waiting for reaching of the
synchronisation point of the prior
unit
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In the panel Parameter Names all texts are entered that appear later in the recipe
parameter dialogue.
Image 42: Configuration of Parameter Texts
Icon
Meaning Icon
Meaning
without function Reset and start:
Parameter of the type time
Reset timer and start
Parameter of the type counter:
Reset counter value and if self-
counting start counter.
Without function Reset, start and request feedback:
Like
Check all parameter types except
for report for feedback = set point.
Request Feedback:
Waiting for cooling down
(Temperature not fulfilled
anymore)
Request Feedback:
Check all parameter types except
for report for feedback = set point.
It is recommended to group the parameters.
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The entire number of functions must be entered in the array “Number of Functions“. A
maximum of 64 functions is projectable.
The number of used logics is parameterized in the array “Number of Logics“. The texts
appear later in the right-mouse-menu in “PhaseControl“.
The logics themselves are generated to runtime. This is described in the user manual.
I
mage 43: Configuration of function texts and logics
All connected analogue values of this unit are listed in the array analogue value
names. The sequence and position of the texts must correspond to the sequence of
the interconnections at the sequence – control block (U_U_SYN).
Image 44: Configuration of analogue texts
The number of the analogue values must be entered. The selection box for the
analogue value in the parameter type dialogue is configured in its size (number of
displayed analogue values) via the number of analogue values.
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All operator requests for this unit are listed in the array texts for the operator request.
An operator request can be reserved for each function. The first operator request can
be used in the first function step, the second in the second function step, etc. With the
check on visible the button „Information“ for the respective operator request is switched
on. The presetting UNIT_PHCON_ORX.pdl e.g. 08_PHCON_OR2, unit 8, operator
request 2 is here available for the user. The examples can be deleted from the image.
I
mage 45: Configuration operator request
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5.4.2 Runtime Configuration
The configuration of the parameter types, the recipe and the parameter is carried out in
the OS Runtime.
5.4.2.1 Parameter Types
For each unit the according type can be configured per each configured parameter.
The parameter types are transferred to the control via this dialogue. There is no
other way to transfer these data to the PLC.
Image 46: Parameter type dialog
For each parameter:
Display type: Number of the decimal places, time format, …
Function: function of the corresponding parameter e.g. time forwards
automatically one in each cycle.
The hysteresis (down/up) is available in the function set point/actual value
comparison. The hysteresis is not editable in all other functions.
Minimal Value: value that can be entered minimally in different dialogues of the
system. If this step is undercut, a warning note is given out and the entry cannot
be accepted.
Maximal Value: Value that can be entered maximally in different dialogues of the
system. If this step is exceeded, a warning note is given out and the entry will
not be accepted.
Hyst. down: If a function with set point/actual value comparison is selected, the
set point regulation in the interval of the set point minus lower hysteresis is
considered as fulfilled.
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Hyst. up: If a function with set point /actual value comparison is selected, the set
point regulation in the interval of the set point plus upper hysteresis is
considered as fulfilled.
The edit windows can be released via ESC.
The following table shows all functions and their mode of operation in the function
block BRC Real.
Image 47: BRC_REAL Block
Id Function Mode of Operation Hysteresis
00 Off Parameter is not used (=no function) No
01 Counter
forward Increases the actual value per each cycle (!) by INC
times ACT_VAL (only valid for AV_SRC = 0) No
02 Integrator Increases the actual value for each cycle by INC times
SAMPLE_T times ACT_VAL (only valid for AV_SRC =
0).
No
03 Counter
backwards Decreases the actual value for each cycle(!) by INC
times ACT_VAL (only valid for AV_SRC = 0) No
04 Time
forward Increases the actual value of each cycle by SAMPLE_T
(=> time forward) No
05 Time
backward T Increases the actual value of each cycle by SAMPLE_T
(=> time forward) but will not reset on step change No
06 Time
backward Decreases the actual value per each cycle by
SAMPLE_T (=> time forward) No
07 Set point =
Actual Value
Checks the analogue value with the set point
considering the hysteresis Yes
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08 Actual Value
>= Set point Compares the analogue value to the set point with
greater than No
09 Actual Value
<= Set point Compares the analogue value to the set point with
smaller than No
10 Protocol Is only shown in the report. The result is always TRUE No
11 Integrator
with Hold Integrator analogue Function 02 Integrator, however it
holds the value in the cycle Hold Held Resume.
Therewith this parameter has the same value at the
abandoning and reentry of the status Running.
No
12 reserved Reserved for later versions No
5.4.2.2 Recipe step sequence
The recipe step sequence is defined in the cross points recipe with step by a single
click. Thereby the step counter (=number that appears in the square generated by a
single click) increases automatically with every click.
Image 48: Step Sequence Configuration
In the upper left corner of the matrix are click squares for deleting (x) increasing (+)
and decreasing (-) the steps by 1, 5 or 10steps.
5.4.2.3 Recipe Steps
Via switching the button ->> you can switch from recipe display to step display. For
each control module (pump, valve, motor, sensor, …) the triggering is set in the step
display and the feedback is evaluated. Furthermore, parameters are defined for this
step (see also chapter 5.4.1.6).
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The following settings can be provided for each cross point by repeated single click.
Between 0 and 1 can be switched with the right mouse click.
Image 49: Color Display of the Control States.
Symbol Meaning Description
Force and
Feedback Control Module is started/opened/fulfilled and the
response is checked
Force and
Feedback Control Module is stopped/completed and the
response checked
Force Control Module is started/opened/fulfilled.
The response is not(!) checked
Force Control Module is stopped/completed.
The response is not(!) checked
Check The response is checked for started/opened/fulfilled.
A triggering does not occur.
Check The response is checked for stopped/completed.
A triggering does not occur.
5.4.2.4 Recipe parameter
The current recipe parameters are loaded in the recipe parameter dialogue via the
recipe parameter button ( ). Via the single click on the step name (1) the
corresponding step appears in the recipe parameter dialogue with name (2) and
number (3). The unit name (4), recipe name (5), and the recipe type (6) are displayed
as information.
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Image 50: Recipe Parameter Configuration
5.4.2.5 Edit Logic in a recipe
The control matrix supports the condition based logic in recipes.
The logic is configured in the engineering faceplate. Click right on a rectangle in the
logic no column. Choose the logic that should be used.
Image 51: Select logic
In the control matrix right mouse click on any cross point in the row with logic then you
can choose:
1. Switch depending on logic
The control module is activated as soon and as long the logic is true. Feedback
is not used for next step condition.
2. Switch depending on logic and wait for feedback on
The control module is activated as soon and as long the logic is true. The step
waits for a feedback to go to next step.
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Image 52: Select logic as enabling condition
The logic itself is configured via right mouse click on the control module name. This
changes the view to the logic view.
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Image 53: Configure Logic
Left click on logic gutter switches between OR or AND logic. (figure xx, section 1). In
section 2 the logic is configured via right mouse click. The result used for the
corresponding control module is build at the top of this logic tree. With go back you
come back to recipe configuration. Logic data is saved with normal save of the recipe.
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5.5 Control modules
5.5.1 Insert and connect control modules
In the BRAUMAT compact library is a series of typicals, which can be copied manually
or via IEA assistant in the project. This should be filed in the file “CM“ below the unit.
Image 54: Available control modules in BRAUMAT compact
The needed control module is copied from the BRAUMAT compact library and in the
corresponding CM hierarchy file of the unit.
The connection to the periphery as well as the connection to the control block in the
plan sequence can be established manually or with the process object view (see
chapter “12.1.2 Aggregate“).
Then the control modules must only be connected to the physical inputs and outputs of
the periphery.
In chapter “13 Control Modules“ the available control modules of BRAUMAT compact
are explained explicitly.
5.5.2 Connection / Import via IEA-Assistant
See PCS 7 manual and PCS 7 Online documentation
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6 Excel Addin
6.1 General
It is obligatory for the parameterization of the text library and the user archives.
Furthermore, this Excel Addin enables the import and export of configuration and
recipe parameters.
6.1.1 Requirements
6.1.1.1 Software
Microsoft Excel 2003/2007
Min. WinCC 6.2
Microsoft Excel is not included and must be installed and licensed by oneself !
6.1.1.2 Hardware
Minimum Requirements
o Processor : Inter Core2Duo
o Clock rate : 2,4 GHz
o Main storage: 1,0 GB
o Hard drive : 250 GB SATA
6.1.2 Development Environment
The Excel Addin is based on Microsoft Excel and consists of four Excel –
workbooks.
The workbooks can be given unit specific names. This enables an unit granular
projection and archiving.
The workbooks „01_TextLib_General.xls“, “01_TextLib_Recipetypes.xls”,
“01_TextLib_RecName_for_Rectype1.xls” and „02_TextLib_Unit.xls“ are used
for the parameterization of the text library.
„03_Archive_Unit_Para.xls“ and „04_Archive_Unit.xls“ are used for the import
and export of the configuration and recipe parameters from the user archives.
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6.1.3 General Settings in order to work with the Workbooks
The setting „Macro Security“ must be set on „low“. This must be changed in the
workbook in Extras/ Options in the tab „Security“ at the feature „Macro Security“.
Image 55: Macro Security
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6.1.4 Online - / Offline - Mode
In the workbooks 03_Archive_Unit_Para.xls“ and „04_Archive_Unit.xls“ is an
Online - / Offline – Mode available.
In the online mode the unit texts (e.g. unite name, function names, logic names,
etc.) are loaded from the WinCC text library and linked in the workbook.
The online mode can only be used, when the respective WinCC project is
opened.
With the start of the workbook the stated unit with the corresponding recipe
type is loaded e.g. unit 2 with recipe type 1. If a different unit is selected after
afterwards, the readout of the function names and the control module be
updated with the button ‘Update texts’.
Image 56: Workbook „Online Mode“
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In the offline mode default values can be embedded in the workbook.
Image 57: Workbook „Offline Mode
For the steps and parameters the altered texts are replaced by step 1…64 resp.
parameter 1…24 and dim 1…24 by using the button “Generate default texts“.
Image 58: Default Texts
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The setting Online /Offline Mode is carried out in the workbook features in the
tab ‚user defined’.
This is only possible when the workbook is closed.
Image 59: „Online - Offline Settings“
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6.1.5 Workbook - 01_TextLib_General.xls
Worksheet 1 “General“:
The entries in the text library and for the parameterization of the recipe type
names can be generated here in German, English and a selectable third
language.
The button “Generate Entries“ opens a form for the generation of a text library
entries.
The generation gets started with the button „Preconfigure textlibrary“.
This is a one-time, mandatory step at the generation of a new project. This
action takes up to 20 minutes.
If a text library exists already, an error will be generated .
“The TextId - range(>=1000) is already occupied by a different application!!“
Image 60: Workbook 01_TextLib_General.xls
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6.1.6 Workbook - 01_TextLib_ Recipetypes.xls
Worksheet 1 “Recipe Types“:
The recipe type names can be parameterized in German, English and a
selectable third language.
The button “Write recipetypes to textlib“ starts the download to the text library.
Image 61: Workbook 01_TextLib_ Recipetypes.xls
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6.1.7 Workbook - 01_TextLib_RecName_for_Rectype1.xls
Worksheet 1 “Recipe Types“:
The recipe type names can be parameterized in German, English and a
selectable third language.
The button “Write recipenames to textlib“ starts the download to the text library.
Image 62: Workbook 01_TextLib_RecName_for_Recipe type1.xls
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6.1.8 Workbook 2 - 02_TextLib_Unit.xls
This workbook is used for the generation of unit parameter.
Worksheet 1 “Cover sheet“:
Parameterized are:
Unit name (German/English)
Unit number
Number of units
Number of control modules
Number of functions
Number of logics
Unit is master or referencing
Number of the master unit (only possible if unit is set in the “Referencing“
mode)
The unit text library can be generated and read with the two arrays.
Image 63: Workbook 02_TextLib_Unit.xls „General“
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Worksheet 2 „Parameter Unit“:
Name of control modules
Name of functions
Texts for operator request
Logic names
Analogue value names
Image 64: Workbook 02_TextLib_Unit.xls „Parameter Unit“
Worksheet 3 „Parameter Unit“:
The parameters are entered in the worksheet 2 for English.
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6.1.9 Workbook 3 - 03_Archive_Unit_Para.xls
This workbook is used for the import and export of recipe parameters (set
points).
This data file can be used for the parameterization and for the archiving of unit
parameters.
Worksheet 1 “Cover sheet“:
Unit number
Recipe type of this unit
With the selection of the unit number and the recipe type the archive that is to be
read out is generated automatically e.g. Unit:2 ; Recipe type:1 ARCH_10201
The button “Write in User Archive“ starts the loading from the Excel file in the
unit user archive.
The button “Read from User Archives“ starts the loading from the unit user
archive in the Excel file.
If a user archive of a selected unit does not exist, the read out resp. writing is
aborted with an error message.(error number:101)
Image 65: Workbook 03_Archive_Unit_Para.xls „General“
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Worksheet 2-33 „Recipe 1“ to „Recipe 32“:
Each work sheet stands symbolically for a unit recipe. 24 parameters are
parameterized for each of the 32 steps.
The yellow marked texts are read out directly from the text library when opening
the workbook, if the online mode is selected.
Image 66: Workbook 03_Archive_Unit_Para.xls „Recipe“
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6.1.10 Workbook 4 - 04_Archive_Unit.xls
This workbook is used for the import and export of the unit parameterization.
Control strategies, functions, and logics of a unit are displayed here.
This file can be used for the parameterization and for the archiving of unit
parameters.
Worksheet 1 “Cover Sheet“:
Unit number
Recipe type of this unit
Plan - Name
The user archives PHCON_CS2,PHCON_FCT2 and PHCON_LOGIC2 are read
out:
Image 67: User Archive PHCON_FCT2
The button “Write in User Archives“ starts the loading in the user archive of the
unit.
The button “Read from User Archives“ starts the loading from the unit user
archive in the Excel file.
If an incorrect plan name is stated, e.g. the read out is displayed with the error
number 104.
Image 68: Workbook 04_Archive_Unit.xls „General
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Work sheet 2 „CS“:
The chain sequence of the steps in the recipes is parameterized here.
They must be parameterized numerically increasingly. Furthermore, steps may not be
selected double and all values must be provided in the sequence of numbers.
Image 69: Workbook 04_Archive_Unit.xls „CS“
Worksheet 3 „FCT“:
The triggering of the control modules in the steps.
Image 70: Workbook 04_Archive_Unit.xls „FCT“
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WinCC Command =
0 Command =
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
_____________
_____________
1
1
1
1
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Worksheet 4 “Logic“:
If a logic is used for the a unit, the provided logic number must be entered at the control
module.
Image 71: Workbook 04_Archive_Unit.xls „Logic
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Worksheet 5 to 37 “Logic 1“ to “Logic 32“:
Each worksheet stands symbolically for a unit logic.
Image 72: Workbook 04_Archive_Unit.xls „Logic1 “
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6.1.11 Possible Error Sources
6.1.11.1 03_Archive_Unit_Para
Connection is set up to the data base?
WinCC Project in Runtime?
User Archive Editor is started?
User archives exist?
Correct unit is selected?
Correct recipe type is selected?
Correct CFC plan name is entered?
Data records existing?
o Is a data record with the CFC plan name existing in the user archive
PHCON_CS2?
o Is a data record with the CFC plan name existing in the user archive
PHCON_FCT2?
o Is a data record with the CFC plan name existing in the user archive
PHCON_LOGIC2?
6.1.11.2 04_Archive_Unit
Connection is set up to the data base?
WinCC Project in Runtime?
Or is User Archive Editor started?
User archives exist?
Correct unit is selected?
Correct recipe type is selected?
Correct CFC plan name is entered?
Data records existing?
o Is a data record with the CFC plan name existing in the user archive
PHCON_CS2?
o Is a data record with the CFC plan name existing in the user archive
PHCON_FCT2?
o Is a data record with the CFC plan name existing in the user archive
PHCON_LOGIC2?
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7 Trending
The picture BR_TREND_OV.pdl is used for the trending.
For example this can be added via WinCC Picture Tree Manager or an own virtual unit
in the technological view can be added for the reports.
Image 73: Trending in the plant view
The picture does not need any further configuration.
For each unit a further picture @BR_TREND_UNIT_xx.pdl must be configured.
Therewith xx is replaced by the unit number. The same unit number as in the CFC plan
of the unit in the parameter EQM_ID of the FB U_U_SYN (see chapter “5.3.2 Unit“)
and as in the text configuration picture of the unit in the caption is entered (see chapter
“5.4.1.6 Adjust Configuration Picture“).
The picture @BR_TREND_UNIT_01.pdl from the BRAUMAT compact library is used
as template for the trend picture @BR_TREND_UNIT_xx.pdl.
The variables for the trending for the corresponding units must be entered in the trend
control in the WinCC Graphic Designer. Below the trend control the name of the unit is
entered in the static text.
The picture name @BR_TREND_UNIT_xx.pdl can also be renamed in an individual
name like TREND_Mill.pdl. This name must then be entered manually in the user
archive BRC_UNIT (see also chapter “14.2 Contents and Settings“)
Recipe Configuration BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 87
8 Recipe Configuration
The recipe configuration prepares the recipe name contribution in the runtime
environment.
Image 74: Recipe Configuration
The dialogues recipe types and recipe names are described in the following chapters.
8.1 Recipe configuration
The recipe names are configured in the dialogue recipe names in the OS Runtime.
8.2 Recipe Types
Recipe types are used, when two areas of a brewery are controlled with one
BRAUMAT compact system e.g. brew house and cellar. In this case the same recipes
are available at the same recipe type for both areas. Recipes of the brewery cannot be
executed in the cellar and vice versa. Therefore, the recipes can be grouped in
different recipe type’s e.g. brew house and cellar.
A user archive must be generated for each recipe type via the table generator (see
also chapter 5.4.1.2 File WinCC User Archive paragraph „Button “Fill / Clear” Recipe
Head Parameter:“).
The recipe types are configured in the OS Runtime in the prompt for recipe types.
However, only those recipe types are shown in this online view, for which a
corresponding archive was generated before in the user archives. All others are not
valid.
A unit can only be connected with a recipe type number. The recipe type is configured
in the CFC plan SCHEDULER in the function block START of the type BRC_USTA
BRAUMATcompact Recipe Configuration
Engineering Manual, 06/2010, A5E02608507B-02 Page 88
Image 75: Recipe Type Settings
For further recipe types the archives must be filed for each unit in the dialogue for
archive generating (see also chapter “5.4.1.2 File WinCC User Archive”).
A unit can only be connected with a recipe type number.
8.3 Start units with different recipes
In the standard connection in the units CFC plans the following unit is started with the
same recipe number as the accessed unit. If a following unit should be started with
another recipe number, this can be done via the function block BRC_USTA. The
connection of the function block BRC_USTA for the following unit is described in the
chapter “15.1.2 Units: BRC_USTA: (TA starter FB1108)“.
In order to start a different recipe on a following unit, the according recipe number must
be configured at the input connector RECTID.
Image 76: Default recipe number
Recipe Configuration BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 89
Typically this is used to start CIP from a unit. One recipe CIP (e.g. No 20) is available
in all units. There is a recipe for each unit that should be cleaned in the unit CIP (e.g.
recipe 01: CIP mill, recipe 02: CIP mashing tub, …). In the according unit the recipe
number is to be entered definitely for the CIP unit.
8.4 Different recipe types in the brewery
Different recipe types are used in different areas (e.g. brew house, CIP, cellar) need
different recipes. In the brew house the recipes are e.g. 01: Pils, 02: Wheat, 03:Lager,
… and in CIP 01: Clean mask cooker, 02: Clean worth pool, 03: Clean lauter tub.
8.4.1 Assign recipe type to unit
Each unit can be assigned to one recipe type only.
The recipe type is configured in sequence chart at input RECT_ASS from block
U_U_SYN. Default 1 is configured.
Figure 77: Recipe type 2 configured in sequence chart
BRAUMATcompact Recipe Configuration
Engineering Manual, 06/2010, A5E02608507B-02 Page 90
8.4.2 Start unit with different recipe type
Is the unit started via block BRC_USTA block (see Chapter 15.1.2) then the recipe type
has to be configured fix. Also the recipe number should be configure at the
BRC_START block. Alternative the recipe number can be connect to a dedicated
parameter.
Figure 78: Start unit with configured recipe type and recipe number
For configuration with scheduler see chapter 8.2 Recipe Types Image 75: Recipe Type
Settings
Before using the recipe type the WinCC user archives must be created. How to
proceed see chapter 5.4.1.2 File WinCC User Archive especially the Button “Fill /
Clear” Recipe Head Parameter: and the Button “Fill / Clear” Recipe Data: are used.
Scheduler BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 91
9 Scheduler
9.1 CFC Plan
The scheduler is implemented in the CFC plan SCHEDULER. The CFC plan scheduler
can be copied from the BRAUMAT compact library.
The scheduler has in A2 a START block for the connection of the units, which should
get started. This unit starts the remaining process via successor units.
Image 79: Connection of Scheduler to the Process
BRAUMATcompact Scheduler
Engineering Manual, 06/2010, A5E02608507B-02 Page 92
The parameter P_UNIT in the block START is connected internally to the block 1 (Type
BRC_UIF). This connection must be disconnected and the block 1 (Type BRC_UIF)
can be deleted.
The parameter P_UNIT in the block START is connected only to the unit, which should
get started. Therewith this parameter is connected to the parameter P_UNIT of the
block U_U_SYNC in the CFC plan of the unit (filed in Sequence).
9.2 WinCC Engineering
The picture BR_WOP.pdl is used for the scheduler.
This can be added e.g. via the WinCC Picture Tree Manager or a own virtual unit in the
technologic view can be added for the scheduler.
Image 80: Trending in the plant view
The following internal variables are needed by the scheduler and filed in automatically.
All internal variables should be generated in the group BRAUMAT_Scheduler
Name Type
WinCCPath Text variable 8-bit symbol set
WP_ActDateTime 16-bit value w/o prefix
WP_ActUserMachine
16-bit value w/o prefix
Windows_DateTime Text variable 8-bit symbol set
WP_PrefixDate Text variable 8-bit symbol set
WP_PrefixUser Text variable 8-bit symbol set
ProjectEnableName Text variable 8-bit symbol set
Following image shows an example.
Scheduler BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 93
Image 81: Example Internal Scheduler Variables
The variable names for the scheduler must be entered in the BR_WOP.pdl. The tag
name consists of scheduler CFC plan followed by the corresponding structures.
All three tag names of the „Interface blocks tag prefix“ must be configured according to
the scheduler CFC name
Image 82: Variables Connection in the scheduler
Captions and texts of the scheduler can be adjusted in the green area, however, these
data are already provided executable.
Further adjustments are not necessary for the scheduler.
BRAUMATcompact Batch Data Export and Report
Engineering Manual, 06/2010, A5E02608507B-02 Page 94
10 Batch Data Export and Report
10.1 Batch Export
The batch export copies and processes the batch data from the WinCC archives in
Excel via an application. For starting the batch export, a button “Export Data“ is
available in the @BRC_TYPICALS.pdl in the area Export Data. This button must be
copied in a picture.
In order to assure the export, the export functionality needs a data directory available
from the local computer. This directory is entered in the data file BRC_UA2XLS.ini
under Settings in the parameter Path.
Image 83: Example for BRC_UA2XLS.ini
Further configurations are not needed for the export of data.
The exported data are filed under the configured path in the subdirectory
01_Output/01_BatchReports/<CalendarYear>/<CalendarWeek>.
The batch report is always generated for the entire system with all units. For this a unit
must be configured as Master. As recommendation this should be the same unit as the
one started by the Scheduler.
For the configuration of the reference unit, the image @BRC_ExportBatchData.pdl is
opened in the Grahpics Designer and the unit ID of the reference unit must be entered
in the array IO ReferenceUnit.
Batch Data Export and Report BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 95
Image 84: Configuration of the reference unit
10.2 Batch Report
The batch report is generated via Microsoft Excel. Thereby a template, generated in
EXCEL, can be used again in BRAUMAT compact.
The function batch report needs a valid entry for the path in the file <WinCC Project
Path>BRAUMAT/BRC_UA2XLS.ini. This entry must be in the operating system. The
following entry structures are filed after the first export:
Image 85: Report Structure
Thereby the report is filed in the folder <Calendar Year> and there in <Calendar
Week>.
BRAUMATcompact Batch Data Export and Report
Engineering Manual, 06/2010, A5E02608507B-02 Page 96
The generating of the template is created from an existing batch export. After opening
the batch export in EXCEL a new table can be pasted. In this new table a batch report
according to demands and creation requests of the customer must be generated. This
altered batch export is then filed as EXCEL template under the path configured in the
BRC_UA2XLS.ini in the sub-directory 00_Templates (see Image 85: Report Structur).
Thereby the data name must be identically (case sensible) to the recipe name, which
was entered in the picture BRC_REC01_NAME in the BRAUMAT compact. If more
languages are configured in the picture BRC_REC01_NAME, a template must be filed
with the corresponding name for each language.
Technological Hierarchy BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 97
11 Technological Hierarchy
The hierarchic structure in the project should reflect the technological structure of the
system. The units (mill, mashing tub, …) form the first hierarchy level. In the next level
are two further hierarchy files (control modules or also only CM and sequence). In the
file Control Modules are the CFC plans of the single aggregates. In the file Sequence is
a CFC plan containing the control blocks. The aggregates of the units are controlled
according to sequence and recipe via this block. Furthermore, a configuration picture is
filed there. In this block are several texts deposited.(see also chapter “5.4.1.4 Adjust
Engineering Picture“)
Both CFC plans (Scheduler and System) are not assigned to a hierarchy.
Image 86: Example Hierarchy Brewery
If a unit should or must be separated in two (sub) units, a further hierarchy level is
installed below the unit. Each of these (sub) units than has the function hierarchy file
Sequence and CM again.
If several facilities e.g. brewery and cellar are implemented in a PLC, two system
hierarchy files are generated in the root level as well.
The corresponding hierarchy file as well as two sub files are generated for the new
unit.
Image 87: Hierarchy of a Unit
BRAUMATcompact Technological Hierarchy
Engineering Manual, 06/2010, A5E02608507B-02 Page 98
The file “CM” should later contain the plans for the single aggregates (valve, motor,
sensor, …). The file “Sequence“ is provided for the CFC .
The CFC for the sequence controller are copied from the BRC library in the
corresponding hierarchy file and renamed.
Image 88: Unit CFC and text configuration picture
Hereby the unit abbreviation (here e.g. MC) of the hierarchy must be included in the
name of the CFC plan resp. the control picture.
The name of the control picture consists of the name of the CFC plan + the ending
_NAME. This convention must be kept.
Connection of CFC Plans BRAUMAT compact
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12 Connection of CFC Plans
12.1 Connection via Process Object View
12.1.1 Unit
The blocks of the sequence controller must be connected with the recipe resp. archive
manager block. The connection via the process object view (PO view) is explained first.
First the sequence CFC (here e.g. TA_SEQ) is opened in the PO view, and then the
tab Parameter. Subsequently it is useful to sort the table according to links and then
enter the following texts in the table Connection.
SCHEDULER\BR_CLOCK.YEAR
SYSTEM\ARCHM.REQxxx_ST xxx next free input on the connecting block
001 for first unit
003 for second unit etc.
SYSTEM\ARCHM.REQxxx_ST xxx next free input at the connecting block
002 for first unit
004 for second unit etc.
SYSTEM\RECM.REQxxx_ST xxx next free input on the connecting block
001 for first unit
002 for second unit etc.
SYSTEM\RECM.REC_ST
SYSTEM\BA_ID.REQxx_ST xxx next free input on the connecting block
001 for first unit
002 for second unit etc.
SCHEDULER\BR_WP_CW.CW
SYSTEM\BA_ID.BAID_ST
SYSTEM\ARCHM.QARCH_ST
SYSTEM\ARCHM.QARCH_ST
BRAUMATcompact Connection of CFC Plans
Engineering Manual, 06/2010, A5E02608507B-02 Page 100
Image 89: Connection via Process Object View (Unit No. 1)
A text file (Unit_2_System_Connection) storing the connection strings, is in the library.
These can be copied in the PO view.
The file is altered for the first unit e.g. as follows:
Image 90: Configuration Data for Process Object View (unit No. 1)
12.1.2 Aggregates
The single aggregates must be connected to the control blocks in the sequence CFC.
It is important that the single aggregate is always connected with all sequence blocks
on the same(!) “channel number“.
Connection of CFC Plans BRAUMAT compact
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At the connection via the process object view ( PO view) is carried out for all aggregate
types according to the same schema.
First the CFC of the aggregate is opened in the PO view in the tab Parameter and the
corresponding text is entered under Connection.
Here on the example Valve:
XX Abbreviation of unit
xx next free number on the control blocks
Link Connection
V_LOCK XX_SEQ\FB_LOCK.FB_xx
QOPENED XX_SEQ\FB_CM.FB_xx
QMAN_AUT XX_SEQ\FB_AUTO.FB_xx
CM_INFO XX_SEQ\U_U_SYN.QCM_INFO
AUTO_OC XX_SEQ\CMD.CMD_xx
Image 91: Connection Aggregate of the Unit MC_SEQ on Channel 08
There is a corresponding text file for each aggregate, which describes the needed
interconnection and can be used as master copy. For example the text file
BRT_V_FBCL_CONN.TXT in the BRAUMAT compact library for the valve
Here on the example motor:
XX Abbreviation of unit
xx next free number on the control blocks
BRAUMATcompact Connection of CFC Plans
Engineering Manual, 06/2010, A5E02608507B-02 Page 102
Link Connection
QRUN XX_SEQ\FB_CM.FB_xx
QMAN_AUT XX_SEQ\FB_AUTO.FB_xx
CM_INFO XX_SEQ\U_U_SYN.QCM_INFO
AUTO_OC XX_SEQ\CMD.CMD_xx
Image 92: Connection Aggregate of the Unit MC_SEQ on the Channel 05
See also the text file BRT_M_CONN.TXT in the library
12.1.3 Use of Configuration Text Data
The configuration file has 3 different areas:
Section 1 gives a brief overview over the functional contents.
Section 2 explains the required steps for each aggregate.
Section 3 contains a master copy with all relevant connections.
Image 93: Example of a Configuration File
Connection of CFC Plans BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 103
After the copying of the file, the file should be adjusted according to Section 3.
XX_SEQ is the CFC plan of the unit, which is filed in the sequence hierarchy file.
Xx explains the channel number for the aggregate.
Image 94: Example for a Configuration File
This configuration file connects the aggregate with the unit ConcStandardise_PHCON
with the channel 11 in the block FB_CM.
Image 95: Example of Executed Connections on Channel 11
The Section 3 is copied in the process object view column Connection via the
clipboard. Thereby the instructions in Section 2 are used.
BRAUMATcompact Connection of CFC Plans
Engineering Manual, 06/2010, A5E02608507B-02 Page 104
12.2 “Manual“ Connection of Aggregate
Instead of the connection via process object view, the connections can also be
established step by step in the CFC plans.
In the sequence control CFC on page A1 is the block FB_CM. The responses of the
aggregates are connected to its inputs.
Image 96: Connection FB_02 to QOPENED
The output “QOPENED“ is linked e.g. from the valve block and the output “QRUN“ from
the motor block.
In the sequence control CFC on page A2 is the block FB_AUTO. The confirmations of
the aggregates for manual/automatic are to be linked on this block.
Image 97: Connection from FB_02to QMAN_AUT
The output “QMAN_AUT“ is connected via the valve block as well as via the motor
block.
In the sequence control CFC on page A3 is the block FB_LOCK. It is confirmed to the
block, if the valve is locked.
Connection of CFC Plans BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 105
Image 98: Connection from FB_02 to V_LOCK
The output “V_LOCK“ is linked from the valve block.
The block CMD is on page A4 in the sequence control CFC. The single aggregates are
triggered via this block.
Image 99: Connection from CMD_02 to AUTO_OC
The block is connected with the input “AUTO_OC“ on the valve resp. motor block.
The block U_U_SYN is on pageA5 in the sequence control CFC. The single analogue
inputs are connected via this block.
BRAUMATcompact Connection of CFC Plans
Engineering Manual, 06/2010, A5E02608507B-02 Page 106
Image 100: Connection from AV02 to V
The inputs “V“ of the analogue channel driver are connected with the inputs “AV0x“ of
the block.
The input “CM_INFO“ of the respective aggregate must be connected on the output
“QCM_INFO“.
Control Modules BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 107
13 Control Modules
13.1.1 List of the Templates (acc. Master Plans)
The following list shows all premade templates.
BRT_CNT_V2_0 Counter
BRT_DIN_V2_0 Digital Input
BRT_DMOF_V2_0 Monitoring function
BRT_DMON_V2_0 Monitoring function
BRT_M_V2_0 Motor with feedback on
BRT_MEAS_V2_0 Analog measurement
BRT_MOF_V2_0 Monitoring function
BRT_MSC_MSS_MV2_0 Motor with feedback on MSS and
Maintenance
BRT_PID_V2_0 PID controller
BRT_PUPA_V2_0 Intervallblock
BRT_V_FBCL_OP_V2_0 Valve with feedback open and closed
BRT_V_FBCL_V2_0 Valve with feedback closed
BRT_V_FBOP_V2_0 Valve with feedback open
BRT_VDS_FBCL_OP_V2_0 Double seat valve with feedback closed /
open
BRT_VDS_FBCL_V2_0 Double seat valve with feedback closed
BRT_VDS_FBCL_OP_O_V2 Double SEAT valve with feedback closed and
open and without seat lifting
BRT_VMAN Manual Valve
BRT_MREV_CMD_U_D_V2_0 Reverse motor with commands UP and
DOWN
BRT_MREV_CMD_S_D_V2_0 Reverse motor with commands START and
DIRECTION
BRT_M_MSS_M_V2_0 Motor with feedback on MSS and
Maintenance
and with speed control
BRT_AMON_V2_0 Analogue measurement
13.1.2 Functionality
All templates are described briefly below. A detailed documentation of the functionality
of the templates can be taken from the blocks Online Help.
To each template the corresponding object resp. the object group form the
@@Template _BRAUMAT_V2_0.pdl is listed additionally. The group is stated
respectively. Within the group any object can be used. The object differ within a group
only by the external display.
BRAUMATcompact Control Modules
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BRT_CNT Counter
This template contains a counter. This can count forwards as well as backwards via
impulse inputs.
Object group: BRT_CNT
BRT_DIN Digital Input
This template contains the block “BRT_DIN“. Digital signals can have a switch on and
off delay. The signal stat is shown in the WinCC via a faceplate. The signal can then be
simulated.
Object group: BRT_DIN
BRT_DMOF Monitoring Function
This template must be set immediately with the BRT_DIN template. The block,
however, has an additional alarm function. A TRUE signal on the input I generates a
TRUE signal on the output Q and generates simultaneously an alarm. The block has
an output Q_ACK, which turns TRUE, when the alarm is acknowledged by WinCC.
Object group: BRT_DMOF
BRT_DMON Monitoring Function
This template is to be set simultaneously with the BRT_DMOF template. However, this
block does not have an Q_ACK output.
Object group: BRT_DMON
BRT_M Motor With Feedback On
This template contains a motor. A standard PCS 7 MOTOR is here integrated
expanded by specific functions like operating hours, runtime switch, expanded
cascading and cascaded operation lock.
Object group: BRT_M
BRT_MEAS Analog measurement
This template administers an analog measurement.
Object group: MEAS_MON
BRT_MOF Monitoring Function
This template contains a BRT_MOF block. This block has a alarm function and via this
signals can have a switch on and off delay. Additionally, the block provides a WinCC
confirmation.
Object group: ?
BRT_MSC Motor With Feedback On
This template expands the PCS 7 Standard MOTOR by simulation values,
maintenance expansions, and parameter.
Object group: BRT_MSC
BRT_PID PID Controller
This template provides a PID controller
Control Modules BRAUMAT compact
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Object group: CTRL_PID
BRT_PUPA Interval Block
This template provides a block for synchronizing of up to 10 Control Modules.
Object group: BRT_PUPA
BRT_V_2Q_FBCL Valve With Feedback Closed and 2 Outputs
This template contains a Standard PCS 7 valve with expansion for interlock, delayed
starting and stopping and BATCH Handling. The valve has 2 output signals still stand
and still stand inverted.
Object group: BRT_V
BRT_V_FBCL_OP Valve With Feedback Open and Closed
This template contains a Standard PCS 7 valve with Open-Close feedback and
expansions for interlock, delayed starting and stopping and BATCH Handling.
Object group: BRT_V
BRT_V_FBCL Valve With Feedback Closed
This template contains a Standard PCS 7 valve with Close feedback and expansion for
interlock, delayed starting and stopping and BATCH Handling.
Object group: BRT_V
BRT_V_FBOP Valve With Feedback Open
This template contains a Standard PCS 7 valve with Open feedback and expansion for
interlock, delayed starting and stopping and BATCH Handling.
Object group: BRT_V
BRT_V_NOFB Valve without feedback
This template contains a Standard PCS 7 Valve without Feedback and expansion for
interlock, delayed starting and stopping and BATCH Handling.
Object group: BRT_V
BRT_VDS_FBCL_OP Double Seat Valve With Feedback Closed / Open
This template contains a Standard PCS 7 Valve with Open-Close Feedback and
expansion for interlock, delayed starting and stopping and BATCH Handling and
double seat positioning.
Object group: BRT_VDS
BRT_VDS_FBCL Double seat valve with feedback closed
This template contains a Standard PCS 7 Valve with Close Feedback and expansion
for interlock, delayed starting and stopping and BATCH Handling and double seat
positioning.
Object group: BRT_VDS
BRAUMATcompact Control Modules
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13.1.3 CM Info
Almost all templates contain one or more blocks, which have the input “CM_INFO“.
This is to be connected generally with the output „QCM_INFO“ of the block
„U_U_SYN“ of the respective unit.
User Archives BRAUMAT compact
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14 User Archives
14.1 Archives
The following image shows the archives filed in BRAUMAT compact.
Image 101: Archives in BRAUMAT compact
This image shows the archives for 3 units with one recipe type. Further archives
develop with projects with further units. For each unit the following archives are added:
+ ARCH_XX with XX of the unit number (EQM_ID in FB U_U_SYN resp. in text
configuration picture of the resp. unit). Thereby single-digit units are filed only
single-digit e.g. ARCH_4 for unit 4)
+ ARCH_1xx01 with xx of the unit number (EQM_ID in FB U_U_SYN resp. in text
configuration picture of the resp. unit).
+ ARCH_2xx with xx of the unit number (EQM_ID in FB U_U_SYN resp. in text
configuration picture of the resp. unit).
Description of the archives, see next chapter.
BRAUMATcompact User Archives
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14.2 Contents and Settings
ARCH_XX
with XX of the unit number (EQM_ID in FB U_U_SYN resp. in text configuration picture
of the resp. system). Thereby single digit units are only filed with a single digit e.g.
ARCH_4 for unit 4)
The batch data are stored in the archive ARCH_XX after finishing a batch. Thereby
also the batch information with recipe name, start and end time,… of the batch as well
as the data of each executed step with step start and end time, parameter values and
analog value respond are stored.
ARCH_1xx01
with xx of the unit number (EQM_ID in FB U_U_SYN resp. in text configuration picture
of the resp. system).
The parameter of the recipes Function Step are stored granular in the archive
ARCH_1xx01. These data are edited by the user via the parameter dialogue in the
engineering faceplate of the unit.
ARCH_2xx
wit xx of the unit number (EQM_ID in FB U_U_SYN resp. in text configuration picture
of the resp. system).
The attribution of a batch to year and calendar week is stored in the archive
ARCH_2xx.
ARCH_901
In the archive ARCH_901 a trend with 128 value pairs (time value) can be entered
in each line. These data can then be used in a BRAUMAT compact application via the
block BRC_SPT.
Thereby the ID of the column REC_ID must correspond to the parameter TR_ID on the
block.
ARCH_951
In the archive ARCH_951 exactly one trend is stored. Thereby each line represents a
value pair time value. This archive is used for the lauder curve and is included in
recipe import/export
BRC_REC01
Is currently not used. Is maintained of compatibility reasons.
BRC_RECTYPE
Is currently not used. Is maintained of compatibility reasons.
BRC_UNIT
In the archive BRC_UINT the unit number of the unit name and the corresponding
trend picture are attributed.
User Archives BRAUMAT compact
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All values are generated executable at the configuration. Thereby the units are filed as
Unit_xx (column UNIT_NAME) and the trend pictures as @BR_TREND_Unit_xx
(column PDL_NAME) with xx of the unit number. The contents of both columns can be
adjusted manually.
BRC_UNIT_PARAMETER
In the archive BRC_UNIT_PARAMETER the parameter types of each unit are stored.
The data are entered by the user in the parameter dialogue in the engineering
faceplate via the button ”Parameter”.
PHCON_CS
The step sequence configuration is stored in the archive PHCON_CS. These data are
entered by the user in the engineering faceplate in the left PHCON Control.
PHCON_FCT
The step configuration for each step and unit is stored in the archive PHCON_FCT.
These data are entered by the user in the engineering faceplate in the right PHCON
Control.
PHCON_FCT_NAME
Is currently not used. Is maintained of compatibility reasons.
PHCON_LOGIC
The logic configuration is stored in the archive PHCON_LOGIC. These data are
entered by the user in the engineering faceplate in the Logic Control via the logic
mechanism (see also chapter 5.4.1.6 Adjust Configuration Picture).
BRC_REDUNDANCY
This is an auxiliary user archive and serves for the transfer of texts between two
redundant servers. Text data (e.g. recipe name, recipe type name) are transferred from
the OS Servers, on which the data was modified, to the redundant partner by the user
archive
.
This data is written in the local text library at the redundant partner.
14.3 Backup and Recovery User Archives
The User Archives can be exported and reimported completely via the Engineering
Picture.
Image 102: Export / Import User Archives completely.
The content of the entire BRAUMAT compact User Archive is exported with the export.
Archives which are compiled applicatory, are not included in the export.
The contents of the entire BRAUMAT compact User Archive is imported with the
import. Archives which are compiled applicatory are not included in the import.
BRAUMATcompact User Archives
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All files are im-/exported in the preset path which is beneath the two buttons. The path
must be set up in the system software. The path can be altered optionally by the user.
The adjustment is saved by the system. Also after the loss of the OS Runtime the
adjustments are still available after a restart.
It is recommended that a back up is carried out regularly. This can also be carried out
via the C-Script, therefore the function BRC_ExportUserArchives(szPath) is to be used.
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15 Expanded Functionalities
15.1 Shared Use of Aggregates / Units
15.1.1 Aggregates : BRC_MUX (CM multiplexer FB1105)
In some cases it can happen that from several units the aggregates (e.g. valves) are
accessed. As the aggregates are basically assigned to only one unit and so are also
the signals (CM_INFO and AUTO_OC) connected with the corresponding blocks, a
MUX block (FB1105) is needed for a multiuse.
Image 103: Use of a valve in several units
If an aggregate is used simultaneous by several units, so the unit with the highest
number (here the TA, which is connected to CM2_INFO) takes priority.
At the output “Q_ACTMOD“ it is distributed which TA is active.
Via the parameter CMD_EXCL the effectiveness of the block can be configured. If a 0
is pending at the input connector CMD_EXCL, the activation (AUTO_Ocx) of all active
aggregates (parameter of the structure CM_INFO) are connected as AND operation,
i.e. if a active aggregate sets the state 1, this will become active also at the output
Q_AUTO_OC.
If a 1 is connected on the output CMD_EXCL, the input AUTO_Ocx is watched
exclusively by the highest (CMx_INFO with x=max.) active aggregate. The value of the
input AUTO_Ocx (regardless if 0 or 1) of the highest active aggregate is interconnected
to the output Q_AUTO_O 1:1.
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15.1.2 Units: BRC_USTA: (TA starter FB1108)
The multiplexer for the units is necessary, when more than two units are needed as
successor resp. predecessor. A typical setting is the CIP. Different CIP settings are
displayed in the following sub chapters.
15.1.2.1 A unit has several successors
The CIP has more than two successors in this setting.
CIP
Mash tun
Wirlpool
Tank A
...
Image 104: The CIP recipe is started on the unit CIP.
The cleaning is started at the unit CIP. A recipe „clean mash tun“ starts the unit CIP
and subsequently the unit „mash tun“ with the same recipe. A recipe „clean tank A“
starts the unit CIP and subsequently the unit tank A with the same recipe.
In the CFC plan of the unit, which has several successor, is a block BRC_USTA set for
each successor. In the BRAUMAT compact library is a template CFC plan included
with a placed BRC_USTA as example under Seq_StartsSeq.
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Image 105: Connection of a unit with several successors
For each successor unit is one block BRC_USTA placed in the CFC plan of the unit
and the outputs QEQM_ID, Q_BA_ID, Q_BA_NA, Q_RECID, and Q_RECT_ID are
connected to the according inputs of the BRC_USTA (name without Q_). The input
P_UNIT of the block BRC_USTA is connected with the according successor unit in the
block U_U_SYN (type BRC_UIF) output P_UNIT.
The start of the according unit (input START in BRC_USTA) is connected with a
Control Module output. Therewith the start of the successive unit is configured like the
open/start of an aggregate in the recipe. Only a start without waiting for feedback is
possible.
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Image 106: Example for starting a successor unit via BRC_USTA.
Synchronization with the successor units:
A synchronisation among the units can be carried out via the inputs SYNCx resp.
outputs QU_SYNCx.
The values of the inputs SYNC1 to SYNC8 of the block BRC_USTA are displayed at
the block U_U_SYN (type BRC_UIF) of the via P_UNIT connected unit at the outputs
QU_SYNC1 to QU_SYNC8.
At the outputs QU_SYNC1 to QU_SYNC8 of the block BRC_USTA the values of the
inputs SYNC1 to SYNC8 of the block U_U_SYN (type BRC_UIF) of the via P_UNIT
connected unit are displayed. Via this data exchange a synchronization can be carried
out.
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Image 107: Connection of the synchronisation of a successive unit
The synchronisation is connected like an aggregate with access and feedback. The
input SYNCx is connected with a output CMD_nn of the CMD block and the output
QU_SYNCx with an input FB_nn in the block FB_CM. Thereby nn must be analogue to
the aggregate connection. The synchronization can therewith be explained like an
aggregate in the recipe (recipe example see Image 106: Example for starting a
successor unit via BRC_USTA.),
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15.1.2.2 One unit has several predecessors
In this setting the CIP has more than two predecessors.
Image 108: The CIP recipe will be started on the according unit which should be cleaned.
For each unit is a cleaning recipe configured e.g. CIP. This recipe starts the own units
and subsequently the unit CIP.
The procedure is very similar to the one in the previous chapter. It is recommended to
read and understand these in advance. .
For each predecessor a block BRC_USTA is generated in the CFC plan of the
predecessor.
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Image 109: Connection of a predecessor via BRC_USTA
Image 110: Connection of a successor via BRC_PMUX
P_UNIT structures of up to
30 USTA blocks
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For each predecessor a block BRC_USTA is set in the CFC plan of the predecessor
and the outputs QEQM_ID, Q_BA_ID, Q_BA_NA, Q_RECID, and Q_RECT_ID are
connected to the according inputs of the BRC_USTA (name without Q_).
The input P_UNIT of the block BRC_USTA in the predecessor unit is connected via a
BRC_PMUX block to the successor unit in the block U_U_SYN (type BRC_UIF)
output P_UNIT.
The start of the according unit (input START in BRC_USTA) is connected with a
Control Module output. Therewith the start of the successive unit is configured like the
open/start of an aggregate in the recipe.
The same mechanism as in the previous chapter under „Synchronization with the
successor units:“ can be used for the synchronization.
The recipe configuration is the same as the one from the previous chapter.
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15.2 Unit Multiplexer
15.2.1 General
In order to start or synchronize several units from one source, the FB BRC_UMX can
be used. An unit in BRAUMAT compact has the possibility to start exactly 2 upstream
and exactly 2 downstream units (chapter 8.4.2). If a unit e.g. wort cooler has many
successor units e.g. all tanks, the Unit Multiplexer provides a dynamic connection of
the source with the respective currently needed target.
Up to 50 units can be defined and approached as successor with this block.
15.2.2 CFC BRC_UMX
The units defined as target e.g. tanks, pass their structure via the BRC_UIF via the
output connection Q_UMX to the input UIF_St01 … 50 of BRC_UMX (marked blue).
Also, the output structure U_NEXT01 of BRC_UMX must be put back to the input
U_A_PREV of BRC_UIF.
The unit defined as source e.g. wort cooler passes its structure U_A_NEXT of
BRC_UIF to the input U_PREV01 … 50 of BRC_UMX.
Either mode Toggle (two target units are used in turns) or single mode (one source is
linked to one selectable target) can be used. The mode is adjusted at the input Mode1
of BRC_UMX.
Input structures of BRC_UMX, which are not used, can be allocated with the output
structure PREV_NOT.
Image 111: CFC BRC_UMX
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15.2.3 User Interface
Symbol display:
For monitoring which target is being filled the unit is marked green.
Image 112: User Interface Multiplexer 1
If the Toggle mode (MODE1=2) is applied, the following unit will be taken automatically
after the source is restarted again.
Image 113: User Interface Multiplexer 2
If the single mode(MODE=1) is applied, only one unit can be selected.
Image 114:User Interface Order
A successor unit can be started with the same recipe data as the predecessor unit
(batch ID, recipe, recipe type) or with different recipe data.
The recipe type can be selected in the detail display of BRC_UMX.
If “Transfer“ is checked, the recipe type of the source is taken and it can only be
chosen between the units of the same recipe range.
If the same recipe and the same batch ID should be used from the source, “Transfer“
has to be checked for the recipe and the batch ID.
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It’s possible to select a different unit in a different recipe range. There the check at
“Transfer“ has to be deactivated. In this case a new recipe has to be selected and a
new batch ID is generated automatically.
With the button „Reset“ all data of the source and the target are removed.
Image 115: BRC_UIF – BAID COMPARE
In the BRC_UIF FB it is possible to activate and deactivate the comparison between
the batch ID of the source and the ID of the destination by next and previous unit
synchronization.
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15.3 Expanded Synchronisation
The synchronization of two units, which have a predecessor/successor relation are
described in the chapter 5.3.3 with chapter 5.4.1.5 and in the chapter 15.1.2.1 under
„Synchronization with the successor units:“
There is the possibility of two units if they have no predecessor/successor relation.
Hereto the units can be synchronised via a recipe set point.
Thereto a parameter must be selected for each involved unit for the synchronization.
This parameter is to be provided with a according name in the engineering picture in
the SIMATIC WinCC Graphics Designer (e.g. Synch value TA5) (see chapter 5.4.1.6
section with Image 42: Configuration of Parameter Texts)
Image 116: Configuration of the synchronisation parameters
The selected parameter must now be connected with each other in the CFC plan of the
respective unit.
Thereby the respective output Q_SP_VAL will be connected with the input ACT_VAL of
the parameter of the other unit.
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Image 117: Connection of the synchronisation parameter in the CFC
The parameter type must be configured in each unit. The following image shows the
example of the unit MC the parameter type recommended configuration
Image 118: Parameter type configuration for synchronization values
Now the value can be used in the recipe. In the following image are the recipes of the
unit ML and of the unit MC synchronized via the set point.
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Image 119: Recipe with synchronization via set points
The parameter is occupied as follows:
Unit ML – Step (1) Value is 0
Unit ML – Step (2) Value is 10
Unit ML – Step (3) Value is 20
Unit MC – Step (1) Value is 0
Unit MC – Step (2) Value is 10
Unit MC – Step (3) Value is 10
Unit MC – Step (4) Value is 20
Unit MC – Step (5) Value is 20
In both recipes should the set point be set on 0 (1). Afterwards the set point is set on
10 in the unit and a 10 is expected back (2). The unit MC waits on 10 (2) before it
continues in step 05. Then the set point is set on 10 (3) and therewith the unit ML
continues its activity. After that the setting is repeated with the set point 20.
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15.4 Standardisation concept in BRAUMAT compact
15.4.1 Overview
The standardisation is carried out once with the adaption of the
parameters from the OS. All parameter alterations that are carried out later
by the user via the OS dialogue at running recipe will not be standardised
anymore.
The standardisation is carried out linear with the factor ‘(Batch quantity /
recipe quantity )’.
The batch quantity cannot be determined via the scheduler at the start of a
unit.
15.4.1.1 Concept
The standardisation concept in BRAUMAT compact is composed by 3 components.
o Standardisable Parameters
It can be determined for each of the 24 parameters for each unit if the
corresponding value should be standardised.
o Recipe Quantity
At the recipe generation it is to be determined for which quantity the
configured recipe parameter should be generated.
o Batch Quantity
At the start of a batch the bacht quantity is entered manually.
If one of the values is not configured resp. smaller or equal 0, the standardisation will
not take place.
If a parameter is set as ‚standardised parameter’, it is valid for all recipes of this unit.
15.4.1.2 Engineering
The standardisation is carried out in the recipe block (CFC Unit, Partition F page 4).
Therefore the inputs AM_BATCH (batch quantity) and NORMPARA (DWORD for the
standardisation coding of the 24 parameters) are used.
The recipe quantity is read out of the user archive at the unit start via the parameter
download. The value is stored in the user archive ARCH_1XXxx in the column
“standard”. The value, used from the UA is visible at the output QAM_REC for the
runtime.
If the output is QAM_REC = -1 and QAM_BATCH = -1, the standardisation has not
taken place.
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Image 120: Standardisation via FB Recipe
The input NORMPARA is transferred from the single outputs of the BRC_REAL blocks
(CFC Unit, Partition E page 1-6) to the recipe block via the Bit to DWORD-Converter
FB_Norm (CFC Unit, Partition F page 3).
15.4.1.1 User Archive
Control the configuration of the archive BRC_UNIT_PARAMETER via the Editor
‚UserArchives’ in WinCC Explorer.
If this archive has been generated newly starting from BRUAMT compact V2.0 SP1,
the parameter EOF_1 has been configured as string with 24 characters.
If this is not the case, please change this parameter to ‘string’ with 24 characters.
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Image 121: Archive BRC_UNIT_PARAMETER
15.4.2 Set Parameter for Standardisation
For each parameter of each unit it can be determined if the values of this parameter
should be standardized.
This configuration is carried out in the parameter dialogue (see Chapter 5.4.2.1
Parameter Types).
If the standardization is set, the corresponding set value is standardized at the unit
start via the function block ‚recipe‘ corresponding to the configured factor from the input
‚AM_BATCH’ and the read recipe value.
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15.4.3 Configure Recipe Quantity
The recipe quantity is configured in the recipe parameter dialogue.
Imge 122: Standardisation Value in Recipe
With the setting of the standardisation in the parameter dialogue (see chapter 5.4.2.1
Parameter Types) an input window appears, in which the standardisation value of the
recipe can be configured. With a value smaller or equal 0 there will be no
standardisation.
The value is written in the corresponding user archive while it is being stored.
15.4.4 Start Batch with a Quantity
The batch quantity must be entered by the user at the start of the batch. This is carried
out in the dialogue for the start of a unit.
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Image 123: Batch Quantity for Batch
The entry of the batch quantity can only be made in the ‘Idle' state of the unit.
Furthermore at least one parameter must configured as standardisable (see 15.4.2 Set
Parameter for Standardisation).
15.4.5 Runtime Events in the Environment Standardisation
Via the standardisation it is possible that parameters with a minimum and maximum
value are standardised beyond these limits.
Example:
The parameter Weight is parameterized with a maximum limit of 100 kg. A set value of
50 kg is entered in the recipe.
The recipe is generated for a standardise quantity of 250 kg.
A batch is started with 1000 kg.
Thereby the set value for the parameter Weight is ‘up standardised’ from 50 kg to 200
kg, which leads to a violation of the maximum value.
This limit violation is signalled at the output Q_L_ERR of the BRC_REAL function block
(which includes the parameter ‚Weight’). This output can be connected to I_HOLD or
I_ABORT of the unit for critical values, so the unit can be put in a safe state.
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15.5 Master Unit- Configure Referencing Unit
15.5.1 General
In an automation system are similar units on which the same recipe is executable. In
case of similar units the recipe should be maintained centrally and available on all
units. Thereby all recipe-specific information (step sequence, step name, step enable
conditions, set points, …) are maintained centrally at the master unit. Unit-specific data
(control module name, …) are configured at the unit.
Master
Unit
e.g . Tank 1
Referencing
Unit
Tank 2
...
Tank 3
Tank n
e.g
.
Referencing
Unit
Referencing
Unit
e.g.
e.g
Image 124: Unit Concept Master referencing
Remark:
If several PLC’s are used, the master and the referencing units must be programmed
within the same PLC. Actually the PLC overlapping master - referencing unit is not
possible.
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15.5.2 CFC Plans
The referencing unit resumes the recipe start resp. via manual operator entry the
recipe of its master. For this a referencing unit must be allocated to its master.
The allocation is carried out via different steps.
Image 125: Allocation of the Master EQM_ID to Referencing Unit
First, the referencing unit must know the EQM_ID of the master. It is effected by the
connection between the output QEQM_ID of FB U_U_SYN of the master unit (A5 in
the sequence plan) and the input EQM_MAST of FB U_U_SYN of the referencing unit
(A5 in sequence plan).
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Image 126: Connection for data exchange from Master to Referencing Unit
Second, the data exchange between master and referencing unit must be provided.
Thereto a connection from the output QEQM_MAST of FB PL of the master unit (D1 in
the sequence plan) to the input EQM_MAST of FB PL of the referencing unit (D1 in the
sequence plan) must be projected.
The PLC is to be translated and a download is to be carried out.
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Result:
In order for the referencing unit to read the recipe parameters of the master unit, the
FB BRC_REC must be configured correctly.
The EQM_ID of the referencing unit must be projected at the input ID of FB BRC_REC
(e.g. 9; this complies with the EQM_ID of the referencing unit).
The recipe parameter archive of the master unit (ARCH_1uurr) must be configured at
the input ARCH_ID of FB BRC_REC (e.g. 10802; this complies with the EQM_ID (8) of
the master unit with recipe type 2).
Image 127: Recipe Configuration Master – Referencing Unit
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15.5.3 WinCC Engineering
The configuration of the texts is carried out in two parts. On the one hand the text data
of the master unit (parameter names, function names, logic names, analogue value
names) are transferred. On the other hand the CM names are configured in a slimmed-
down text configuration data (workbook 2 of Excel Addin ).
Image 128: Configuration of a Referencing Unit
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Image 129: Referencing Unit Declaration
The project image is set up identically for a master unit with a “normal“ unit. The recipe
generation is omitted for a referencing unit and a button “Load Master Recipe“ is
provided for the manual transfer of the master recipe, if the referencing unit is started
already. The button is linked with the Dynamic Wizard “Connect Picture Block with Test
Point“ to the PL block of the unit analogue the button “Write in Text Library“.
Image 130: Overview Line Referencing Unit
15.5.4 Online Engineering
An altered overview line is provided with the introduction of the master unit.
Image 131: Overview Line Referencing Unit
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Each unit contains a column “Master Unit“, in which the unit name of the master, if
defined, is displayed.
15.5.5 Expansion
Each referencing unit is a fully-fledged unit with all FB in the CFC. This allows
individual adjustments of a referencing unit. E.g. if a valve is missing in a referencing
unit (e.g. because it is the first unit in the sequence) the report of this valve e.g. can be
set permanently on 1 (= open). This is carried out in the sequence plan e.g. at the
report FB (A1) by a compact configuration of a 1 at the respective input. Recipe-wise
this valve is triggered and anticipated on 1 at the report.
15.6 Set Point Trends
15.6.1 (BRC_SPT: BRAUMAT compact setpoint trend ) – Line Archive
FB BRC_SPT is set in the line archive (ARCH_901) for the set point trends. The block
is included in the CFC plan SP_Trend.
Up to 128 value pairs for each trend can be configured in the user archive ARCH_901
at that set point archive. Each line represents a trend in the ARCH_901.
These trends can be provided in the system via the block BRC_SPT. Thereby the
block is connected with the archive manager like in the following image.
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Image 132: Line Archive in the CFC Plan
The input REC_ST of the block BRC_SPT is connected with the output REC_ST of the
block FB_RECM. The output REC_ST of the block BRC_SPT is connected with the
input REQxxx_S with xxx from 001 to 128 of the block FB_RECM. It is recommended
to use the first 100 inputs REQxxx_S for the unit connection. It is recommended for the
archives to use the inputs REQxxx_S from 120 to 125. The ID xxx of the input
RECxxx_S is to be entered at the block BRC_SPT.
The user archive ID 901 is to be entered as archive ID (ARCH_ID) at the block
BRC_SPT.
The use of the archive trend data is generated by the consecutively described
connection to the block BRC_SPT.
Input on BRC_SPT Values
Description
TR_ID 1…n Via the TR_ID the line, which should be read, will
be parameterised in the user archive 901 (column
REC_ID). (See also consecutive image)
REC_REQ 0…1 0 1 requests the data from the archive
ARCH_901. When the data are uploaded in the
block, it is shown at the output NEW_DATA by a 1.
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RESET 0…1 0 1 Resets the entire block.
TR_ENA 0…1 1 Trend is released and the data of the set point
trend appears at the output Q_T and Q_VAL
0 Trend is stopped
TR_RESET 0…1 0 1 The trend is reset and starts from 0.
EN_EXT_X 0…1 1 Input EXT_VAL is used as input value. The value
Q_VAL is intercalated with the value pairs based on
this input value.
0 Q_T is identified via the time in seconds.
EXT_VAL any States the input value, which should be used as
base for the intercalation.
A set point trend is provided for each line in the user archive ARCH_901. Thereby
REC_ID is the TR_ID which should be parameterised accordingly at the block
BRC_SPT. REC_NA states the trend name, which is displayed at the output QNAME.
In CNT is the number of the value pairs entered. The value pairs of the set point trend
are parameterised from T_001/VAL_001 to T_128/VAL_128. By means of these value
pair the block BRC_SPT intercalates the according values at the inputs Q_T and
Q_VAL.
Image 133: User Archive ARCH_901 with two set point trends
15.6.2 (BRC_SPTX: BRAUMAT compact set point trend ) – Trend
Archive
The FB BRC_SPTX is set for the set point trend in the Trend Archive (ARCH_20101).
The block is included in the CFC plan SP_TrendEx.
With this set point archive a value pair will be configured for each line in the user
archive ARCH_20101. The ARCH_20101represents exactly one trend. If further trends
of this kind are necessary, further archives can be generated with the table generator.
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This trend can be provided in the system via the block BRC_SPTX . Thereby the block
is connected to the archive manager like in the following image.
Image 134: Trend Archive in the CFC Plan
The input REC_ST of the block BRC_SPTX is connected with the output REC_ST of
the block FB_RECM. The output REC_ST of the block BRC_SPTX is connected with
the input REQxxx_S with xxx from 001 to 128 of the block FB_RECM. It is
recommended to use the first 100 inputs REQxxx_S for the unit connection. It is
recommended to use the inputs REQxxx_S from 120 to 125 for the archives. The ID
xxx of the input RECxxx_S is to be entered at the block BRC_SPTX.
The user archive ID 20101 is to be entered as archive ID (ARCH_ID) at the block
BRC_SPT. Or at respectively further archives their archive number.
The use of the archive trend data is generated by the consecutively described
connection to the block BRC_SPTX.
Input on BRC_SPT Value Description
REC_REQ 0…1 0 1 requests the data from the ARCH_901.
When the data are uploaded in the block, it is
shown at the output NEW_DATA by a 1.
RESET 0…1 0 1 Resets the entire block.
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TR_ENA 0…1 1 Trend is released and the data of the set point
trend appears at the output Q_T and Q_VAL
0 Trend is stopped
TR_RESET 0…1 0 1 The trend is reset and starts from 0.
EN_EXT_X 0…1 1 Input EXT_VAL is used as input value. The value
Q_VAL is intercalated with the value pairs based on
this input value.
0 Q_T is identified via the time in seconds.
EXT_VAL any States the input value, which should be used as
base for the intercalation.
For each line is a value pair provided in the user archive ARCH_20101. By means of
these value pairs the block BRC_SPTX intercalates the corresponding values on the
outputs Q_T and Q_VAL.
15.7 Operating Locking
The operating locking of the single aggregates is carried out on the aggregate blocks
(e.g. valve BTR_V).Normally there are 8 interlock inputs available at the BRAUMAT
aggregates. These inputs are ODER connected. If for example a valve should be
locked, the locking condition should be connected to an interlock input.
In the following image the output QCLOSED of another (invisible in the image) valve is
negated and connected to the ILOCK3.
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Image 135: Connection Interlock
In the visualisation the locking state in an own faceplate is displayed. If a locking is
pending, this locking will be marked red. The displayed text can be parameterised in
the CFC plan by double click of the input.
Image 136: Display Interlock in Runtime
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15.8 Open User Specified Expansion
For the expansion of the application a block is provided on the control level for project
specific adjustments.
The block is available as source code in UNIT_USR_FB_TEMPLATE. This block must
be decoded with the SCL compiler e.g. a function block 1990 is generated.
This block provides internally a step sequence with which the command to the control
modules can be altered.
The block is added in the CFC plan for the relative unit in the page A4 and the
following connections are executed.
+ The connection CMD of the FB CMD of the type BR_PHCON is disconnected
and reconnected to CMD_IN of the FB 1990.
+ FB_IN is connected with Q of the FB_CM in A1.
+ FBEx_IN is connected with Q of the FB_extended in C3
+ UNIT_ST is connected with Q_UNIT_ST of the FB U_U_SYN in A5
+ AV is connected with QP_AV of the FB U_UZ_SYN in A5
Image 137: Adding Project Specific Expansion
Die Vorlage für die Projektspezifische Erweiterung beinhaltet folgende UDTs.
UDT1990
The UDT1990 provides the current analog values, counter values resp. Integrator
values.
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UDT1901
The UDT1991 gives the states of the control module resp. occupancy of predecessor /
successor connection.
Thereby 3 input variables (xCMDIN, xFBIN, xFBExIN) are occupied with this UDT.
xCMDIN shows the commands of the PhaseCon to the periphery, xFBIN shows the
feedback of the control module (see FB FB_CM of the resp. unit) and xFBExIN shows
the feedback of the parameters.
The output variable xQMD is also of the type UDT1901 and shows the executable
commands to the control modules.
In the first step in the block the input xCMDIN is copied in xQMD.
The variable UNIT_ST shows the status of the unit. The value occupancy is explained
in the comment of the template under “Status of the Unit“.
In the area „e.g. user code …“ only the input values can be evaluated and the output
values new allocated. This evaluation can be implemented according to the request
status independent or status depending.
15.9 Step Counter and Sum Counter
Via the measuring point type BRT_CNT_V2_0 a step counter and a sum counter can
be realised. Thereby the function block BRT_CNT can be configured via the input
SET_MIODE, with 1 = reset with batch start and 2 = reset with step start.
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Image 138: Sum and step counter
The counter has two impulse inputs IN_1 and IN_2 with which, the counter value is
added by the value at the corresponding value input VAL_IN1 and VAL_IN2 at a
positive edge. If a value should be sub ducted, a negative value must be pending at the
value input.
See BRAUMAT compact Demo mash tub volume counter for the water quantity Plan
02_CNT01 A1.
15.10 Time Step Monitoring
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15.10.1 Temporal Step Monitoring
The step monitoring time for each step can be set at the block PL input MON_TIME.
The current expired monitoring time is issued at the output QMON_TIM. As soon as
QMON_TIM is greater than MON_TIME, the output QMONT_EX is set on 1 and all
non-fulfilled forward conditions are shown red in the Phase Control.
Image 139: Step time monitoring
In case a different step monitoring time for each step is required the input MON_TIME
has to be connected to a parameter block at output Q_SP_VAL.
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15.10.2 Step Time in Minutes
To display and configure the monitoring in minutes the I_TYPE is set to 2: Integer and
the input INC must be set to 1.666667e-2.
Image 140: Schrittzeitüberwachung
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15.11 Projection 60 Units
This alterations require a restart of PLC!
15.11.1 New CFC – chart
Create a new CFC – Chart in the hierarchy folder SYSTEM, e.g. SYSTEM_01.
Image 141: New CFC - chart
15.11.2 Install additional „BRC_BAID“
After coping the „BRC_BAID“ to the new CFC – chart SYSTEM_01 the following
parameter must be adjusted in order not to generate the same Batch ID number.
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Image 142: BRC_BAID
The number is displayed in the runtime at this point:
Image 143: Display in Runtime
See also chapter 4.1.1.2 BatchID - Generator (BRC_BAID)
15.11.3 Install additional „FB_RECM“
If an additional “FB_RECM“ is copied to the SYSTEM_01 – CFC - chart, the address
R_ID_1 must be adjusted.
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Image 144: Parameterize FB_RECM
15.11.4 Install additional „FB_ARCHM“
If an additional “FB_ ARCHM “ is copied to the SYSTEM_01 – CFC - chart, the
address R_ID_1 must be adjusted.
Image 145: Parameterize FB_ARCHM
Please compile and download the changes made to the PLC – program.
Remark:
The settings (new communication parameters) will only become active on a restart of
the PLC.
15.11.5 Create new raw data variables
Use the BRC – Taggenerator in order to generate the new raw data variables
„SYSTEM_01/REC_DATA“ and „SYSTEM_01/ARCH_DATA“.
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Image 146: Raw Data variables
See also chapter 16.2.2. Netpro
Compile the OS afterwards.
15.11.6 Skripting
The actions ‚M1ArchiveTrigger.pas’ and ‚M1RecipeTrigger.pas’ need to be adjusted for
the new CFC – chart ‘SYSTEM_01’.
Copy the existing actions and save them as new actions, e.g. with the extention ‘_01’.
Image 147: Triggeractions
The name of the CFC – chart is a constant for the trigger action and therefore needs to
be adjusted.
E.g. ‚SYSTEM_01’ .
Image 148: Adjust chart name in the code of the trigger action
The variables used to trigger the actions need to be adjusted as well.
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Image 149: Adjustment of M1ArchiveTrigger_01.pas
Image 150: Adjustment of M1RecipeTrigger_01.pas
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15.12 Update Group Display
In order to guarantee that the messages, alarms, and operating requirements from the
process images are passed up to the superimposed process images, „Update Group
Display“ must be checked in the project editor (WinCC-Explorer). This function is
contained in the PCS 7-Standard and is repeated here for general information.
Image 151: Create Group display
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15.13 Automatic Jump
15.13.1 Jump Coordinator
15.13.1.1 General
The jump coordinator helps to simplify the step sequence jump of a unit.
In diverse processes e.g.
a.) In the filtration it has to be possible to jump from one step to a much further
following step and also back.
b.) At the filling of tanks with several brews the return to the fill-step is
necessary over and over again.
Therefore the 64 steps of a unit are shown in 64 lines in a table.
Each line has 11 columns. The columns are arranged as follows:
9 columns for 9 jump events (EVENT_01…EVENT_09)
A jump event is a signal in the AS application. The event can be linked at
the block input as binary value. For each column is a separate event
available.
1 column for the jump back (EVENT_RB)
The jump back address is entered in this column. If it is intended to jump
back to the same function after a highest priority jump, the own function
number is displayed here. If it is intended to jump back to a different
function, the corresponding value must be entered here.
1 column for a jump with highest priority (EVENT_PRIO).
The jump is released to the corresponding parameterized function. At the
same time the value from the jump back column is stored as possible
jump back address.
A current event is shown as active order. Consequently there are 11 different orders.
A jump back by an event (EVENT_RB) occurs only if a high priority jump
(EVENT_PRIO) was set.
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Image 152: Jump Table
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15.13.1.2 Block BR_PHCJP
Image 153:BR_PHCJP
The block BR_PHCJP is in CFC Partition F1.
For the communication with the user archive an additional connection (marked blue)
must be projected from the output REQ_ST to a free input of the recipe manager
(System Chart, FB_RECM). A premium input connector e.g. REQ_100 or higher is
recommended, as the inputs REQ 1 – 100 are recommended for the unit.
As well as a connection from FB_RECM “REC_ST“ to the input REC_ST of
BR_PHCJP.
The yellow marked binary inputs can be linked with an event. The event EVENT_PR
has priority and is carried out before all other events. Here the Not-Halt signal can be
linked.
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As several events exist in a unit, it can be necessary that a step comparison is inserted
prior to the triggering.
This can be carried out e.g. with the BRT_MOF.
Image 154: Example Step Comparison
Example: In step 9 at an undercut of a level a jump should be carried out.
The step comparison is marked blue, the undercut of the level is marked brown, and
the event yellow can now be linked to e.g. EVENT_01.
A jump destination should now be entered in the jump table.
If the jump table of a unit is altered, while it executes a recipe, the unit must be
restarted again. At an ID alteration of a jump destination of a function in the jump table,
it is needed to switch to a different line.
15.13.1.3 WinCC Engineering
The user archive can be generated via table generator.
For example the user archive 501 is filed for the unit 1.
Image 155: Table Generator
A switch must be projected in the engineering display. It can be linked to BR_PHCJP
with the Dynamic Wizard via “Connect Picture Block with Test Point“.
Image 156: Engineering Display with Jump Destination
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15.13.2 Jump with recipe set point
15.13.2.1 AS configuration
For automatic jump in a sequence a set point (jump to step) and a binary command is
required.
The input L_FCT_SET on function block PL (SEQUENCE CFC chart, Partition D, page
1 or page 2) has to get the jump to destination. The jump is released as soon at input
L_FCT_SET has a valid value (1 to 64. No additional trigger is required.
The actual set point Q_SP_VAL from any parameter function block (e,g. P4 in
SEQUNCE CFC chart, Partition C, page 1) is used as jump destination. The
Q_SP_VAL is converted via R_I function block (Real to Int) and then used as a
multiplication input at multiplication function block (MUL_I).
The jump is released via a command from function block CMD (SEQUNCE CFC chart,
partition A, page 4). The binary output (e.g. F_28) is converted via function block
BO_W (bool to word) and function block W_I (word to int) to an integer. This result is
used as second multiplication input at the MUL_I function block. With this multiplication
configuration the output of MUL_I is 0 (no jump) or the output is the jump to destination
(command 1 multiplied with jump to destination is jump to destination.
Image 157: Jump CFC
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15.13.2.2 OS Configuration
For automatic jump in a sequence a set point (jump to step) and a binary command is
required. Therefore in the PHCON_NAME picture of the related unit a jump to event
and
Image 158: Jump to event
A set point with no unit of measurement
Image 159: Jump set point
In case the jump should be released depending on any logic the logic has to be defined
also.
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15.13.2.3 Recipe Configuration
In the recipe the jump can be released via the binary output directly or combined with
any logic. (see „Jump :28“ in Image 160). The jump destination is a parameter as every
other standard parameter. As jump to destination the parameter must be forced (violet
1) in order to allow online parameter change.
A set point for jump to destination should be configured as parameter type protocol
with no digit and a limit between 1 and 64.
Image 160: Jump recipe
15.13.3 Combination Jump via Recipe Set Point with Jump
Coordinator.
The functionality of the jump via recipe set point can also be combined with the jump
coordinator. For this the jump coordinator is combined like in chapter15.13.1 Jump
Coordinator.
The jump destination is not linked to the input L_FCT_SE but to the input FCT_ET of
the jump coordinator BR_PHCJP (see Image 153:BR_PHCJP). The releasing signal is
linked to the input EVENT_EX of the jump coordinator BR_PHCJP.
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15.14 Condition based operator request
15.14.1 Automatic Operator Request Reset
Based on a signal a step should move further to the next step or an operator request
should be popup. Once the operator request is used as condition the signal is ignored.
The operator request will be acknowledged automatically at step start if a dedicated
signal is set. If the signal is not set in a certain time the operator has to acknowledge
manually.
15.14.1.1 AS Configuration
In the unit CFC chart one input of the control matrix commando block (CMD, partition
A. page 4) is connected to the input of new OR function block. The input FB_02 is
reconnected from the feedback function block (CM_FB, partition A, page 1) to the new
OR function block. The OR output is connected to FB_02 on the FB_CM (FB_CM,
partition A, page 1)
Image 161: CFC Automatic Operator Request Reset
15.14.1.2 OS Configuration
In the PHCON_NAME a new logic has to be defined and if required a new parameter is
entered.
15.14.1.3 Recipe Configuration
A parameter (parameter type time) is needed. If this is an new parameter the
corresponding type must be configured via the parameter type
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In the logic the signal and the time parameter (Image 162 pre run time) are used in a
AND logic. The time parameter is checked against 0 (time not over).
Image 162: Logic Automatic Operator Request Reset
In the recipe the logic is used for the previously defined parameter. The logic itself is
not checked (yellow =). The parameter (e.g. Pre run time) is only forced. The operator
request is forced and checked. Via the logic the operator request is automatically
acknowledged if the signal is set.. The operator request does popup and disappears
after the configured time in case the signal is set. The operator request is not
automatically acknowledged in case the signal is set after the configured time. The
operator must acknowledge the operator request to move to the next step.
Image 163: Recipe Automatic Operator Request Reset
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To control the used logic a time parameter is used. This time parameter controls at
step start the time during the operator request can be acknowledged automatically via
setting the signal. After the time is over the operator request must be acknowledged by
the operator. The parameter must be at least 3 seconds.
Image 164: Set point Automatic Operator Request Reset
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15.14.2 Operator request OR Signal as move net step condition
Move to the next step can be released by a signal (e.g. empty sensor signal) or(!) by
an operator request.
The step enabling condition is based on operator request OR a signal. The net step is
enabled either the operator acknowledges or the signal is set.
15.14.2.1 AS Configuration
In the unit sequence CFC chart one control matrix command (CMD, partition A, page
4) is connected to the feedback (FB_CM, partition A, page 1). This control matrix item
(see CMD_28 and FB_28 in Image 165: Connection for operator request or signal)
This connection is used to move to the next step.
Image 165: Connection for operator request or signal
15.14.2.2 OS Configuration
In the Excel Addin sheet 2 02TextLib_unit.xls a new logic must be defined.
15.14.2.3 Recipe Configuration
To make a operator request OR a signal an enabling condition a OR-logic is used. In
this logic the operator request and the signal (e.g. feedback motor) are used in one
OR.
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Image 166: Logic for operator request or signal
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In the recipe the logic is used for the previously defined signal (see chapter 0). The
operator request has to be forced only.
Image 167: Recipe for operator request or signal
15.15 Encode / Decode for CM_Info
15.15.1 Encode CM_INFO
The block BRT_CM_E (FB1074) is available for the use of the BRAUMAT technology
objects without unit- and matrix reference. The standard inputs can be set with it.
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Image 168: Engine outside a unit
Hence, for example an engine or valve of an utility can be used. Thereby it is possible
to set an engine at the start of the SPS in automatic.
15.15.2 Decode CM_INFO
In order to use standard blocks of other libraries in the system, the structure CM_INFO
can be fragmented in its single elements with the block BRT_CM_D (FB_1072).
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15.16 Free Batch Name
The system generates automatically a batch name e.g. 2010 25 0100004 on the one
hand by the week planer on the other hand by the FB BRC_UMGN „Unit Manager“.
Image 169: Free Batch Name
Additionally it is possible to parameterize a free batch name of the unit. If a free name
is selected, it is marked yellow during the unit allocation.
A checkup of the batch name does not occur, especially not concerning the
uniqueness. The Batch name is an attribute of the batch which uniqueness is carried
out via the Batch ID.
15.17 Locking of Step Change
A step relay can be locked step-relatedly in a running recipe via the recipe
paramterizing. This lock is valid for the manual relaying as well as for the direct step
jump via the input L_FCT_SET at BR_PHC96 – function block.
15.17.1 AS - Configuration
The input LOC_STON at the block PL (PL, Partition F, page 2) is connected with the
output CMD_03 of the command block CMD (CMD, Partition A, page 4) in the unit CFC
plan.
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Image 170: CFC for Locking the Step Change
15.17.2 OS – Konfiguration
The CM03 is ‘ac’ parameterized as SWS locked in the Excel – Addin
‚02_Textlib_Unit.xls’.
Image 171: Text Parametrizing of Step Change Lock
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15.17.3 Recipe Configuration
A lock for the manual relay in the step view of PHCON Matrix can only be projected via
the CM03 (SWS locked).
This CM can only be projected as ‘force’.
Image 172: Recipe with Step Change Lock
15.17.4 Runtime Events
In the corresponding step the two buttons for the relay in the following step and for the
switch in the single step operation are locked in the online view of the running recipe.
If the single operation is active and it is being changed in a step, in which SWS locked
is projected, the single step operation is left automatically.
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Image 173: Online Recipe with Active Step Change Lock
If a direct jump in an user-defined projected step was tried via the right mouse button
despite an active step change lock, this is denied with the following message:
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Image 174: Error Message at Tried Jump Despite Active Lock
If the step change lock is active and a jump is requested via the input L_FCT_SET, the
following message is set:
Image 175: Error Message at Jump via L_FCT_SET Despite Active Lock
The requested jump will not be carried out.
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15.18 Change of the Set value at Running Recipe
The set values of a step, which is executed later or sooner (jump) can be changed at a
running batch. These set values are only valid for the recipe runtime, as the set value
change is not read back in the recipe data management (UserArchive). If the unit is
restarted, the set values are reread newly from the UserArchive.
Via the button in the parameter faceplate of the online recipe it can be switched from
the view of the set value of the current step in the view of the set value of an user-
defined selected step.
Image 176: Button for View Switch of Set Values
Via the two arrow buttons the step number, which should be displayed, can be
maximised or minimised in the set value view of an user-defined selected step. Hereby
it is only possible to navigate though the steps of the current running recipe.
Image 177: Selection of an User-defined Step of the Current Running Recipe
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If the step is selected, which is currently active, it is signalled by the red colouring of
the step text. If the set value is being changed in this step at this point, it has no impact
on the current running step. This alteration is only active, if this step is rerun in the
running recipe.
Image 178: Warning at the Selection of the Current Running Step
15.19 Set Value Adoption in the Runtime
A set value of the current running step can be altered in the parameter faceplate of the
online recipe.
This new set value is adopted automatically in the following steps, if in these steps a ‘#’
is parameterized as set value in the recipe.
Example:
A set value of 20 seconds is parameterized for the Timer 1 in Step F1.
Image 179: Set Value Parameterizing I
In the follwing steps F2 until F9 ‘#’ is always parameterized as the set value for Timer
1.
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Image 180: Set Value Parametrizing II
If the recipe is started, all set values are loaded from the UserArchive.
In step 1 only the set value of 20 seconds is used for Timer 1.
Image 181: Set Value Entry at Running Recipe_I
If only the set value of Timer 1 is altered e.g. to 33 seconds in step 1, this new set
value is used at first in this step.
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Image 182: Set Value Entry at Running Recipe_II
This set value remains also in the following steps, as here in the recipe a ‘#’ was
parameterized.
Image 183: Set Value Entry at Running Recipe_III
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If this parameter is used again in the following recipe, the last altered set value is used
as well.
Image 184: Set Value Entry at Running Recipe_IV
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15.20 Batch data export and supervision of the batch
archive
The export of the batch data archives („ARCH_XX“ und „ARCH_2XX“) (XX – stands for
a runtime variable from 1-99) is very important because there is a maximum of records
displayable for the User Archives. For this reason the records must kept under this
border.
The border of display for a User Archive counts 320.000 fields, which is the product of
lines and columns. Therefore “ARCH_XX” has a maximum of 300 and “ARCH_2XX” a
maximum of 3000 records.
From a faceplate it is possible to configure the exports. Included are the export path,
the border entry and the activation of the different export possibilities. There are 3
different functions for a export: a periodic monitoring of the maximum and minimum
borders, a function to export all existing archives over a button or at a certain date and
another function to export all records which are older than a date.
15.20.1 Functionality
The User make the choice if the batch data will be exported in a faceplate and also
how the data will be exported. The configuration will be written at the block “BREXDAT”
in plan “SYSTEM”. The block sets at configured time a trigger. Thereby a action
(“Export.pas” or “ExpAll.pas”) will be triggered which does the export.
The block reports at successful export, incorrect export or if no export was done
because of no data in archive.
15.20.2 AS-Configuration
For the export two blocks needed, one block which delivers the actual time and another
which sets trigger. The blocks can be found in the BRAUMAT compact library under
the names “BRWP_CLK” and “BREXDAT”. The blocks should be put in plan
“SYSTEM” under the sheet “A5”. As following displayed the bocks have to connected.
The function block “BREXDAT” must be named ‘DataExport’ in CFC.
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Image 185: Connecting the DataExport function block.
Source Destination
Chart Block I/O name Chart Block I/O name
SYSTEM (A5) BRWP_CLK DAY SYSTEM (A5) BREXDAT ActDAY
SYSTEM (A5) BRWP_CLK MONTH SYSTEM (A5) BREXDAT ActMONTH
SYSTEM (A5) BRWP_CLK YEAR SYSTEM (A5) BREXDAT ActYEAR
SYSTEM (A5) BRWP_CLK HOUR SYSTEM (A5) BREXDAT ActHOUR
SYSTEM (A5) BRWP_CLK MINUTE SYSTEM (A5) BREXDAT ActMINUTE
SYSTEM (A5) BRWP_CLK SEC SYSTEM (A5) BREXDAT ActSEC
15.20.3 OS-Configuration
About the User Object "BRT_EXPDAT" you can go to the faceplate. The object is
stored in the "@ BRC_Typicals.pld".
It will display two values, the cycle time and the date of export. Both are set in the
faceplate and are displayed in the user object. A hook for the values indicates whether
the corresponding option is active.
Image 186: Block icon of the DataExport block
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The faceplate will open with the "standard" image. In this picture, three major options
are adjustable.
The "change" button is used to set the export path for all batch exports archive.
The threshold test and the limits of record are as follows: a check mark is set at the
limit test, so after a cycle two batch archives ("ARCH_XX" and "ARCH_2XX") sought
and tested for the limits. The time behind the hook here determined the interval of the
threshold test.
The limits are entered at “borders for records". The upper limit determines at how many
entries the batch archive will be exported. The lower limit determines how much data in
batch Archives remain available. This is sorted according to time and always exports
the oldest batch data.
If the lower limit set to 0, the archive will completely emptied.
If the upper limit set to 0, the archive will always emptied when it is found.
Image 187: Faceplate ‘Stamdard
By default, the cycle time is 10 minutes and the boundaries for the archives
"ARCH_XX" at 220 LL and 300 UL and for the archives "ARCH_2XX" at 800 LL and
1000 UL. The default export path is "C:\TEMP". This means every 10 minutes looking
for archives, e.g. ARCH_1 and the accompanying ARCH_201. If both archives were
found, both will be checked whether there are more than 330 or 1000 entries. If the
limit is exceeded, the archive entries reduced to 220 or 800 and the data stored in the
export path as a csv file. If the limit is not exceeded, the archive will remain intact. In 10
minutes looking for the next archives.
For example ARCH_2 does not exist, the function search until an archive is found. The
control variable is increased so often until the name of an archive is found, or none of
the 99
th
possible Archives is found. If only ARCH_1 exists, so this archive checked
every 10 minutes. If there are two archives, so after the example, each checked all 20
minutes.
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15.20.4 OS – Further functions
The drop down box leads to 3 additional images, "Job1", "Job2" and "messages".
Image 188: The drop down box for the picture choice
In the "Job1" of faceplates are two further possibilities for an archive export.
About the "Start" button it is possible to immediately export all batch archives
completely and empty them. If you press the button, a prompt appears with the options
"OK" or "Cancel" in which the user is asked again whether he really wants to start the
export.
The second possibility is also to export archives all batch completely, however, to set
specific day and time. In the calendar can be selected the day and in the two fields, the
time in 24-hour time format. If the hook "Export all batch archives on" is checked the
entire export starts on date and time set up.
The calendar looks when opened on the current day when the hook "Export all
archives in the batch" is not set. If checked then the calendar is set on the day and into
the input fields, the set time is entered.
Image 189: Picture “Job1” : Both export possibilities, on the right is the prompt
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In the "Job2" there is a feature of all the entries that are older than a date to be
exported from the archive and then deleted.
The calendar is also set to the current day at the opening of the image. About the
"Start" button all entries will be exported that are older than the set day in the calendar.
Before the export starts a prompt appears with the options "OK" and "Cancel" on which
the user must confirm once again whether he would really start to export.
Image 190: Picture “Job2” The export function “older than”, on the right is the prompt
The image "messages" consisting of a message display for the export block
(BREXDAT). Here, the messages can be viewed and extinguished.
The following messages are possible:
Auto-Export: ARCH_XX/2XX successful
Total exports: successful
Aged data export: successful
Auto-Export: ARCH_XX/2XX failed
Total exports: failed
Aged data export: failed
Export triggered - No data available
If there exist a problem and looking up the debug information does not help, please
check if the export path exists.
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15.21 Export und import of recipes
Within BRAUMAT compact a recipe is divided up in single control sequences for every
unit belonging to the same recipe type. It is possible to ‘copy’ a single recipe and the
system automatically copies the data of each unit and saves it in a file.
15.21.1 Functionality
The operator can export a recipe that is selected in a faceplate. All required data of the
specific units will be exported and saved in csv – format. Additionally a configuration
file with the extension ‘.brc’ will be generated.
This information can be imported on every recipe of the same recipe type.
15.21.2 AS-configuration
The function block BRC_ACTR (FB 1130) must be inserted in the CFC – chart
‘SYSTEM’. The instance name must be ACTIVE_RECIPES.
This function block checks if a recipe that needs to be imported is actually running in
the PLC and locks the start of all involved units during the import is running.
The output QACT_REC of the function block SB_IF in the unit chart needs to be
connected to the input ACT_RECXX of the function block ACTIVE_RECIPES.
The output QBA_ENXX of the function block ACTIVE_RECIPES needs to be
connected to the input BA_EN of the SB_IF function block.
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Image 191: Connection in CFC
15.21.3 OS- Configuration
If several PLC’s are used within the project it is necessary to configure on SYSTEM -
CFC – Chart for each PLC.
The import / export is designed to manage up to 10 PLC’s. The CFC – chart name
must be entered at the Button ‘BTN_REC_NAMES’ in the engineering picture. The
total number of SYSTEM charts must be entered at the attribute ‘Count_SNC’.
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Image 192: Configuration: Button BTN_REC_NAMES
Image 193: Recipe names
In order to export a recipe the operator has to select recipe type and a recipe in the
faceplate shown above.
By using the button the dialog to select a folder for the export opens.
Hint:
If the export / import is triggered on an OS_client the path must be entered in UNC –
format.
UNC-path example: \\server\RecipeStorage\
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During an export the following files will be generated:
Filename Content
<Filename>_PHCON_CS2.csv total User Archive PHCON_CS2
< Filename >_ARCH_1<Unit><RecTyp>.csv A single file for each unit file for each unit. This file
contains the reference values from the user archive
ARCH_1<Unit><RecType> for the exported recipe.
< Filename >_LTArch.csv Values of the lauter curve for the exported recipe
< Filename >.brc Text file; contains the path information for all the other
files
The files can be moved together to a different folder before an import is started.
The files must never be renamed.
After the selection of a recipe type and a recipe name the import can be triggered via
the Button . A Windows – dialog will open in order to select a ‘.brc’ – file.
During the import process the imported data will be written to the user archives and the
PLC as well. In order to trigger a recipe import no other import must be active and the
recipe to be overwritten must not be running on any unit.
During the import process the start of all units of the ‘imported’ recipe type is locked.
After an successful import the name of the imported recipe will be written to the
faceplate ‘recipe names’ and the textlibrary.
Possible fault messages:
Error Error message
Common error Error during import of recipe!
The imported recipe does not match the
selected recipe type Error during import of recipe!
The recipe to be overwritten is active in a unit.
Import not possible . Recipe number actually used!
The import is already active on a another OS. Import not possible . Import already active
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16 Plant - distribution on various controllers
According to the structure of the plant it might be reasonable to use various controllers
and / or use various BRAUMAT compact systems.
In this chapter two common configurations will be described:
2 x Single Station with 2 x AS
1 x Single Station with 2 x AS
If more controllers are necessary they can be implemented according to this example.
16.1 System configuration 1
16.1.1 Structure of the project
2 x Single Station with 2 x AS
Image 194: System configuration 2x Single Station 2x AS
Single Station 1 Single Station 2
AS02AS01
Brewhouse Fermentation
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16.1.2 Multi project
It is reasonable to set up one PCS7 multi project with two controllers and two single
stations.
Image 195: Multi project architecture 2x Single Station 2x AS
It is for example possible to set up the complete Brewhouse (recipe type 1) on single
station 1 / AS01 and the complete fermentation (recipe type 2) on single station 2 /
AS02.
By splitting up the controllers in single projects it is possible to remove them temporary
for editing from the multi project. With the second single station parallel editing of the
project can be done (PSC7 standard).
2x Singlestation_MP
AS01_PRJ
AS02_PRJ
OS_PRJ
Single Station 1
Single Station 2
AS01
AS02
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16.2 System configuration 2
16.2.1 Structure of the project
1 x Single Station mit 2 x AS
Image 196: System configuration 1x Single Station 2x AS
Single Station
AS02AS01
Brewhouse Fermentation
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16.2.2 Multi project
It is reasonable to set up one PCS7 multi project with two controllers and one single
station.
Image 197: Multi project architecture 1x Single Station 2x AS
It is for example possible to set up the complete Brewhouse (recipe type 1) on AS01
and the complete fermentation (recipe type 2) on single AS02. Both controllers will be
mapped to one operator station (single station 1).
16.3 Equipment ID
16.3.1 System configuration 1
The equipment ID of a unit can be set from 1 to 99 for the system Single Station 1 /
AS01.
The equipment ID of a unit can be set from 1 to 99 for the system Single Station 2 /
AS02.
16.3.2 System configuration 2
The equipment ID of a unit can be set from 1 to 99 for the combined system Single
Station 1 / AS01 / AS02.
2x Singlestation_MP
AS01_PRJ
AS02_PRJ
OS_PRJ
Single Station 1
AS01
AS02
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16.4 Recipe type
16.4.1 System configuration 1
The recipe type can be set from 1 to 10 for the system Single Station 1 / AS01.
The recipe type can be set from 1 to 10 for the system Single Station 2 / AS02.
16.4.2 System configuration 2
The recipe type can be set from 1 to 10 for the combined system Station 1 / AS01 /
AS02.
16.5 CFC - Typical ‚SYSTEM’
The CFC typical ‘SYSTEM’ needs to be implemented in controller AS01 and controller
AS02. Although both charts are in different controllers the compilation of the OS will
result in an error.
Therefore the typicals need to be named distinct for the complete project. It is
reasonable to add a controller identifier extension to the name of the typical, e.g.
‚SYSTEM_AS01’ and ‚SYSTEM_AS02’.
Image 198: CFC Typical ‚SYSTEM’
Furthermore in every System- chart the number of the controller needs to be set at the
function block BRC_BAID.AS_NO.
With this setting a controller coding will be added to the generated Batch ID.
Image 199: AS - Number
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16.6 CFC - Typical ‚SCHEDULER’
If the Scheduler needs to be used in the Brewhouse and the Fermentation the typical
‘SCHEDULER’ must be implemented in AS01 and AS02. Although both charts are in
different controllers the compilation of the OS will result in an error.
Therefore the typicals need to be named distinct for the complete project. It is
reasonable to add a controller identifier extension to the name of the typical, e.g. ‚
SCHEDULER _AS01’ and ‚ SCHEDULER _AS02’.
Image 200: CFC – Typical ‚Scheduler’
The name of the CFC – chart must be set in the picture BRC_WOP.pdl in the OS –
project.
Image 201: Adjustment in OS - picture
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16.7 Scripting
The C – actions ‚M1ArchiveTrigger.pas’ and ‚M1RecipeTrigger.pas’ need to be
adapted. Both trigger actions must be set up for every SYSTEM – chart.
Image 202: Triggeractions
The name of the CFC – SYSTEM - chart is hard coded within the triggeraction. The
name need to be adapted.
In this example ‚SYSTEM_AS01’ bzw. ‚SYSTEM_AS02’.
Image 203: Adapt chart name in trigger action
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The trigger variables need to be adapted as well.
Image 204: Adapt the variable for M1ArchiveTrigger_AS01.pas
Image 205: Adapt the variable for M1RecipeTrigger _AS01.pas
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16.8 Unit - Start via U_A_NEXT / U_A_PREV
The connection U_A_NEXT to U_A_PREV between two units is a bidirectional
structure - connection.
Via this structure the batch – information is transmitted from the predecessor unit to the
successor unit. Furthermore in this structure contains bits to start the successor and to
synchronise the two unitis.
In order to transmit this structure from one controller to the other the function blocks
BRC_UNXS (FB 1121) and BRC_UNXR (FB 1122) have to be used.
With this function blocks and an additional connection in Netpro it is possible to send
and receive up to four U_A_NEXT – structures between two controllers.
Image 206: Transmission of the U_A_NEXT structure from AS01 to AS02
AS01
AS02
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16.9 Unit start via function block USTA
Using the function block USTA it is possible to start more than two successor units
from a source unit. The FB_USTA receives the batch information and a start
command. It converts this signals to the P_UNIT structure that is connected to various
units.
The connection P_UNIT between two units is a bidirectional structure - connection.
Via this structure the batch – information is transmitted from the predecessor unit to the
successor unit. Furthermore in this structure contains bits to start the successor and to
synchronise the two unitis.
In order to transmit this structure from one controller to the other the function blocks
BRC_PUXS (FB 1123) and BRC_PUXR (FB 1124) have to be used.
With this function blocks and an additional connection in Netpro it is possible to send
and receive up to two P_UNIT – structures between two controllers.
Image 207: Transmission of the P_UNIT structure from AS01 to AS02
16.10 Shared Equipment
In some cases it can happen that from several units the aggregates (e.g. valves) are
accessed. As the aggregates are basically assigned to only one unit and so are also
the signals (CM_INFO and AUTO_OC) connected with the corresponding blocks, a
MUX block (FB1105) is needed for a multiuse.
Via this structure the batch – information is transmitted from the unit to a control
module.
AS01
AS02
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In order to transmit this structure from one controller to the other the function blocks
BRC_CMXS (FB 1125) and BRC_CMXR (FB 1126) have to be used.
With this function blocks and an additional connection in Netpro it is possible to send
and receive up to 5 CM_INFO – structures between two controllers.
Image 208: Transmission of the P_UNIT structure from AS01 to AS02
AS01
AS02
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17 Redundant Server/Client-System
BRAUMAT compact supports the use of a client as well as of a redundant server from
version 2.1. The realization of such a system (optionally with or without redundancy) is
described in the following chapter, which contains the makeup of the network structure,
the engineering in the SIMATIC Manager, and the engineering steps in WinCC.
17.1 Network Structure
In order to avoid configuration errors at further realization it is recommended to sketch
the makeup of the network structure similar to the one below before the setup of the
(redundant) Server/Client-System, and to provide the corresponding network
parameters.
After the applied realization of this planning, the successful parameterization should be
tested (e.g. using PING command in the command row).
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17.2 Engineering in SIMATIC Manager
The following paragraph describes how the operating stations are set up in SIMATIC
Manager, how the network settings are parameterized and how other settings must be
carried out.
17.2.1 Hardware Configuration
File new multi projects or open an existing one (e.g. BRAUMAT compact demo
project). Insert a new SIMATIC PC station and name after the computer name of the
master server (e.g. BRCSERV1).
Start HW-Configuration and set up as follows (proposal):
At the configuration of the network card it can be chosen between the interface via
TCP/IP or via MAC addresses.
1. Interface on ISO Level 3 (TCP/IP level):
The IP address listed in the network configuration and the sub net template
must be entered in the property prompt of the network card.
Note: Please activate the following option in SIMATIC Manager: option menu -
> install PG/PC interface -> select „TCP/IP (Auto)“
2. Interface on ISO Level 2 (MAC address):
The MAC address listed in the network configuration must be stated in the
property prompt of the network card.
Save, compile, and subsequently download HW-Configuration.
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Repeat the steps above for the standby server, however, file a „WinCC Application
(stby)“ on Pos. 1 in the HW-Configuration.
Open HW-Configuration of the Client and file a new „WinCC Application Client“ on Pos.
1 resp. replace an existing „WinCC Application“.
: The computers might need to be restarted in order to enable the alterations in the
HW-Configuration. Please open the station manager (double click the symbol in the
system tray) of the servers and look in the register „Diagnose“, if a request to restart is
pending.
17.2.2 Install Netpro
Start Netpro and set up an own S7 connection to AS for each PC. Save, compile
everything and download all stations. Open the CFC-Plan „System“ and check or if
necessary adjust the following connections on block „FB_RECM“ in plan A, paragraph
1:
1. ID_1 = Enter Partner-ID of Server 1 to AS (s. Netpro)
2. ID_2 = Enter Partner-ID of Server 2 to AS (s. Netpro)
3. R_ID_1 = Enter R_ID of RECM_DATA for Server 1
4. R_ID_2 = Enter R_ID of RECM_DATA for Server 2
Proceed the same way with the block “FB_ARCHM” (plan A, paragraph 2):
1. ID_1 = Enter Partner-ID of Server 1 to AS (s. Netpro)
2. ID_2 = Enter Partner-ID of Server 2 to AS (s. Netpro)
3. R_ID_1 = Enter R_ID of ARCHM_DATA for Server 1
4. R_ID_2 = Enter R_ID of ARCHM_DATA for Server 2
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17.2.3 Other Configuration
Generate server data (Master-Server right mouse click) and assign a server for the
client as well as all TH files to their respective AS or OS.
The OS names can be altered as wished (e.g. from OS(stby)(nr) to Server_Stby). The
configuration should look approximately like that:
Open any CFC plan. Close all textual connections (Options Close Textual
Connections). Subsequently compile completely and download completely.
Install OS-Path and define Master/Standby-Server (RMB on OS Object properties).
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Start BRAUMAT compact project upgrade on the ES (!) and upgrade the entire WinCC
project files, as these data would be overwritten at a reload of the operating stations.
The exact approach is explained migration notes.
Compile the Master-Server.
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17.3 Engineering in WinCC
The subsequent paragraph describes how the single operating stations (Master-
Server, Standby-Server, Client) must be set up.
17.3.1 Install Master-Server
Open WinCC-Explorer of the server on the ES. Install Server-Startup (install
Taggen.exe etc according to Engineering guide. Warning: State path on the server!).
Subsequently open the C-Script Editor and execute the function „regenerate Header“.
Open the BRAUMAT compact Tag Generator via the icon in the WinCC – Explorer and
generate all required raw data tags.
Open the BRAUMAT compact Table Generator via the icon in the WinCC – Explorer.
Through right mouse click, is opening following selection.
Image 209: Start Table Generator
Generate all user archives (UA).
Change to the view Excel – Addin and open the excelsheet ‘01_TextLib_General.xls’.
Generate all text entries in the text library (takes about 10 min.).
Now project specific configurations can be carried out via the Excel sheets in the tab
‘Text Library Unit’.
End the RT and carry out the redundancy set ups in the WinCC explorer. Activate the
comparison for all previously generated user archives!
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IMPORTANT:
Start C-Script editor and open the global action BRC_RedundancyCheck.pas. In there
set the parameter bRedundancyEnabled=TRUE. Thereby the cyclic redundancy data
comparison is activated.
Download the project to the server in the SIMATIC Manager and start the RT on the
sever.
Select the process image „System“, push the button „table Generator“ and preallocate
all already generated tables in the user archive (UA) with data sets.
17.3.2 Install Standby-Server
Download the Standby Server in the SIMATIC Manager of ES.
: Short after the RT started (ca. 1-2 Min. later), the text library of the standby server
synchronizes with the master server. This happens in the background and is not visible
for the user.
The activated BRAUMAT compact redundancy monitoring in APIDAG is signalized by
‚|’ (cyclic execution every 10 seconds (Standard)). Depending on the cycle time and the
runtime of the store script, a delay arises until the user data are in the Standby-Server.
17.3.3 Install Client
Start BRAUMAT compact project upgrade on ES (!) and upgrade the Client-Project.
Switch to Client and open the WinCC-Explorer. Subsequently open the C-Script Editor
and regenerate Header. Start RT.
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Note: All data, changed on a client are always saved to the Master Server and saved to
the Standby Server at activated redundancy monitoring. There is no own data
management on a Client!
The activated BRAUMAT compact Client-Data Monitoring in APIDAG is signalized by ‚-
` (cyclic execution every 10 seconds (Standard)). Depending on the cycle time and the
run time of the store script, a delay arises until the user data are in the Master Server.
It is important that a preference server is configured for all components of the server
data.
For this open the Client OS Project on ES. In WinCC Explorer right mouse button on
server data. Select Configuration in the subsequent menu … .
Image 210: Standard server for server data
17.3.4 Use of „make“
In order to compile and download several operating stations resp. automation systems,
it is recommend to use Make. All compiling and downloading procedures are executed
consecutively in a batch process and then shown in an overview protocol, in which
possible warnings during the single procedures are pointed out.
Request: Mark multi project -> automation system -> compile and download objects
Note: The options selected last (e.g. Delta-/Entire(!)loading) are used at the compiling
and downloading of single systems.
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Subsequently the WinCC runtime environments of the operating stations can be
started (recommended sequence: Master server, Standby server, Client).
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18 Redundant Single Station
18.1 Minimal Configurations – An Oververiew
Please refer to the document „[2] Minimal Configurations PCS 7 V7.1
“.
Based upon using the Engineering Station as an Operator Station in process mode, or
realizing several OS with as few PCs as possible, various constellations are possible.
The following variants were selected according to feasibility and sensibility within the
context of PCS 7.
In connection with the configurations shown here, possible solutions are described,
where the configurations do not differ considerably.
Generally, when using the engineering computer as OS, certain functionality losses
must be taken into account, as for certain activities the OS project must be closed. This
will also be discussed below in more detail.
18.2 ES/OS-Master und OS-Standby (Single Station
Redundancy)
Note:
The described configuration is only functional in PCS7 V71 SP2 and SP3 with WinCC
V7.0 SP2 HF5 or higher.
18.2.1 Configuration Description
As a constellation option with two PC stations, the ES is used as OS stand-alone
station again, similar to the first variant, with only one PC.
However, it uses the same OS project, which was previously loaded to a further OS
stand-alone station. Before the OS project is activated on both stations, the mutual
redundancy parameterization is performed.
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Image 211: Hardware setup ‘redundant Single Station’
Abbildung 212: PCS7 Projektierung ‚redundante Single Station’
18.2.2 Paticularities / restrictions
Due to the nontypical PCS 7 configuration with only one OS there are differences in the
system behaviour which must be considered:
The first activated OS takes on the master role.
For the complete download, Runtime must be deactivated for both computers,
and the WinCC Explorer must be closed. During this time, neither operator
actions nor archiving is possible.
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For a delta-download, Runtime on the ES must be closed again for compiling
the OS. It can then be re-activated for testing the modified OS the downloading,
Runtime must be terminated and the WinCC project must be closed.
o As a result to this no operator actions can take place at the ES computer
at that time
A client can only be connected to one Single Station. Redundancy is not noticed
on the client.
NOTICE:
If Runtime remains active on the ES during the OS compilation, it might happen -
depending on the changes made - that a subsequent delta download is carried out
incompletely and results in errors. Afterwards, only a complete download will be
possible.
Runtime being active on the ES computer results in the runtime archive being
stored under the multiproject path. Therefore, they are also included into the ZIP
file during archiving and cause increased storage space as well as archiving
times.
Workaround:
o Deactivate Runtime on the ES computer.
o Reset archive in the OS project on the ES computer and close the entire
PCS 7 project.
After archiving and reactivating Runtime, the archives are updated again.
Please note that more time will be needed for checking.
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19 Restart After CPU–Stop
At a power failure of the CPU with a following restart the recipes start at the same
point, where the recipe was before the CPU – Stop.
19.1 AS - Configuration
For each unit it is possible to switch to ‚Hold’ or ‘Run’ at a unit restart. This is carried
out once at the function block BR_PHC96 of the corresponding unit in the CFC.
Image 213: Input for Unit Start Behavior
19.2 Functioning
The selecting OB is determined in the blocks BR_PHC96, BRC_UMGN, BR_PHCJP,
BRC_REC, BRC_BA_H, BRC_BA_S, BRC_REAL and BR_PHCXF via RD_SINFO. At
a CPU start OB100 is always run through.
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The blocks BR_PHC96, BRC_UMGN, BR_PHCJP, BRC_REC, BRC_BA_H,
BRC_BA_S, BRC_REAL and BR_PHCXF have a so called ‘full download signal’.
Herewith it is determined automatically, if an entire download was carried out before
the restart or not.
If the OB 100 flow is recognized and the full download signal is not set, an intializing
routine will not be run though. The batch data will remain.
If the full download signal is set, the intializing routine is carried out and all batch data
will be reset.
The blocks BR_PHC96, BRC_UMGN, BR_PHCJP, BRC_REC, BRC_BA_H,
BRC_BA_S, BRC_REAL and BR_PHCXF can run systematically through the
initializing routine in case of need. Hereby a positive edge is necessary at the input
INIT.
Image 214: Input for Targeted Block Initialization
Web BRAUMAT compact
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20 Web
The Web Navigator package consists of special WinCC Web Navigator Server
components that are installed on the server computer, and of WinCC Web Navigator
Client components that run on the Internet computer.
The pictures displayed on the WinCC Web Navigator Client can be controlled just like
in a normal WinCC system. In this way, the project running on the server computer can
be controlled from anywhere in the world.
In order to set up the Web Server / Web Client, please refer to the PCS7 standard
documentation:
- WinCC / Web Navigator Documentation
- WinCC / Web Navigator Getting Started
- Web Navigator Information System
- WinCC / Web Navigator Installation Notes
- WinCC / Web Navigator Release Notes
20.1 Braumat compact Web Components
Due to the various plant configurations the Web Navigator Package will not be
preinstalled on a BRAUMAT compact Bundle.
Please install this PCS7 component on the computer you want to use as a Web
Server.
After the Web Navigation is installed the BRAUMAT compact Web Components can be
installed.
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Image 215: Setup Web components
Please set up the Web Server / Web Client as described in the above listed PCS7
standard documentation.
20.2 Restricted functionality of BRAUMAT compact on Web
Clients
The functionality of BRAUMAT compact is restricted on a Web Client.
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The functions listed below are not available on a Web Client:
20.2.1 Editor Recipe names
Save Recipe names
Load Recipe names
Export Recipes
Import Recipes
Edit Recipe names
Image 216: Editor Recipenames
20.2.2 Batchreport
Generate Batch reports with the parameter
definition
Generate Batch reports batch data
Image 217: Batchreport
20.2.3 Save Data: Export / Import UserArchive data
Export UserArchive data
Import UserArchive data
Path selection for Import / Export
Image 218: Export / Import
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20.2.4 Manage Batchdata
Path selection for Import / Export of
Batch data
Image 219: Manage Batch Archives
Further Information in dealing with BRAUMAT compact BRAUMAT compact
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21 Further Information in dealing with BRAUMAT
compact
21.1 Consequences of the over-all Translation
The DB blocks are newly organized by an over-all compilation of the CFC plans. After
that an OS translation is necessary. Before the OS Runtime can be restarted, the row
data variables, generated via the tag generator, must be deleted. Therefore the entire
variable group can be deleted in the WinCC Explorer under Named Connetion
BRAUMAT_PHC96.
21.2 Packed ET200S Addresses
The packing of ET200S digital addresses in HW-Configuration is not allowed.
With using ET200S digital modules the HW config allows the packing of addresses.
This is not recommended in a PCS 7 environment. Packing the addresses loses the
diagnose functionality of ET200S and leads to problems when creating driver function
blocks.
21.3 Recommendation Time Synchronisation
Basically the mechanism for the time synchronization, which are available in the PCS
7, can be used. For this especially the manual „[1] PCS 7 Time Synchronisation“ is to
be considered.
The PLC must basically be operated in the UTC.
For BRAUMAT PCS 7 compact the time synchronisation is used in a work group
without central time master as standard.
Therefore, in order to configure traditionally, the chapter [1] 4.8 is to be used for the
PCS 7 Box, the chapter [1] 4.4 for the OS, and [1] 4.5 for the AS.
Remark:
When using PCs with several network cards build in and adjusting the ISO – protocol
an ‘echo – effect’ of the time master signal might happen. The fault message ‘another
time master on the bus detected’ might appear. In this case the networks need to be
clearly separated.
21.4 Use of the ISO Protocol
The ISO protocol may only be used in the BRAUMAT compact environment with
Named Connections. The use of ISO protocols without Named Connection is not valid.
BRAUMATcompact Further Information in dealing with BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 220
21.5 Scheduler
When creating a new BRAUMAT compact project the scheduler pictures might not be
displayed correctly in WinCC runtime.
In this case it is necessary to open the following pictures in the Graphics Designer and
save the again. During this process the used VB scripts are linked again and the
scheduler pictures will be working correctly:
BR_WOP
@BR_WP_EDIT_WP
@BR_WP_EDIT_CH
@BR_WP_EDIT_IN
@BR_WP_EDIT_NO
@BR_WP_EDIT_PA
@BR_WP_EDIT_TI
Document Cross Reference BRAUMAT compact
Engineering Manual, 06/2010, A5E02608507B-02 Page 221
22 Document Cross Reference
The manual refers to the following documents
No.
Title
Order No.:
[1]
SIMATIC Process control system PCS 7
PCS 7 Time Synchronisation Function
Manual
01 / 2008
A5E01216577
-
01
[2]
Minimal Configurations PCS 7 V7.1
http://support.automation.
siemens.com/WW/view/de/24023824
[3]
SIMATIC HMI
WinCC / Web Navigator Getting Started
11/2008
[4]
SIMATIC HMI
WinCC / Web Navigator Installation Notes
11/2008
[5]
SIMATIC HMI
WinCC / Web Navigator Documentation
11/2008
[6]
SIMATIC HMI
WinCC / Web Navigator Release Notes
11/2008
[7]
Web Navigator Information System
11/2008