BRAUMAT compact V3.0 SP1 · 2015. 3. 16. · 15.6.1 (BRC_SPT: BRAUMAT compact setpoint trend ) – Line Archive 140 15.6.2 (BRC_SPTX: BRAUMAT compact set point trend ) – Trend Archive

BRAUMAT compact V3.0 SP1

Engineering Manual

09/2012 A5E02608507B-02

GeneralGeneralGeneralGeneral 1111 InstallationInstallationInstallationInstallation 2222 DemoDemoDemoDemo ProjectProjectProjectProject 3333 SystemSystemSystemSystem OvervOvervOvervOverviewiewiewiew 4444 CreateCreateCreateCreate NewNewNewNew ProjectProjectProjectProject 5555 ExcelExcelExcelExcel AddinAddinAddinAddin 6666 TrendingTrendingTrendingTrending 7777 RecipeRecipeRecipeRecipe ConfigurationConfigurationConfigurationConfiguration 8888 SchedulerSchedulerSchedulerScheduler 9999 BatchBatchBatchBatch DataDataDataData ExportExportExportExport aaaandndndnd ReportReportReportReport 10101010 TechnologiTechnologiTechnologiTechnologicalcalcalcal HierarchHierarchHierarchHierarchyyyy 11111111 ConnectionConnectionConnectionConnection ofofofof CFCCFCCFCCFC PlPlPlPlansansansans 12121212 ControlControlControlControl ModulesModulesModulesModules 13131313 UserUserUserUser ArchivesArchivesArchivesArchives 14141414 ExpandedExpandedExpandedExpanded FunctionalitiesFunctionalitiesFunctionalitiesFunctionalities 15151515 PlantPlantPlantPlant ---- distributiondistributiondistributiondistribution onononon variousvariousvariousvarious ccccontrollersontrollersontrollersontrollers 16161616 RedundantRedundantRedundantRedundant Server/ClientServer/ClientServer/ClientServer/Client----SystemSystemSystemSystem 17171717 RedundantRedundantRedundantRedundant SingleSingleSingleSingle StationStationStationStation 18181818 RestartRestartRestartRestart AfterAfterAfterAfter CPUCPUCPUCPU–––– StopStopStopStop 19191919 WebWebWebWeb 20202020 FurtherFurtherFurtherFurther InformationInformationInformationInformation inininin dealingdealingdealingdealing withwithwithwith BRAUMATBRAUMATBRAUMATBRAUMAT compactcompactcompactcompact

21212121

DoDoDoDocumentcumentcumentcument CrossCrossCrossCross ReferenceReferenceReferenceReference 22222222

Engineering Manual, 06/2010, A5E02608507B-02 Page 2

Safety guidelinesSafety guidelinesSafety guidelinesSafety 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.

DangerDangerDangerDanger indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken.

WarningWarningWarningWarning

indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken.

CautionCautionCautionCaution

indicates that minor personal injury or property damage can result if proper precautions are not taken.

AttentionAttentionAttentionAttention draws your attention to particularly important information on the product, handling the product, or to a particular part of the documentation.

Qualified personnelQualified personnelQualified personnelQualified 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 usageCorrect usageCorrect usageCorrect usage Note the following:

WarningWarningWarningWarning 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.

BrandsBrandsBrandsBrands 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 liabilityDisclaimer of liabilityDisclaimer of liabilityDisclaimer 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


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 Librar y 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


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



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



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



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



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



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


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


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.



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.



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



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



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.



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



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


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


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 Li brary 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


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


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


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


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.



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>.



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.



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.



4.2.1.2 Manual/Automatic Response (FB_AUTO , FB_AUT OY , 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.



4.2.1.3 Interlock Response (FB_LOCK , FB_LOCKY , FB c_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.



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.



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).



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.



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 1st recipe, the 2nd step sequence to the 2nd 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).



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.



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.



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



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 5555 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.



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 ��5555 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.



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

Create New Project BRAUMAT compact


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.

BRAUMATcompact Create New Project


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.



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.



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



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.



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“)



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



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\.

� �



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.



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



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”



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.



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.



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.



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“.



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



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.



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.



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



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)


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



In the panel Parameter Names all texts are entered that appear later in the recipe parameter dialogue.

Image 42: Configuration of Parameter Texts


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.



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.

Image 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.



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.

Image 45: Configuration operator request



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.



� 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



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).



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.



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.



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.



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.



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

BRAUMATcompact Excel Addin


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.

Excel Addin BRAUMAT compact


6.1.3 General Settings in order to work with the Wo rkbooks

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



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“



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



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“



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



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



6.1.7 Workbook - 01_TextLib_RecName_for_Rectype1.xl s 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



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“



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.



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“



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“



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“



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“



WinCC Command =

0 Command =

1

1 1

1 1 1

1

1 1

1

1 1

1 1 1

_____________

_____________

1 1 1 1



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“



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 “



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?

BRAUMATcompact Trending


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


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


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


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


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


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


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


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


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


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


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


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


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


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


SYSTEM\RECM.REQxxx_ST xxx � next free input on the connecting block

001 for first unit


SYSTEM\RECM.REC_ST

SYSTEM\BA_ID.REQxx_ST xxx � next free input on the connecting block

001 for first unit


SCHEDULER\BR_WP_CW.CW

SYSTEM\BA_ID.BAID_ST

SYSTEM\ARCHM.QARCH_ST

SYSTEM\ARCHM.QARCH_ST

BRAUMATcompact Connection of CFC Plans


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“.



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



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



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.



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.



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.



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


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


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


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 Outp uts

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 Clo sed / 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


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


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


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


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


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


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


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.

Expanded Functionalities BRAUMAT compact


15 Expanded Functionalities

15.1 Shared Use of Aggregates / Units

15.1.1 Aggregates : BRC_MUX (CM multiplexer FB110 5) 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.

BRAUMATcompact Expanded Functionalities


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.



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.



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.



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.),



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.



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



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.



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



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.



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.



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.



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.



Image 119: Recipe with synchronization via set points

The parameter is occupied as follows:

Unit ML – Step (1) Value is 0



Unit MC – Step (1) Value is 0





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.



15.4 Standardisation concept in BRAUMAT compact

15.4.1 Overview

• The standardisation is carried out once with the ad aption of the parameters from the OS. All parameter alterations t hat are carried out later by the user via the OS dialogue at running recipe w ill 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 sch eduler 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.



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.



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.



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.



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 Standardis ation 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.



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

Unite.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.



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).



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.



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



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



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



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.



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.



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.



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.



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.



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



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.



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.



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



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.



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



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.



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.



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“.



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.



Image 149: Adjustment of M1ArchiveTrigger_01.pas

Image 150: Adjustment of M1RecipeTrigger_01.pas



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



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.



Image 152: Jump Table



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.



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



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



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.



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.



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


In the PHCON_NAME a new logic has to be defined and if required a new parameter is entered.


A parameter (parameter type time) is needed. If this is an new parameter the corresponding type must be configured via the parameter type



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



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



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


In the Excel Addin sheet 2 02TextLib_unit.xls a new logic must be defined.


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.



Image 166: Logic for operator request or signal



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.



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).



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.



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



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.



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:



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.



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



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.



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.



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



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



15.20 Batch data export and supervision of the batc h 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.



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



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 99th 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.



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



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.



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.



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’.



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\



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

BRAUMATcompact Plant - distribution on various controllers


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

Plant - distribution on various controllers BRAUMA T compact


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



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



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



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



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



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



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



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



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



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

Redundant Server/Client-System BRAUMAT compact


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).

BRAUMATcompact Redundant Server/Client-System


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.



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)


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):



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



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).



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.



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!



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.



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.



Subsequently the WinCC runtime environments of the operating stations can be started (recommended sequence: Master server, Standby server, Client).

BRAUMATcompact Redundant Single Station


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.

Redundant Single Station BRAUMAT compact


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.

BRAUMATcompact Redundant Single Station


� 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.

Restart After CPU–Stop BRAUMAT compact


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.

BRAUMATcompact Restart After CPU–Stop


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


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.

BRAUMATcompact Web


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.

Web BRAUMAT compact


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

BRAUMATcompact Web


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


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


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


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

Documents

BRAUMAT compact V3.0 SP1 · 2015. 3. 16. · 15.6.1 (BRC_SPT: BRAUMAT compact setpoint trend ) – Line Archive 140 15.6.2 (BRC_SPTX: BRAUMAT compact set point trend ) – Trend Archive