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Copyright © Siemens AG. All Rights Reserved.

C E M A T - V 5 Integrated System for Cement Plant Automation

Systemspecifikation

Reference Manual System / Glossary

CEMAT-CS VERSION 5 Reference Manual System Glossary

Introduction 1

Process Control System PCS 7 2

CEMAT V5 BASIC System Description

3

CEMAT V5 B General Object Description

4

5

6

7

8

9

10

11

Glossary 12

13

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Reference Manual System Introduction

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Introduction

Content Introduction 1

General ...................................................................................................................2 Documentation structure.........................................................................................3

Introduction Reference Manual System

1 - 2 Copyright Siemens AG. Alle Rechte vorbehalten.

General You have here the System Manual for CEMAT V5. This manual is part of the Reference Manual. It should support you in performing the work required to configure your plant.

The Reference Manual is part of a comprehensive CEMAT V5 complete documentation. In the current version V5, this consists of the volumes listed below.

After the installation of CEMAT V5 the CEMAT documentation is available as PDL in directory D:\Cem_V5\Docu

On the following pages you will find the content of each manual.

Engineering Manual

Reference Manuals

System Objects Glossary

Reference Manual System Introduction

Copyright Siemens AG. All Rights Reserved. 1 - 3

Documentation structure The manuals contain the following chapters:

Engineering Manual

1 Introduction 2 Preparations 3 Installation of a PCS 7 Project 4 Assignments 5 Engineering Examples 6 PLC Engineering 7 PLC-PLC Coupling 8 OS Engineering 9. WinCC Server 10 WinCC Multiclient 11 Project administration 12 free 13 Graphic Templates 14 Tips&Tricks 15 Update Information

Introduction Reference Manual System


Reference - System

1 Introduction 2 General System Information 3 System Description (Short form) 4 System Description BASIC (B) 5 System Description DIGNOSTIC (D) 6

Reference - Objects

1 Introduction 2 General 3 Unidirectional Drive 4 Damper 5 Valve 6 Annunciation Module 7 UM-Module 8 Route Module 9. Group Module 10 Selection 11 Silopilot 12 CNT-Module 13 RT-Module 14 Controller Module 15 Analog Output 16 Adapt 17 Measured value Integrator 18 Bidirectional Drive 19 Annunciation 8 Module 20 Bidirectional Drive SIMOCODE 21 Damper SIMOCODE 22 GO Control Communication

Reference - Glossary

1 Introduction 2 Definitions and Instructions

Referenzhandbuch System Process Control System PCS 7

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Process Control System PCS 7

Contents Process Control System PCS 7 1

SIMATIC PCS 7 – a concept that shapes controls systems ........................................ 2 Introduction...................................................................................................... 2

The system and its components................................................................................... 3 The engineering system .................................................................................. 3 The operator interface systems....................................................................... 3 The bus systems ............................................................................................. 3 The automation systems ................................................................................. 4 Structure of the I/O peripherals ....................................................................... 4 Libraries of control system function blocks...................................................... 4 Connection to the field bus with PROFIBUS................................................... 4 Integration of the operational management level ............................................ 4 The batch package.......................................................................................... 4 Conformity classes in the SIMATIC S7 family................................................. 5

The Heart of a Control System – the Engineering System .......................................... 6 The engineering system .................................................................................. 6 The SIMATIC Manager – at the very top of the Engineering System ............. 8 The system components – the constituent parts of the Engineering System . 9

Operating and Monitoring Systems ............................................................................ 13 Introduction.................................................................................................... 13 The SIMATIC PCS 7 operator stations ......................................................... 14 Optional OS packages for control systems ................................................... 15

How do System Components Communicate with one another.................................. 18 Bus systems used in SIMATIC PCS 7 .......................................................... 18 MPI – Multi Point Interface ............................................................................ 18 PROFIBUS .................................................................................................... 19 Industrial Ethernet (SINEC H1) ..................................................................... 21 Connection to the field bus............................................................................ 21

Automation Systems................................................................................................... 23 The central components ................................................................................ 23 Incorporating I/O peripherals via ET 200M.................................................... 24 Signal modules .............................................................................................. 25

Control System Functions .......................................................................................... 26 General system functions.............................................................................. 26 Message processing in SIMATIC PCS 7....................................................... 28 Status message and diagnostic concept....................................................... 32 Using a process variable – the operating characteristics.............................. 33 Defined start and restart characteristics........................................................ 34 Redundancy concept..................................................................................... 36 Reports, logging and archiving...................................................................... 36

Process Control System PCS 7 Referenzhandbuch System


SIMATIC PCS 7 – a concept that shapes controls systems

Introduction SIMATIC PCS 7 has a modular structure and is thus scalable – from individual small–scale automation solutions through to complex control systems.

This principle will allow you to implement your automation task in the optimum manner.

The benefits for you SIMATIC PCS 7 has the following benefits:

• The reliability and performance of a homogeneous control system

• All selected components are modular and can be combined

• Mature technology with widely–available and sophisticated standard products

• Price advantages through low engineering, operating and maintenance costs

• Reliable decision–making and future upgrades through the use of world standards

• Open interfaces to hardware and software that facilitate fast migration to the upgraded system platform

The uncomplicated interaction and optimum division of work enable our customers to make use of the strengths and find user–specific solutions for wide–ranging automation tasks.

The central design principle is openness • To guarantee extendibility and linkability, SIMATIC PCS 7 is:

• open for communication with other devices and systems: using SIMATIC NET, including PROFIBUS (see section 4 )

• open for industry–specific expansion: via export/import interfaces to the engineering system, support for library functions, ODBC and OLE automation interfaces

• open for seamless integration of other system components into hardware and software



The system and its components

A specimen system configuration with SIMATIC PCS 7

The engineering system The engineering system can be structured as a separate station within the interconnected system, as shown in diagram 1-1. However, it can also be loaded as a software package on the OS components. Section 3 presents the engineering system tools.

The operator interface systems Operator interface systems based on SIMATIC WinCC can be used in SIMATIC PCS 7.

The components are supplemented with functions for use in

control systems.

The following types of operator station are available for local and central use:

• operator panels

• single–user systems and

• multi–user systems

The bus systems The following bus systems from the SIMATIC NET family are used with SIMATIC PCS 7:

• Industrial Ethernet (SINEC H1)

• PROFIBUS

• MPI

• PROFIBUS DP

Industrial Ethernet, PROFIBUS and MPI can be used as system buses, whereas PROFIBUS DP can be used as a field bus.

Industrial Ethernet (SINEC H1) can also be used as a terminal bus.



The automation systems Various central processing units from the SIMATIC S7–400 automation

system with integral PROFIBUS DP interfaces for linking the I/O peripherals

are available for use with SIMATIC PCS 7.

Section 5 presents the central processing units available for your automation

tasks.

Structure of the I/O peripherals The conventional field signals are linked via I/O modules. The ET 200M distributed peripheral is used to set up the I/O peripherals.The ET 200M is a modular peripheral device with degree of protection IP 20. It is described in greater detail in section 5.2. I/O modules with intrinsically safe signals are available in addition to the conventional modules.

An assembly system is available for setting up ET 200M in cabinets.

Libraries of control system function blocks As a fast and effective solution to control system problems, there are extensive libraries with blocks of differing degrees of complexity.These blocks provide a standardized user interface (standard operating screens) and a uniform messaging concept during operation, in addition to high automation performance.The scope and functions are described in section 6.

Of course, as well as using the libraries, the user can also create his own function blocks.

Connection to the field bus with PROFIBUS SIMATIC PCS 7 provides a homogenous link to the PROFIBUS DP (distributed peripherals) field bus and thus follows the trend towards distributed structures that can be constructed and operated in a more flexible, simple and cheap manner.

PROFIBUS DP enables communication with the peripherals via ET 200M and between field devices and the automation systems.

The peripheral devices that can be linked using PROFIBUS and the available field devices are listed in section 6.

Integration of the operational management level PCS 7 does not end at the margins of the process management level.PCS 7 Warehouse forms the outer framework for a range of modules to supplement the core functionality of SIMATIC PCS 7 and integrate the control system seamlessly into the rest of the company’s IT system.

PCS 7 Warehouse guarantees two aspects which are essential for obtaining information:

1. Every authorized end user has access to the control system’s data.

2. The data required is made available in a form that it can use, i.e. as the most meaningful unit of information.

The batch package In addition to the options for operating a plant in discontinuous mode already available in the basic PCS 7 setup, the system also supports recipe–oriented operation within plant through the use of a special batch package.



Conformity classes in the SIMATIC S7 family In PCS 7, features that allow interaction between components of a system are available in several conformity classes.They thus provide varying levels of user–friendliness and functionality during configuration and operation.

The functionality of PCS 7 with its special control system features and tools for selected components thus offers the maximum level of system performance and user–friendliness.

The entire range of SIMATIC components can be used with all tools from lower conformity levels available within the system family in order to implement automation tasks with PCS 7.

Since it is an open system, PCS 7 can also work and exchange data with other components that conform to the supported standards.

PCS 7 conformity classes



The Heart of a Control System – the Engineering System

The engineering system SIMATIC PCS 7 is a universal engineering system for configuring your control system and supports the system–wide and plant–wide processing of projects. The engineering system is so flexible that it can be used equally well with all equipment, from small–scale through to the largest plants.

From the initial plant configuration, right through to technical support for its operation, you can work with the same tools on our project database during every phase.Thus, throughout the plant’s entire life cycle, you will only use one set of tools.

However, control system engineering does not take place in isolation.Open import /export mechanisms enable the engineering system to be integrated into your existing plant configuration infrastructure.

The versions of the individual SIMATIC PCS 7 components are all coordinated. STEP 7 is the control component against which all the other components (options) are matched. Perfect interaction between components is guaranteed by the Siemens system conformity test.

System–wide and plant–wide engineering



The concept of component–independent, plant–wide configuration has the following advantages:

• Configuration with the equipment phase hierarchy enables a plant to be structured ”top down” by functional aspect.

• The user handles general objects that correspond to his equipment phase environment (part systems, PICS units, etc.)

• In larger plants, several people can work on a project at the same time using networked PCs

This enables entire units to be used several times by copying and then modifying the configuration, for example.



The SIMATIC Manager – at the very top of the Engineering System SIMATIC Manager is the platform for comprehensive project management by the engineering system.

SIMATIC Manager is the navigator that organizes access to the objects (data) and tools.

Thus, SIMATIC Manager will provide members of the project team with user–friendly and efficient support. It will manage, process, archive and document your projects.The system simultaneously supports the system component and equipment phase views of the plant. In this way, you can manage all the plant data in the view of your plant structure.

With the equipment phase hierarchy, the engineering system provides a means of transferring the equipment structure of the plant onto the configuration in PCS 7 and mapping it onto objects such as charts, reports, operating screens, etc.The functional part of the plant is shown on screen in the form of a logical hierarchy, such as the one with which you will already be familiar from the Windows File Manager.The objects are ordered within the object hierarchy to reflect the equipment phase structure of the plant, as shown in diagram 2-2:

Objects in the equipment phase view of a plant

With the hierarchy, you also stipulate the addressing scheme you want to use for the designation system.In so doing, you can also select the number of hierarchical levels and the number of characters per level. You also specify whether the hierarchical level contributes to the identification or not. Thus, you can choose between hierarchical higher level designations or flat, date–oriented designations for the I&C / PICS units and control functions.



The system components – the constituent parts of the Engineering System

The engineering system consists of the following components:

• STEP 7 with SIMATIC Manager, the central database and HWCONFIG for configuring hardware and networks.It also contains the servers which perform mediation functions between the AS and OS for the general programming

• SCL (Structured Control Language) a high–level programming language similar to PASCAL for creating blocks

• CFC (Continuous Function Chart) for graphical programming of basic automation functions

• SFC (Sequential Function Chart) for graphical programming of production sequences

• SIMATIC Manager supplemented with the equipment phase hierarchy view

• WinCC (Windows Control Center) for OS configuration

• Netpro for graphical programming of communication between the devices making up the control system

• DOCPRO for documenting the configuration data

• Import /Export Assistant for the bi–directional exchange of data with other CAE systems

These components are supplemented with libraries containing prepared blocks for AS and OS.

SIMATIC Manager coordinates tools and objects



CFC Continuous Function Chart for configuring the data flow Simple and clear programming of automation tasks will save you both time and money. That is exactly what you get with CFCs.

Programming with CFCs is based on blocks. All blocks are placed in a CFC chart, programmed and set to the desired data flow using drag&drop.

Function blocks are contained in libraries. An elementary library is provided with the CFCs. Other libraries with more sophisticated function blocks can be added. See section 6 for a detailed description.In addition, you can also program your own blocks in all the S7 generation languages and combine them in the individual libraries.

The blocks used in the CFC support the type–instance concept. When a block type is used, an instance is created with local data. The functionality is present only once – in the block type.

SFC Sequential Function Chart for configuring the control flow Sequential control systems are typically used in control system plants that operate discontinuously. However, in continuous plants, as well, part tasks can often only be controlled by sequential control systems. Such tasks include start–up and shut–down operations, working point changes and status changes when the operating mode is switched.

Sequential control systems are configured by placing steps and transitions in the chart. Sequences, parallel and alternative branches and loops are used to build up the topology of the sequential control system.

Automation systems created with CFCs and SFCs are mutually compatible and can be run together in a central component.For example, the process signals created using CFCs are also available for use in the SFCs.

Sequential control systems are programmed graphically in the SFC. The elements of a sequential control system are placed in a chart in accordance with fixed rules. The user can then concentrate solely on the equipment phase aspect of the configuration.

The detailed configuration is carried out once the chart topology has been created.This is when the transition conditions and actions are programmed in close cooperation with the CFC.The interfaces between the CFC blocks can be transferred to the transitions and steps by drag&drop, where they are used to control the process flow.

The charts created with SFC can be displayed and used without additional programming in WinCC. They are then available to the operator in WinCC, enabling him simply to monitor and operate the sequential control system while the plant is operating.



Import / Export Assistant Your engineering system does not exist in isolation. It can be integrated into your existing plant configuration infrastructure.Data from early planning phases and data from other CAE systems, e.g. in the form of lists of I&C units from the functional and plant planning, can be transferred to and used in the engineering system.

This is where the Import / Export Assistant comes into its own.When the I&C unit data is imported, the hierarchical information (plant identifiers), signals and the function charts allocated to units are automatically generated. Time–consuming and potentially incorrect double inputting is thus avoided.The process can also be reversed: Modified data can be re–exported to external planning systems, e.g. in order to compare documentation.

There is also an open and flexible interface for exchanging data. The user can configure this interface to suit his own working conditions.

Bi–directional exchange of data between the planning system and engineering system

OS configuration Configuration of the OS is also organized via SIMATIC Manager. It enables OS stations to be incorporated into the system component view.In the equipment phase view, OS objects, such as flow charts, can be arranged by function.

All OS–specific configuration work is carried out using the resources provided, such as creation of flow charts using the graphic editor or programming of actions, archives, logs and curves.

The signals are configured without the need for multiple input at a unit. The engineering system supplies the AS and OS involved with the necessary signaling data. When programming with CFC/SFC, messages are implicitly programmed at the same time through the use of function blocks.Dialogs are available for adapting the message texts.

The links between WinCC display driver blocks, messages and archived variables are created implicitly in the AS with the blocks, i.e. without additional programming. For example, if a motor block is used in the CFC, the variables used to provide the associated standard operating screen in WinCC are automatically generated by WinCC.



Support for testing and commissioning The engineering system is not just used for configuring. It also provides support for testing and commissioning. SIMATIC PCS 7 comprises comprehensive test and commissioning functions.

These include:

• CFC with test and commissioning modes which you can use to display and modify the values of the variables in your chart during operation

• SFC with test and commissioning modes which enables you to monitor and change the SFC flow and to display the transition status in the individual transitions

• SCL with high–level language debugger

• all the functions from STEP 7 INFO

• simulation of the S7 AS with S7 PLCs within the engineering system

• process signal simulation at the driver blocks for I/O modules.

• switching WinCC to runtime mode and optimizing with online modification programming

System documentation Using the documentation tool (DOCPRO) of the SIMATIC PCS 7 control system, the user can document plant data from different angles and according to different criteria, and thus create user–specific system documentation for his automation. This may be, for example:

• full or partial documentation with

• a centrally managed footer

• cover sheet

• table of contents

• individual documents consisting of CFC / SFC charts, WinCC screens, etc

The full documentation option enables all the programmed data for a SIMATIC project to be documented in context. To do this, select the ”Full documentation” function. If you only want part of the data, select the objects to be documented using selection dialogs.

In addition to the system documentation that can be generated via the document management feature, it is also possible to create documentation directly from the individual tools.This means that the objects currently being processed can be individually documented at any time.



Operating and Monitoring Systems

Introduction In SIMATIC PCS 7, the operator communication and visualization systems are based on SIMATIC WinCC (Windows Control Center). With SIMATIC PCS 7, the operator communication and visualization stations are known as operator stations (called OS in the rest of this manual). The following variants are available:

• Operator panels (OP)

• Single–user systems

• Multi–user systems

Several variants of WinCC and several performance levels are available for the different hardware platforms. Software packages, classified by the number of variables, and optional packages (WinCC options) allow the individual user’s choice to be tailored to the amount of equipment used and the functional extensions required.

In this way, you can, for example, extend an existing plant configuration with several single–user systems to create a multi–user solution which uses the old hardware and software components.

Configuration data and archived data are both stored in a relational database (Sybase Anywhere) and can be read from there via Open DataBase Connectivity (OBDC) and Standard Query Language (SQL) since WinCC is linked to the Sybase connectivity tools.

Applications running in parallel to WinCC (e.g. Excel) can request process data from WinCC via DDE. WinCC also allows the integration of commercially available OLE Custom Controls (OCX).

SIMATIC PCS 7 operator stations are available for Windows 95 and Windows NT 4.0.

As with all SIMATIC components, you can switch to the configuration part via the Windows 95 / Windows NT 4.0–compatible user interface. Reusable blocks and preset programming parameters, together with the incorporation of existing standard and user programs, will help you rapidly achieve your objectives.

The on–line configuration enables you to make a local modification without having to interrupt the current process operation and visualization. Commissioning can be carried out just as quickly from the operating platform.



The SIMATIC PCS 7 operator stations SIMATIC PCS 7 provides a whole family of operator stations suitable for various tasks.From local use in the plant using the OP modular systems, right through to multi–user systems for control rooms. Diagrams 3-1 to 3-3 show the various types of OS. Additional OS systems can be added, provided that the additional system bus load / number of connections required to supply these operator stations do not exceed the rated values.

The operator panel is connected to the system bus via a communication processor (CP). The OP gives great flexibility for increasing the number of operator communication and visualization channels.

The single–user system is a single–channel operator station connected to the system bus via a CP interface. If more than one operator communication channel is required, then several single–user systems can be run in parallel on the system bus with great flexibility.The entire configuration data set is used on each operator station.

Note The single–user system can also be used as the basis for the engineering system.

A multi–user system consists of several operator terminals (process terminals) that are supplied with data by an OS server via a terminal bus. The terminal bus exists quite independently of the system bus, which is used solely to supply data from the OS server to the process terminal, engineering system and host computer.

The advantages of a multi–user system are that:

• the OS server only has to supply data once via the automation systems or, if there are several operator communication channels, via the process terminals.

• the process terminals can be set up and arranged with great flexibility

• it is relatively cheap to set up

• the system and terminal bus are totally separate



Optional OS packages for control systems The BASIC Process Control package gives WinCC the extra functions it needs for use as a SIMATIC PCS 7 operator station. This considerably reduces the engineering work required through the use of meaningful basic data.

Example: OS runtime desktop with screen assignment

The functions of BASIC Process Control include:

• basic data with the screen divided into: overview area, workspace and the keyset area

• hierarchical process image with graphical programming of the picture tree (Picture Tree Manager)

• ability to browse through the picture tree during process management

• flagging / retrieval of the screen composition

• group status displays to guide the operator through the graphical picture tree

• process images can be selected by name (in the process management part)

• sign of life monitoring with plant configuration image

• split–screen wizard for setting the screen resolution and multi–channel mode

• message wizard

• extended set of graphics objects, e.g. 3D bar charts



The ADVANCED Process Control package comprises user–friendly control system functions for transferring the plant view to the process management system, for example.

The functions of the ADVANCED Process Control option include:

• user administrator with plant view (disable/enable areas) for process management

• I&C units can be selected by name (in the process management part)

• acknowledgement in the graphics part

• active/passive time synchronization

• on–line selection and display of groups of curves

• curve wizard

• selection of curves by I&C unit name

• transfer of configuration data files via PROFIBUS

Protected access to a single–user terminal or a terminal of a multi–user system can be further increased through the use of chip cards for checking input privileges. The chip card is the modern ”key” to accessing operator terminals.

The protection is set up so that input at the OS is only authorized while the chip card is inserted in the reader on the OS, thus guaranteeing a unique identification. If a unique identification is required (e.g. for validation purposes), then a chip card reader must be attached to each process terminal.

Note This option is available for the single–user OS and the process terminals of a multi–user OS.

For the purposes of long–term data acquisition, e.g. in order to meet validation requirements, the data recorded at the operator stations, such as logs, measured values and sequential event logs, can automatically be sent to storage with this option.The data is sent to external disks such as EOD/MOD or to other drives.

An optional upgrade for operating 2 screens from a single operator terminal.These screens can be operated with a mouse and a keyboard.

No additional configuration is required for multi–screen mode at your operator station. Subsequent extension is also simplicity itself through the use of the split–screen wizard.

Note This option is available for the single–user OS and the process terminals of a multi–user OS.

An object based on the Windows–OCX technology can be used to incorporate video camera pictures into process images.Such images can also be incorporated in the form of a window overlaid over the workspace. A graphics card is used to incorporate camera images into the process management interface.

This option is available for the single–user OS and the process terminals of a multi–user OS.

All industrial plants require a unique system–wide time that automatically switches between summer and winter time in order to synchronize the individual components of a process control system.

There are two different systems for receiving the date and time at operator stations:

DCF 77 receiver

GPS receiver



Time synchronization with the DCF 77 receiver: The radio clock module receives the official time of the Federal Republic of Germany from the atomic clock at the German Physikalisch – Technische Bundesanstalt in Braunschweig via the Mainflingen long–wave transmitter.

Time synchronization with the GPS receiver: This hardware module can be used for date/time synchronization, wherever your WinCC system is located.The GPS (Global Positioning System) works anywhere and is independent of national time transmitters.

This option is available for the single–user OS and the server of a multi–user OS.

The sequential control systems for SIMATIC S7 created using the SIMATIC SFC are visualized in the same format on the OS using this optional package. To do this, the user calls the charts to be visualized in navigation and overview format. In overview, the representations of steps and transitions containing a step comment can be opened or the dynamically supplied transitions can be displayed.

This option is available for the single–user OS and on the server of a multi–user OS. Inerting

Example: Sequential control systems are transparent to the plant operator

No additional engineering is required: upon request by the user, the charts are transferred from the engineering system to the SFC visualization package and prepared for visualization and user. This user–friendly viewer function for sequential control systems is quick and easy to learn and is totally transparent, both when the plant is operating normally and in the event of a fault.

Operator stations enable the use of a signal module. Such modules are used to control up to three different signaling devices (e.g. 3 different lamp lighters or 3 buzzer tones for different message classes). A hardware acknowledgement button can also be connected. It also contains a hardware watchdog that can signal the failure of a WinCC operator terminal.

This option is available for the single–user OS and the process terminals of a multi–user OS.



How do System Components Communicate with one another

Bus systems used in SIMATIC PCS 7 Powerful system and field bus systems are essential for implementation of control systems, particularly those with distributed automation.

The following bus systems from the SIMATIC NET product family are used:

• Industrial Ethernet (SINEC H1)

• PROFIBUS

• MPI

• PROFIBUS DP

A standard Ethernet bus is used as the terminal bus for WinCC multi–user systems.

The system bus connects all the components of the control system (AS, ES, OS and host computer), thus enabling them to communicate with one another.

The system bus is the backbone of the system and is based on Industrial Ethernet, PROFIBUS or MPI. The different characteristics of the buses, bus topologies and the various transmission media supported mean that the system bus can be adapted to suit a broad spectrum of requirements, such as:

• cost

• number of stations (from 32 to 1000)

• range (from 50 m to 21 km)

• performance (from 9.6 KBit/sec to 10 MBit/sec)

• availability

• electromagnetic compatibility

MPI – Multi Point Interface SIMATIC NET MPI is the ideal system bus for small–scale plants.

The advantages of MPI interconnection are its simple structure, the easy to handle ports and cabling and the low cost of connecting devices.Up to 31 stations can be operated in an interconnected MPI system.

Compatible systems The following SIMATIC PCS 7 components can be connected to MPI:

• all S7–400 CPUs using the integral interface

• OPs using the integral interface

• operator stations, ESs and PCs using MPI CP or PROFIBUS CP (CP 5412 A2)



PROFIBUS PROFIBUS is the system bus for SIMATIC PCS 7 designed for medium–sized to large plants with high performance requirements.

Up to 127 stations can be connected to one PROFIBUS.

The PROFIBUS can work at baud rates of 9.6 kBit/s to 1.5 MBit/s.

Compatible systems All SIMATIC PCS 7 components can be connected to PROFIBUS. Namely:

• AS central components with connected 443–5 Basic communication processor

• operator stations with PROFIBUS CP5412 A2 interface module,

• engineering system on PC using the PROFIBUS CP5412 A2 interface module for PC

Terminal system/transmission media If 2–wire cable is used, the low cost per metre of the cable compare extremely favorably with fiber–optic cable. The terminals are very easily connected with screw–type terminal connectors – another cost saving.

The strengths of fiber–optic cable are that it can cover large distances, has absolute immunity to electromagnetic interference, total lightning protection, cannot be accidentally energized and easily allows redundancy to be established in the bus medium.

Fiber–optic cable can be set up in line, ring and star networks through the use of OLMs (Optical Link Module).

In SIMATIC PCS 7, OLMs are used as follows:

• By creating a redundant fiber–optic cable ring (one or more terminal systems (AS, OS, ES, PC) can then be connected to each OLM using 2–wire cable)

• Transition from 2–wire to fiber–optic cable

Redundancy It is always sensible to create redundancy in the bus medium if:

• operator communication and visualization functions for entire plant components must be maintained under all circumstances – even if a bus component fails.

• during operation, the system bus can only be extended by disconnecting the LAN cable.



Networking with PROFIBUS, fier-optic cable



Industrial Ethernet (SINEC H1) Industrial Ethernet is the system bus for SIMATIC PCS 7 designed for large–scale plants with high performance requirements.

Up to 1000 stations can be connected to industrial Ethernet.

Industrial Ethernet works at baud rates of up to 10 MBit/s.

Compatible systems The following SIMATIC PCS 7 components can be connected to industrial Ethernet:

• AS central components with connected 443–1 communication processor

• operator stations with CP1413 industrial Ethernet interface module,

• engineering system on PC using the CP1413 industrial Ethernet interface module for PC.

Terminal system/transmission media All three types of cable are suitable for industrial use: triaxial cable, industrial twisted–pair and fiber–optic cable.

Connection to the field bus Today, little additional installation work is required to enable data to be exchanged between the automation system and distributed peripherals and intelligent field devices.

The standardized PROFIBUS DP is used for the SIMATIC PCS 7 control system. The ET 200 M distributed peripherals and a range of field devices are connected using PROFIBUS DP, as can be seen in diagram.

Connection of field devices with SIMATIC PCS 7



while the process is running, data is sent to and from the field devices (ET 200M with connected I/O peripherals or other field devices) by the token blocks running within the automation systems.When a field device link is configured, the CFC simply places these blocks in the appropriate CFC/SFC charts and further processes the signals thus provided.The blocks required for connection of the field device are contained in the SIMATIC PCS 7 “Field device blocks” library.

The actual field devices are configured using the tools provided. Incorporation of field device configuration into the ES is planned for a future upgrade.

There are two interface options for PROFIBUS DP:

1. via the PROFIBUS DP interface integrated into the CPU 414–2 or 416–2,

or

2. if several PROFIBUS DP lines are operated from one S7–400 AS, by means of up to 4 additional CP 443–5 Extended communication processors plugged into the central component.

All the SIMATIC NET PROFIBUS installation accessories are available for setting up the PROFIBUS DP field buses (see PROFIBUS assembly tools).



Automation Systems

The central components Central components for use with SIMATIC PCS 7 are made up of a small number of components from the SIMATIC S7–400 automation systems. Central components with appropriate CPUs and different pricing and performance levels are available for various applications:

• AS 416_800ac/_1600ac/_800dc/_1600dc

• AS 414_384ac/_384dc.

Each central component consists of:

• S7–400 rack with 9 slots

• a CPU to suit the type of central component used

• 24 VDC or 115/230 VAC power supply

• 384/800/1600/3200 KB RAM

• 2 MB SRAM load memory

• license for the PCS 7 libraries

The CPUs used here each have, as standard, two interfaces – MPI and PROFIBUS DP – and can therefore be used in small systems without the need for additional CPs.

The integral MPI interface is a low–cost entry–level option for connecting the MPI system bus.

If PROFIBUS is used as the system bus in your plant, an additional 443–5 Basic CP should be added to the central component.

The PROFIBUS DP port integrated into the CPU is used to connect the ET 200M distributed peripherals or PROFIBUS DP–compatible field bus devices.

Lower conformity levels are required if other automation systems, e.g. the S7–300 series, are to be incorporated into the SIMATIC PCS 7 as an automation system (see section 1.4). Since standard S7 connection mechanisms are used, they cannot automatically be incorporated into the PCS 7 control system signaling concept, for example.

Of course, they can be used as lower–level programmable controllers (again connected directly to the system bus) as a solution to less sophisticated control problems, for example.



Incorporating I/O peripherals via ET 200M Distributed ET 200M components are available for connecting peripheral devices.In SIMATIC PCS 7, input/output modules are plugged into the ET 200M distributed peripherals.

The ET 200M peripherals are connected to the central component (CPU) via PROFIBUS DP. PROFIBUS DP thus enables communication between the central components and the ET 200M distributed peripherals.

The ET 200M is operated as a station on the PROFIBUS DP field bus. Consequently, there is considerable flexibility in the structure of the I/O peripherals, either in central machine rooms or in local switch rooms.

To enable several PROFIBUS DP lines to be supplied by a single central component within your application, up to 4 additional 443–5 Extended communication processors can be plugged into the central component.

The ET 200M is a modular peripheral device.It can only be upgraded with the signal modules and function modules from the S7–300 series. As an option, ET 200M has the functionality required to connect and disconnect modules while your plant is in operation.Of course, this can be done without interrupting the automation tasks carried out by the central component and without affecting the other modules.

The ET 200M modular peripheral consists of:

• a DIN rail (as an alternative rail for the active backplane bus).

• an IM 153 interface module.

• an active backplane bus for the “connection and disconnection” functionality consisting of up to 8 expansion buses between the modules.

• an optional power supply unit.



Signal modules Only module types from the SIMATIC S7–300 series can be used in the ET 200M peripherals.

The following module types can be used:

• standard signal modules from the S7–300 series

• special class B control system I/O modules with increased diagnostic capability

• explosion–proof I/O modules for connecting signals from hazardous areas

An overview of the available module types is given in the appendix.

The control system I/O modules have extra functionality with respect to diagnostic capability, channel–specific error displays, diagnostic interrupts, internal module monitoring, retention of the last value or use of a substitute value if the central component or the load current power supply fails.

Explosion–proof (ex/EEx ib) modules with channel–specific isolation are available for binary and analog input and output signals.

The potentially redundant modules (see appendix A) enable redundancy to be incorporated into the processing of I/O signals.These modules allow redundant/non–redundant actuators/sensors to be set up in the field.

Homogeneous integration into SIMATIC PCS 7 is guaranteed for the modules listed in the appendix. These include associated driver blocks (see libraries) with integral control system monitoring.

In addition, all the other module types from the range available for the S7–300 assembly system can be used and integrated with basic STEP 7 mechanisms from a lower conformity level. In this case, automatic integration into the SIMATIC PCS 7 status message concept is omitted.



Control System Functions

General system functions Higher–level control system functions are available for SIMATIC PCS, in addition to the individual SIMATIC PCS 7 components.

• central time synchronization

• sign of life monitoring for the AS and OS PCS 7 components

• clearly defined start and restart characteristics in the AS, bus and OS components and thus throughout the entire system

• redundancy

• message processing

• operating concept

• integrated control system monitoring and diagnostics

Time synchronization The WinCC “Advanced Process Control” option is required for the functions described in this chapter.

For central time synchronization in SIMATIC PCS 7, a single operator station is responsible for synchronizing the time of all devices connected to the PROFIBUS system bus.

Time synchronization

It is also possible to declare two operator stations as the time master within the interconnected system. The two stations will coordinate themselves so that only one time master actively synchronizes the time across the system bus. If a time master set up in this way fails, the other will automatically take over the synchronization function.



Time synchronization guarantees a maximum deviation of 20 msec from the time in the AS and OS systems present on the system bus.

The operator station, as the active time master, can be externally synchronized via:

• the DCF 77 receiver and

• the GPS receiver

One low–cost entry–level option is to use the PC clock of the OS as the master time.

DCF 77 and GPS receivers are linked to the operator station as separate devices via the serial COM port, thus allowing plant–independent synchronization.

The DCF 77 receiver, as a radio clock, receives the official time of the Federal Republic of Germany across the whole of Europe.This is a low–cost time synchronization option within Europe.

The GPS (Global Positioning System) works anywhere and is independent of national time transmitters since the system is based on 24 satellites, all of which use the time of their on–board clocks.Since Windows is installed as a country–specific version on the operator station, the time thus transmitted is converted into the correct time for that country.

The GPS module thus enables SIMATIC PCS 7 to be used anywhere in the world, even with plant–wide time synchronization.

The SINEC time transmitter can be used where industrial Ethernet is the system bus.

Sign of life monitoring The WinCC “Basic Process Control” option is required for the functions described in this chapter.

In the SIMATIC PCS 7 control system, the sign of life monitoring OS function enables the correct functioning of AS and OS systems connected to the system bus to be monitored. You thus constantly have a current overview of the status of your plant.

The monitoring function is carried out by the operator stations and each OS monitors all other connected ASs and OSs with which it has a communication link.

Sign of life monitoring is automatically activated when the OS is started up and typically runs in cycles of between ten seconds (default) and one minute.

The sign of life monitoring reads the operating status from each AS.If a change in status is detected (e.g. from RUN to STOP), the OS generates a status message.

A status message is also generated if a system does not respond to a monitoring prompt because the power supply to an AS has failed, for example.

The overall plant status can be visualized on the OS. A plant configuration image which displays the operating statuses of each monitored component can be created without additional programming, simply by pressing the appropriate function key on the OS keyboard.



Diagrammatic representation of a plant configuration

Failed AS and OS systems are:

• identified as faulty by a status message and

• their operating status is displayed in the plant configuration image

The values and statuses represented by failed ASs in the OS are also identified as faulty in the graphic displays.

Message processing in SIMATIC PCS 7 The messaging concept of the SIMATIC PCS 7 control system helps the operator to respond to sporadic events. Such events may result from normal, unusual or undesirable statuses within the process and control system and are individually signaled to the operator. In addition to these events, operator input is also fully integrated into the messaging concept. Such input is incorporated into available message lists and archives in the same way as process signals.

There are three classes of message:

• Process signals

• Status messages

• Operator messages

Process signals report events that occur during the automated process, such as limit violations for measured values and process messages.

Status messages are caused by faults which SIMATIC PCS 7 detects in its own components and then signals.Such faults range from failure of a component through to a broken wire signal from a connected I/O device.

Operator messages are generated when process variables are used, e.g. when the οperating mode of a closed–loop controller is changed.Operator messages are automatically generated when the operating displays contained in the libraries are used.

Central messaging concept Messages are created when the process is executed in the automation systems. The individual messages thus generated are sent to the operator stations concerned via the system bus. The time at which messages occur is retained in the automation systems and transmitted with the message. The messages are displayed in the OS message lists in chronological order and with the time at which they occurred.



SIMATIC PCS 7 uses a central acknowledgement concept. When a message is acknowledged on the OS, this acknowledgement is passed on to the signaling block in the AS. From there, it is rerouted as an acknowledged message to all connected OS stations.

The following table9-1: Acknowledgement characteristics of the message

Message class Message type Acknowledgement Alarm AH, AL incoming, flashing on Warning WH, WL incoming, flashing on Tolerance TH, TL no acknowledgement, no flashing AS status messages S, F incoming, flashing on OS status messages S incoming, flashing on, (OS internal or Batch went out without status flexible status message) Preventive maintenance M incoming, flashing on Process message PM incoming, flashing on Process message PM no acknowledgement, no flashing Operator request OR no acknowledgement, no flashing Operator message OM no acknowledgement, no flashing, went out without stauts



Organisation of messages The optional WinCC “Basic Process Control” packages provides the following message lists:

• New list

• Old list

• Sent list

• Operator list

• Status list

• History.

Messages in the new list could be, for example, all messages that have not yet been acknowledged.The old list contains only messages that have been acknowledged but are still present.The history shows all messages that have passed through a complete message cycle.

When message lists are selected, only messages belonging to the currently selected area are displayed.

Message classes The process signals are divided into several subclasses:

Table: Process signals

Alarm high, low (AH, AL) (Alarm High, Low)

Warning high, low (WH, WL) (Warning High, Low)

Tolerance high, low (TH, TL) (Tolerance High, Low)

General process message (PM) (Process message requiring acknowledgement)

Process message (PM) (Process message not requiring acknowledge-ment)

Status messages are also divided into various subclasses:

Table: Status messages

Fault in the control system (S) (System)

Fault in the field (F) (Field)

Preventive maintenance (M) (Maintenance)

The operator messages are divided into the following subclasses:

Table: Operator messages

Operator request (OR) (Operator Request)

Operating message (OM) (Operating Message)

Note The message classes and displays are automatically configured using the message wizard in the WinCC “Basic Process Control” option for SIMATIC PCS 7.



The equipment phase hierarchy provided in the ES allows the user to allocate plants, units and equipment phase functions to areas that are reflected in the process management carried out at operator stations. When messages reach the operator station, they are entered into the message lists, thus providing a view of a specific area.

Process and status messages from equipment phase blocks visualized on the OS contain the loop–in–alarm function.This function enables the standard operating display for this I&C unit to be selected as a loop display directly from the message list. The function is automatically made available by the system and no additional configuration is required.

Information text can also be configured for each message. This text is simply entered at the same time the message is created.



Status message and diagnostic concept Control system monitoring is an integral component of SIMATIC PCS 7 and is directly available when the components are used, without additional configuration.It is used to generate status messages that provide the user with clear information on the fault status of a control system component. Control system components are sensors, transducers and all system components and modules, right through to the power supply. The interaction between the functions of these components is also monitored for faults.

Control system monitoring and diagnostics thus serves to minimize the troubleshooting time required in the event of faults in components of the control system and in the field (sensors, actuators, switchgear). This increases the availability of a control system.

The aim is independently to output important information from the control system to the operators and control system technicians, enabling them to locate the source of a fault.

Control system monitoring is an integral system function that affects all hardware and software components and runs continuously in the background in parallel with the user functions. Consequently, no special user programming is required for this type of monitoring.

In the OS, such status messages are handled in the same way as process signals. They can be acknowledged and, if required by the user, stored in the external archive. The process responses to control system errors (e.g. switching to a safe status) can be predetermined by programming.

SIMATIC PCS 7 contains a three–stage application model for the purposes of control system diagnostics:

1. The operator is alerted by status messages containing information on the affected function. All incoming status messages are displayed and archived.The operator is guided to the loop display and thus given information on the possible effects of fault on the process. The configured responses are automatically initiated.

2. The operator informs the responsible control system technician of the fault (if there is no–one at the control system technician’s workstation).The control system technician has access to all the status messages and can select an overview of all the status messages present.The displayed error messages contain information on the cause and location of the error, such as the rack and slot of the module concerned. Diagnostic messages provide the control system technician with other details on the error messages.

3. If the fault cannot be rectified by replacing a module, the control system technician will call in a Siemens system specialist. The specialist, who has all the necessary know–how and system diagnostic and test functions, can access all parts of the system and rectify the fault. If necessary, he can also use the teleservice facility.



Using a process variable – the operating characteristics SIMATIC PCS 7 provides a set of operating characteristics as a system function for reliable operation of your plant.These operating characteristics control the requirements for reliable and error–free operation of your plant.

An integrated set of operating characteristics is provided in the AS and OS library blocks. The OS blocks (also known as standard operating displays) are permanently associated with an AS block. This combination enables customized and error–free operation.

The AS and OS blocks provided in the libraries can be used to implement all process control functions in a plant. From simple use of analog and binary values, which can be used as an operator communication unit for user–configured input, through to the operating screen for control blocks, the libraries contain all the blocks needed to allow the operator to control the process.

The operating characteristics comprise:

• displaying the applicable value, which is also the basis for automation

• displaying the higher level designation of an item and the unit

• disabling and enabling, according to the situation

• testing for violation of operating limits

• testing for plausibility – incorrect operator input is immediately rejected

• alternative characteristics (e.g. limiting / rejecting) if the operating limits are exceeded

• logging the operator input (operator message)

The function blocks are contained in libraries. They contain separate catalogs for SIMATIC CFC and WinCC Designer. The characteristics described here are integrated into the equipment phase blocks as standard.

Thus, analog value operation is implemented in the AS by placing a standard operating display (e.g. OP_A for Operation Analog) in the CFC chart. Operator communication at the OS is configured with WinCC. At the station, the name of the AS block instance is allocated to the associated standard operating display (e.g. OP_A). This standard operating display has three display modes that can be used as required. During process management, the standard operating display for entering operating inputs and displaying other information is called up by clicking on the screen symbol.



Defined start and restart characteristics Starting and restarting the SIMATIC PCS 7 control system and the individual components are system functions that run automatically. Consequently, these characteristics do not have to be configured separately and it is not necessary to follow a specific order when switching on the individual systems.

Plant–specific start characteristics can be implemented using FBs that have been specifically tailored to the plant concerned and can also be called during start–up.

If individual communicating components fail, the communication links required are automatically reestablished when these components are started or restarted.

Starting / restarting the automation system (AS) Essentially there are two types of start characteristics:

• manually–activated startup (e.g. by operator input on the front panel of the AS or via the ES) and

• automatic startup (e.g. if the power supply fails and is then restored).

The start characteristics for the AS (see diagram 9-7) incorporate the following steps:

Start characteristics of an AS

1. The AS is switched on or the power supply is restored.

2. The AS initializes itself and checks that the hardware components are working correctly and have the correct parameter assignments. The programmable I/O modules present in the configuration are also loaded with the intended parameter sets.

3. The start–up OB is called.This organisation block (OB) is run once only after a cold restart, i.e. when the AS is started up for the first time. All function blocks (FB) contained in the start–up OB are executed, as shown in diagram 9-8.

Calling the start–up OB



At the end of startup, the AS sends a message frame to the communicating stations that have already signaled to the AS. This enables, for example, the operator stations connected to this AS to query the message status of the AS once more, in order to detect any changes that occurred while the AS was down.

The blocks contained in the libraries have integral start characteristics. When CFCs are used for configuration, the blocks for starting / restarting are inserted into the startup OB.The suppression of output signals required to prevent transients at the outputs can be programmed in the output drivers.

Starting / restarting with OS Startup, i.e. switching an operator station to runtime mode, is initiated by selecting ”Activate” project in the WinCC Control Center.

The restarting of an operator station (e.g. when the power is restored) is guaranteed by including WinCC Control Center in the Windows Autostart groups. After restarting, operator stations automatically return to their last operating state (WinCC Control Center or WinCC Runtime). Consequently, after a power failure, they will automatically return to runtime mode.

The start characteristics for the operator station (see diagram 9-10) incorporate the following steps:

Starting an operator station

1. The OS is switched on or the power supply is restored.

2. Communication is established with the automation systems in accordance with the configured user data. All connections required for communication will be established automatically and the OS will signal to the AS to receive the configured AS data, such as process and status messages.

3. After signaling, the current status is read from the AS in order to construct the process image in the OS. Appropriate synchronization mechanisms ensure that the messages are received and displayed as soon as they are registered.

The archives are then created, if not already present.

When the OS is switched off, the memory–resident parts of the archives are saved to hard disk and the archive is closed.

During startup, if an AS is contained in the configured data is not present on the bus, then the OS will attempt to link up. As soon as the configured AS is present on the bus, the OS will switch the AS to background mode without affecting the plant, which will already be operating.



Redundancy concept

Redundancy in operator stations Redundancy in operator stations ensures that the operator is still informed of the status of his plant and can continue to manipulate the process, even if an OS fails. It also enables the number of useable screens to be reduced temporarily.

A combination that meets this requirement is shown in diagram9-11.

Each operator station is set up as a multi–user system, i.e. it can simultaneously run several process terminals that are independent of one another.

If the process terminals set up in a control room are now supplied by independent OS servers, failure of an OS server with the process terminals connected to it will result in a slight quantitative restriction in use.There will be no reduction in quality (i.e. a reduction in the functional scope).

Of course, this redundancy concept can also be used for setting up single–user versions.

Redundancy in the bus system The SIMATIC NET PROFIBUS bus system enables medium redundancy to be established in the system bus.

Section 5 “Bus systems used in PCS 7” contains more information on the available options.

Redundancy in automation systems In future SIMATIC PCS 7 upgrades, it will also be possible to set up a redundant AS for highly reliable and error–free automation systems.

Reports, logging and archiving

Reports The operator stations provide an integrated reporting system that can be used to log user data, current and archived measured values and current and archived messages. Reports are electronic forms that are supplied with the required data once only, i.e. when a report is generated. They are then provided on the output medium available to the OS (screen, print to file, output to printer).

The basic OS system contains reports that can be used immediately They can also be used as templates for plant–specific reports. OS process images can also be part of a report, if desired. All the graphical configuration resources that are available for creating the process image can also be used for creating a report.

Logging Operator input listings are an integral system service which work in conjunction with the standard operating displays from the libraries.They are integrated into the sequential event log as a message line in the same way as process signals and status messages. There is a separate message class for operator messages. The runtime signaling system also contains a separate message list, known as the ”operating list”, to enable the operator input to be quickly called up.

As mentioned with respect to operator input listings, all messages are written to the sequential event log.They are thus archived and can be viewed on the OS screen, output to the printer or prepared for storage on an external disk.



Archiving For the purposes of long–term data acquisition, e.g. in order to meet validation requirements, this option enables the data recorded at the operator stations, such as logs, measured values and sequential event logs, to be sent automatically to storage.The data is sent to external disks such as EOD/MOD or to other drives. It is stored in a generally readable data format so that it can be further processed with standard PC tools. Data can also be archived via the operational management level.

Edition: 2003\02\25

System Description – Short Version

CEMAT V5

Brief Description

A&D AS CC CP

Brief Description / Data Sheets System Description


Table of Contents

CEMAT V5 i

Brief Description 2

What is CEMAT V5 ? ...............................................................................................2 System Configuration Technical Data .....................................................................4 Bus Systems Technical Data ...................................................................................4 Process Stations Technical Data .............................................................................7 Engineering Station Technical Data ........................................................................9 Device Functionality and Configuration Examples ................................................14

Device Designations and Functions: ........................................................14 Configurations...........................................................................................16

System Description Brief Description / Data Sheets

3 - 2 Copyright Siemens AG. All Rights Reserved.

Brief Description

What is CEMAT V5 ?

CEMAT is a consistent, modular control system on PCS7 V5 basis with the following components that are exactly matched to each other :

CEMAT ES ➩ Consistent, object-oriented engineering system

CEMAT AS ➩ Open/closed-loop control and communications components for S5 / S7

CEMAT OS ➩ Redundant operator control / monitoring components and archiving components ➩ Library for all control system objects with information, diagnosis, multimedia dialogs ➩ Annunciation system with additional service functions

CEMAT MIS ➩ Logging, statistics and long-term archiving system

CEMAT AddOns ➩ Cement-specific process optimization applications.

There is no separation between PLC and DCS tasks; the system provides the necessary communication between the individual components.

PLC = Programmable Logic Controller ; DCS = Distributed Control System

CEMAT is a comprehensive system with the following functionality:

➩ Easily expandable through the use of distributed client/server architecture

➩ Flexible adaptation to additional requirements

➩ Management information with simple report generation through the use of MS-Excel, long-term archiving with archive plans

➩ Maintenance support

➩ Laboratory automation

➩ Furnace management with fuzzy expert control

➩ Mill control.

CEMAT uses PCS7 as the system platform with...

➩ Standard hardware components

➩ SIMATIC S7 416/417

➩ SIMATIC NET bus components, Ethernet H1, L2 DP Profibus

➩ Windows NT as operating system platform for all control system functions (operations system (operator control and monitoring), MIS, expert system, etc.)

➩ Single-user systems and redundant multi-user systems with a single system software component.



CEMAT V5 Function Scope

- The project environment is pure PCS7. The SplitSreenWizard is used to create the picture layout, key record (screen divided into three parts) - The CEMAT color codes have been included in the message system - PCS7 now handles the curve archiving and display - The CEMAT module library uses the polling communication from the WinCC data manager - Control interfaces with IndustrialX and display types for each module type - Group status call is provided - Group instance list is provided - Group faults can be derived from the groups/paths status words. - Time synchronization by PCS7 hardware (CP1613).

- CEMAT operator control environment as in V4.12 - Message line with sound output and information dialog call - Message output can be defined with plant section granularity - Message dialog with simple search criterion input - Message selections can be stored - Information server to supply the information dialogs and object-specific entries

- Extended diagnosis - Inclusion and invocation of the Interlock Faceplates from CFC to display online- interlock signals - Object browser for all CEMAT objects with tabular attribute display - Interfaces to multimedia programs and free user applications - Displays of object-related Dxf plans

- PCS7 modules can be connected with an adapter module to the group/paths control.



System Configuration Technical Data

System Configuration

Typical Maximum Comments

Control systems per shared process bus 2 to 4 9 Switches can be desirable for bus loading reasons.

Operator stations per control system 6 to 8 96 Multi-client stations to maximum 6 server/redundancy pairs.

Engineering stations per control system 2 4 At least one engineering station per plant.

AS per control system 6 to 10 20 Preconfigured

AS communications channels 2 6

Server per control system 2 (redundant) 6

Curve server per control system 2 (redundant) 6 Two separate curve servers (redundant) are needed when more than 1000 values are archived.

Bus Systems Technical Data Terminal Bus System

Type designation Industrial Ethernet Manufacturer Siemens / Hirschmann Protocol IEEE 802.3 Transfer speed 10 / 100 Mbit/s Number of possible nodes 1024 Maximum bus length Up to 150 km Cable type - Coaxial - Optical-fiber 50/125 glass fiber - Miscellaneous

Yes Yes Industrial Twisted Pair

Bus components

Network cards 3COM Intel EtherExpress

Redundancy Yes bus in ring structure



Plant Bus System Type designation Industrial Ethernet Manufacturer Siemens / Hirschmann Protocol IEEE 802.3 Transfer speed 10 / 100 Mbit/s Fast Ethernet Number of possible nodes 1024 Maximum bus length Up to 150 km Cable type - Coaxial - Optical-fiber 50/125 glass fiber - Miscellaneous

Yes Yes Industrial Twisted Pair

Bus components

Network cards CP443-1 for S7 400 CP1413, CP1613 for PCs

with AUI/Tp and RJ 45

Redundancy Yes bus in ring structure with super vision components

Field Bus System Type Profibus DP

Manufacturer Siemens Protocol IEC 1158-2, EN 50170 Transfer speed Max. 12 Mbit/s Number of possible nodes 96 or 125 nodes Max. bus length 2-wire: 1000 m

Optical-fiber: up to 15 km

Cable type - Coaxial - Optical-fiber 50/125 glass fiber - Miscellaneous

No Yes 2-wire (Profibus type)

Bus components

Optical Link Module Interfaces

Type Profibus PA

Transfer speed Siemens Protocol IEC 1158-2 Manufacturer max. 31 kbit/s

Number of possible field devices 31 not Ex-area 10 Ex-zone 1



Device Configuration

Operator Control and Monitoring System

Type designation Actual PC Minimum requirements Manufacturer Siemens Processor type Pentium IV CPU clock frequency >= 850 MHz Installed RAM memory 512 MB RAM, max. expandable to

1 GB Hard disk >= 30 GB Hard disk seek time <= 8 ms Cache memory 512 kB Bus interfaces Etherlink III 3 COM (terminal bus)

SIMATIC, CP1613 (process bus)

Monitor size - Manufacturer - Refresh rate

21“ Siemens 85 Hz

Number of colors Resolution

64 K 1280 x 1024

Keyboard type Standard PC keyboard Trackball/mouse Yes Diskette drive required? No Magnetic tape drive detachable No User interface

CEMAT V5 Based on PCS7

Number of process pictures Number of circles Number of trend pictures Total number

No system limit No system limit No system limit No system limit

Limit HD and time

Length of alarm list

Typically 8 days (parameterizable), limited by the available memory



Process Stations Technical Data

Process Station Type designation SIMATIC S7-400 Manufacturer Siemens Processor type CPU 416 – 3DP / 417 / 417H CPU clock frequency Instruction cycle time from 0.08 µs Processor loading Total: Of which: - Base load : - Application programs.

Max. cycle time 200 msec 50 ms

Cycle times - Parameterizable in steps - Step size?

<= 200 ms Yes 10 ms

Installed RAM memory - Spare in MB RAM, max. expansion Load memory

2 x 1.6 MB 2 x 0.8 MB 2 x 1.6 MB min. 4 MB

RAM battery backup - Type - Bridging time - Lifetime

2x Lithium AA 1.9 Ah

Real-time clock? Calendar ?

Yes Yes

Timestamp resolution Where does the timestamp take place?

<= 200 ms In the CPU

Plant bus - Type: - Protocol:

Industrial Ethernet, Fast Ethernet IEEE 802.3

Field bus - Type: - Protocol

Profibus EN50170 IEC 1158-2

Full-graphic documentation current program

Yes CFC function plan

Field bus Profibus DP - Max. number / PNK: - Max. nodes / bus: - Full functionality? - Fiber-optic between buildings.

13 loops 96 / 125 Yes Yes

Other field buses: - Profibus DP/PA - Profibus FMS - Interbus S

Yes Yes No



Process Station Peripherals Central modules - Type - Maximum expansion Diagnostic capability of the I/O modules - Except I/O module? - Except channel?

S7-400 16382 byte DI 16382 byte DO 1024 byte AI 1024 byte AO Yes Yes

Decentral modules - ET200S - All modules usable? - ET200M - All modules usable?

restricted Yes

Not yet included in diagnostic and driver concept.

Analog modules - Type - Single potential separation - 0 – 20 and 4- 20 mA

Yes Yes

High-performance modules, manufacturer-dependent

Counter, positioning, path acquisition modules, etc.

Base data for assignment of the process station Response times for Binary signals - Average - 10% of the signals

max. 500ms 200ms

Average amount of:

Drivers:

Paths:

Analog inputs:

Setpoints:

Setpoint controllers:

DI/DO

300

50

300

50

30

4000/1000



Engineering Station Technical Data

Engineering Station Type designation Actual PC Minimum requirements Manufacturer Siemens Processor type Pentium IV CPU clock frequency >= 850 MHz Installed RAM memory. 512 MB RAM, max. expansion to

1 GB Hard disk >= 30 GB Hard disk seek time <= 8 ms Cache memory 512 KB Bus interfaces Etherlink III 3 COM (terminal bus)

SIMATIC, CP1613 (process bus)

Monitor size - Manufacturer - Refresh time.

21“ Siemens 85 Hz

Number of colors Resolution

64 K 1280 x 1024

Keyboard type Standard PC keyboard Trackball/mouse Yes Diskette drive required? No Magnetic tape drive detachable

4 / 8 GB No

System engineering Separate description Programming languages - CFC - SFC - SCL ST structured high-level

language

Yes Yes Yes

Object-oriented operation Yes Module libraries Base functions PCS7

Technological modules CEMAT V5

Connection capabilities for: - OLE, DDE - ODBC - API

Yes Yes Yes

PFK pictures and variable change on the ES and reload online

PFK – objects alternately change on the ES load on the 2 servers

Online change behavior – Simple logic:

Perform PNK – change on the ES and reload online

PFK = Process Remote Component PNK = Process Local Component



Volume of Project Data Typical Maximum Comments Communication / control system Process objects 2600 11 000 (drives ,counter and measured

values) Events (message bits) Depending on the number of

objects Number of AS (on the SINEC H1) 8 12 Telegrams per second 10 approx. 15 Acquisition cycles for measured valued (concurrently) 10 % curves with 1s

90 % curves with 5 s / 10 s Updating cycle in the picture < 1 s 1 - 2 s Pictures Number of pictures 60 - Number of controls (stat. and dyn.) per picture 250 approx. 800 Max. 70 IndustrialX

Drive functions - per control system - per AS

900 120

2700 225 Distributed over several servers

Measured value - per control system - per AS

800 100


Quantity values (counters (CNT), runtimes (RT)) - per control system - per AS

800 100


Controllers - per control system - per AS

120 15


- Short trend - per control system 500 2000 Distributed over several servers Trend curves (OS) - per control system 500 2000 Typical distribution:

10% with 1 sec. archiving cycle 40% with 5 sec. archiving cycle 50% with 10 sec. archiving cycle




Curves

Number of curve frames per graphics picture

1 6

Number of curves per curve frame 6 8 Number of curves per picture 6 36 Number of measuring points in the measured value archive

500 2000 > 1000 measured values requires a separate curve server

Number of measured values per measuring points on HD

All Depends on the acquisition cycle, for recording longer than 1 week

Number of measured values per measuring point in main memory

30 Time duration 10 minutes

Depends on the acquisition cycle

Logs

Number of logging printers 1 3

Message sequence logs (active) No yes

Number of message archive logs 3 5 Number of log lines per message 3 3

Number of variables in the log element 2 2

MIS logs 50 to 100 Unlimited Limits set by the HD capacity and running times

Recipes 25 to 50 Unlimited Limits set by running times

Alarms / messages 30000 Unlimited Object dependent Number of message archives 1 1

Number of current message archives 1000 2000

Number of long-term message archives 8 days 30 days

Message burst without message loss 50 100

Messages permanent 2/ sec.

Note: Some of the maximum values are significantly larger than the typical values and can normally be "approached" when other requirements are reduced. The typical values apply in combination and have been tested in this form.



System Performance CEMAT V5

The times listed here have been measured in a test. Note that some of the test pictures used here have a complexity that is seldom reached in practice: Test conditionen: - Multiclients with PDL-Cache - Network Hardware CP1613, CP443-1 / 100Mbit , OMS - cyclic service activ


Picture selection time Incl. initial update of the picture without additional background loading

Picture with purely static content 1 s 1 s

Picture with 140 controls, 100 bitmaps

2 s 3 s

Picture with 240 controls 3 s 5 s

Picture with 70 digital and 2 curve displays each with 6 curves

3 s 5 s

Dialog selection in the process picture 1 sec 1 sec Variable updating 1 sec 1 sec Process event -> screen

Operator response 1 sec 2 sec Operation and confirmation

AS response time

AS response time S5 0.3 sec 0.8 sec 1 cycle

AS response time S7 0.2 sec 0.4 sec 1 cycle

Curve output

Output/selection trend archive 2 sec 2 sec 6 curves Output/selection long-term archive 10 sec

Max. value depends on the selection criterion

Output/selection message archive 2 sec 32 sec Max. value depends on the selection criterion

Establish protocol 10 sec Max. value depends on the log type and interval



Memory Requirement Typical Maximum Comments

Pictures

Storage capacity on HD 300 kB > 900kB

Storage capacity for a control 30kB 40kB Approx. 400 controls (stat. or dyn.) per picture

Measured value archive

Memory for archive 28 byte/ meas. val.

Message archive DBASE III archive 468 kB

for 10 000 records



Device Functionality and Configuration Examples CEMAT is built in a modular fashion, i.e. you can configure your control system to meet your wishes and requirements.

Device Designations and Functions: OS Operator Station (Multiclient) An OS is designated as being a process operator station that uses the Infobus to communicate with the servers. Functions: - Administers picture data (in case of PLC-Cache use) - Communication with servers - Process management user interface present.

Server A server is designated as being a PC that can communicate with SIMATIC- S5/ S7 PLCs and OS stations. The process image is maintained and the archiving of the messages / measured values performed on the server unit. Functions: - Administers message archives - Administers curve archives (when curve server activated) - Communication with PLCs - Communication with OS devices - Central confirmation and recipe administration - As a multi-user system it can supply 16 OS devices.

MVA Curve Server (for more than 1000 measured values)

A MVA is designated as being a station that can communicate with SIMATIC PLCs and OS stations. The curve server runs on the MVA. Functions: - Administers curve archives - Communication with PLCs - Communication with OS devices.

ENG Engineering Station An ENG is designated as being a central engineering station. Functions: - Engineering of PLC and OS applications with the PCS7 data manager. - Process picture creation with WinCC - Central storage of the engineering data - Administers picture data - Process management user interface online test - Communication with ASes - Remote diagnosis using RAS - Step 7 Software - Step 5 Software can be installed if needed.

AS or AG Automation Unit Base functions for open/close-loop control, measurement, groups, paths Communication to the control system Communication from AS to AS



Terminal bus: Via terminal bus the (TCP/IP protocol) the OS Server data is transfered to the Multi Clients

Plant bus: Via plant bus (PROFIBUS, Industrial or Fast Ethernet) the interconnection between PLCs is performed and the Process values are transfered from the PLCs to the OS and OS Servers.

Field bus: The field bus transfers the process values from decentralised peripheral units to the PLCs. Some of the field units can be parametrized via this bus.

OSM/ ORM/ Switch: With the Optical Redundancy Manager and the Optical Switch Modules of the Fast Ethernet it is possible to build an optical ring with a baudrate of 100Mbits.

Printer: Print output to a file or the printer - Selectable connection of the printer (parallel, serial, remote printer) - Support for all printers that can run under Windows NT

Printer types: - Hardcopy printer to print a process picture - Logging printer to print a message list or a recipe - Engineering data printer to print the project data.

Availability, Redundancy The SINEC H1 bus has to be installed as a ring. In case of two CP 443-1 in one PLC a CPU 417H is required.

In a control system, any PLC can be operated from any operator station.

The following applies to CEMAT V5: At least 2 servers, or for smaller plants, 2 engineering stations must be installed so that the operator control and monitoring functions can be performed with the other device should one device fail. When 2 servers are used, the associated OS stations of the failed server automatically switch to the second server. Because the message server and the curve server run on these devices, the redundancy is also provided for messages and curves.



Configurations

SIMATIC S7-400

Terminal BusFast Ethernet

ET 200MField Technology

Intelligent Peripherals

Plant bus Fast Ethernet

Field bus Profibus DP

Field bus Profibus PA

PMS / MIS

Operator StationOS – Single-User

Engineering Station

1- 6 Redundant OS -Server

Operator Stations 1 - 16 Multi Client

for each OS-Server

Leistungsbeschreibung Brief Description / Data Sheets


Example configuration with 6 Servers

MC 1

ORM Sv2

ES 1

Sv3Sv6 ES

3/ 5

CP1613 CP1613

3Com 3Com

MC 18 SICLOCK TM

S7-416

No 1 S7-416

CP443-1 CP443-1Fast Ethernet: One „Ring“ for T and S-Bus

Sv4

CP1613

3Com

S7-416

No 7

CP443-1

Sv5

CP1613

3Com

S7-416

CP1613

50 % of the multiclients are assigned to the default server x.1

and 50 % are assigned to default server x.2

ES V ith

Sv1

CP1613ES 2

3Com 3Com

ORM

CP443-1



Example 3

Operator Station

Automation Systems

Brief Description / Data Sheets

3 - 19

Specification

CEMAT V5

General Object Description

A&D AS CC CP

General Object Description CEMAT V5


Table of Contents

CEMAT V5 i

General Object Description 3

CEMAT modules......................................................................................................3 Introduction to the module description (AS).............................................................4 General display rules (OS).......................................................................................9 Representation types of the objects ......................................................................12

Symbol ......................................................................................................12 Faceplate ..................................................................................................13 Diagnostic dialog.......................................................................................15 Limit value dialog ......................................................................................17 Parameter dialog.......................................................................................18

Operator control and monitoring with picture modules ..........................................19 Where does operator control take place?.................................................19 Limit-value dialog - Operation...................................................................21 Parameter-table dialog - Operation ..........................................................21 Group-state dialog - Operation .................................................................21 How are operator commands entered? ....................................................22 Who can monitor?.....................................................................................23 Logging of operations ...............................................................................23 Message class ..........................................................................................24

Infoserver - Description..........................................................................................25 Display ......................................................................................................25 Operator Control .......................................................................................26 Configuring................................................................................................28

Message Line Functionality ...................................................................................30 Display ......................................................................................................30 Operator Control .......................................................................................31 Configuring................................................................................................32

Extended Diagnosis with the Interlock Module ......................................................33 Display ......................................................................................................33 Operator Control: ......................................................................................33 Configuring................................................................................................34

Adapter Module for Non-CEMAT Modules ............................................................35

2 • Table of Contents General Object Description

Display...................................................................................................... 35 Configuring ............................................................................................... 35

Multimedia Interfaces ............................................................................................ 39 Display...................................................................................................... 39 Configuring ............................................................................................... 39

CEMAT Object Browser ........................................................................................ 41 Display...................................................................................................... 41 Configuring ............................................................................................... 42

CEMAT Message Dialog ....................................................................................... 43 Display...................................................................................................... 43 Operator Control....................................................................................... 46 Configuring ............................................................................................... 48

Storable Message Selections................................................................................ 49 Display...................................................................................................... 49 Operator Control....................................................................................... 49 Configuring ............................................................................................... 49

Technical questions regarding the PCS................................................................ 50

System General Object Description


General Object Description

CEMAT modules The library "ILS_CEM" contains all blocks which are required for a running CEMAT PLC. The Reference Manual Objects describe the functions of the CEMAT Object modules. All further Blocks are listed in the general documentation of PCS 7.

This chapter describes the general information about the CEMAT modules which is not specific for a certain object. You will find information about performance, an introduction to the module description (AS), general display rules (OS) and the representation forms of the objects.

In addition you will find operating instructions for the HMI.

Module data FB/FC Number

Module (Type Name)

Comment from symbol list

FB1001 C_DRV_1D Unidirectional drive FB1002 C_DAMPER Damper FB1004 C_ANNUNC Annunciation FB1006 C_MEASUR Measured value FB1007 C_VALVE Valve FB1009 C_ROUTE Route FB1010 C_GROUP Group FB1011 C_SILOP Silopilot FB1013 C_SELECT Selection FB1015 C_COUNT Counter FB1016 C_RUNNT Run time FB1020 C_FB_PLC AS object FC528 OB1_SYS2 ILS OB1 end FC529 OB35_SYS1 ILS OB35 start FC530 OB35_SYS2 ILS OB35 end FC1001 C_SPEEDM Software speed monitor FC1011 C_SPCNT Pulse acquisition silopilotFC1017 C_MUX Multiplexer group/route FC1088 C_PUSHBT Console keys FC1102 OB1_SYS1 ILS OB1 start FC1103 C_OB1SY1 CEMAT OB1 start

CAUTION: The modules specified in the table require the following FB,FC and DB:

DB678-DB682 FB50, FB1030 FC509 to FC530 and FC1061, FC1062

** not relevant



Cycle-time measurements for sample configuration: Group Route Select Motor Damper Annun. Meas.

value Valve SP Cycl.

S7 PBK Compil.

min. Load min.

Map.min.

18 52 36 90 15 150 60 45 0 158ms 472 2.5 2 7 20 30 40 200 30 300 200 20 6 302ms 846

Communication resources (PBK) for CPU 416-2 max. 600 i.e. number of CEMAT modules, max. 550 CPU 416-3 max. 1800 i.e. limitation via the cycle time

Introduction to the module description (AS) The module descriptions always have the same form. This helps you to find the required information quickly when you read the description of the individual module. Here is a description of the sections:

Type/number The listed blocks have to be called if you want to use the object. The blocks are listed with name and number.

Module name: Unique name of the S7 Block, e. g. C_DRV_1D For the CEMAT Objects this corresponds to the name of the object type.

Module no.: Unique number of the function block (FB) or function (FC)

Calling OBs This provides details of the organizational blocks (OBs) in which the described block must be installed.

In contrast to the general PCS 7 libraries the CEMAT library has some specialties. Most of the CEMAT blocks must be called exclusively in the OB1 task. Exceptions to this are the counter and the pulse evaluation of the software speed monitor and and the silo pilot. These blocks can be called in a time interrupt OB. Detailed information is available in the object descriptions.

Some blocks of the system chart have to be called in more than one task, e.g. the system part of the PLC-PLC coupling. If you copy the complete system chart from the delivered library into the S7 program of your project, the blocks are automatically called in the right tasks.

When you install the modules in the CFC they are automatically called after the most recently installed module. If necessary, you must change the processing sequence with the run-time editor. The CFC creates the necessary OBs during the compilation.

Function This contains a summary of the function of the module. The section operating principle contains further information for complex modules.

Operating principle This contains more detailed information on the function of individual inputs, operating modes, time processes, etc. You should understand the interrelationships described here in order to use the module effectively.

General Object Description System


Error handling The error display is located in the CFC plan at the ENO Boolean module exit. The value corresponds to the BIE (binary result in STEP 7-STL on completion of the module) or the OK bit (in SCL notation) and means:

ENO=BIE=OK=1 (TRUE) -> the module result is correct.

ENO=BIE=OK=0 (FALSE) -> the result or the general conditions for this calculation (e.g. entry values, operating mode, etc.) are invalid.

Start-up charactristics A differentiation is made between:

First run The module is called initially from the OB in which it has been inserted. This is usually the OB in which the normal, process-related processing takes place (e.g. OB1). The module is preset with the status corresponding to the input parameters. These can be default values (also refer to I/O bar) or previously configured values, which, for example, you have parameterized in the CFC. No special start-up behavior is described unless the module deviates from this rule.

Start-up The module is processed once during a CPU start-up. To ensure this, the module has to be called from a start-up OB (where it is included automatically by the ES). The start-up behavior is described in this case.

The CEMAT object modules don’t have start-up characteristics. The blocks are called exclusivly in the cyclical program.

Time characteristics A module with time characteristics must be installed in a cyclic interrupt OB. It calculates its time constants/parameters using its sampling time (the time interval between two successive, cyclical processing steps). The sampling is determined by the step downs for the so-called run-time group. This ensures that the module is not processed for every OB passage. This sampling time is entered in the I/O bar, in the SAMPLE_T parameter.

The time behavior is mentioned only when the module exhibits such behavior.

The CEMAT object modules don’t have time characteristics. However for some of the objects the run sequence is important. This is described under time characteristics.



Annunciation characteristics The module with this behavior reports various events to the higher-level OS. When present, the parameters needed to create the annunciation are documented. Modules without annunciation behavior can be augmented with additional annunciation modules. The description for modules with annunciation capability contain an indication of the annunciation behavior.

Module states The status of the CEMAT Objects is shown in the symbol through change of the bitmap or change of the color and in the faceplate through a short info text. The presentation of the visualization status is shown under module status.

Commands The possible commands for the object are listed in the OS variables table.

I/O bar of ... The I/O bar provides the data interface for the module. You can use this to pass data to the module and to fetch results from the module.

Element Meaning Format Default Type Attr. HMI Permitted

Values U1 Summand 1 REAL 0 I Q + >0

The "I/O-bar" table shows all input and output parameters of the module type which the user can access with his configuring means. Those elements that can be reached only from the module algorithm are not listed (so-called internal variables). The columns have the following meaning:

Element Name of the parameter, derived from the designation, e.g. PV_IN = Process Variable INput (process quantity, control quantity). Where appropriate, the same name convention as for SIMATIC is used.

Meaning Function (possibly short description)

Format S7 data type of the parameter (BOOL, REAL, etc.).

Default The value of the parameter before the module runs for the first time (provided it has not been changed during the configuring).



Type Type of the module algorithm access to the parameter; a differentiation is made between inputs, non-isolated inputs and outputs (refer to table).

Parameter Types:

Abbreviation Type I Input. Value supplied to the module (display in the CFC: left-hand

parameter list) O Output. Output value (display in the CFC: right-hand parameter list) IO Input/Output. Non-isolated input, which can be written from the OS and

rewritten from the module (display in the CFC: left-hand parameter list)

Attr. (Attribute) Additional characteristics of the parameter when used under CFC. Non-connected input and input-output parameters can be parameterized (only input-output parameters for online FCs). Output parameters cannot be parameterized and can be transferred in the CFC by connecting to an input of the same data type. Additional or deviating properties of the parameter are specified as follows:

Attributes of the parameters:

Abbreviation Attribute B Can be operated (only using the OS). An OS can make write access to the

element. It is implicitly not visible in the CFC. E Transferred to the OS when changed M MESSAGE ID not parameterizable for annunciation module (e.g. ALARM

8P). ID specified from the annunciation server. Q Connectable. The element can be connected with another output of the

same type. U Not visible in the CFC. Because the element is supplied by the CFC or the

OS, it is not displayed in the CFC (e.g. message ID). It is a default value that can be changed in the CFC.

HMI The parameters marked with "+" can be changed and monitored from the associated OS module.

Permitted values Additional limitation within the data type value range.



OS variables table In the OS variables table the detail information for all HMI variables is llisted for the object type. These variables are used to exchange information between AS and OS.

The following information can be seen in the table

S7 Parameter Name Parameter name used in the S7 program (internal information)

Assignment Symbolic name of the parameter used in the CFG-File (internal information)

OS Variable No. Variable number used in the CFG-File (internal information)

Designation German Description text of the parameter in german

Designation English Description text of the parameter in english

Output level Where is the information shown in the OS S = in the Symbol O = in the Faceplate D = in the Diagnostic dialog

Presentation Number/NK Number of Digits for representation on the OS Unit Unit of the value Type Parameter type I = Input O = Output I/O = In/Out

Value range Value can be entered between this range

Annunciation Class Message class, e. g. ALF = PLC Control System Annunciation

Fault Class Classification according to the origin of the fault E = Electrical S = Safety M = Mechanical P = Process

Event Text Text which is displayed in the alarm line

Operator Authorization Assigned authorization code according to the user administrator (see list under “Operator Authorization”)



General display rules (OS) Prerequisites PCS7 must be installed in order to use faceplates. The base data wizards from PCS7 must also be executed. The Splitscreen Manager must have been configured.

Text and color layout Text

The Arial font is used as standard. The following classes are available:

Class Type size Character font Output 10 Bold Input / Keys 10 Normal Labelling (frame) 8 Normal

The colors are specified as follows.

Fields

Color Class Type Background Character / Frame Input Frame White Black Output Frame Gray Black Keys 3D Gray Black

Bars and Annunciations

Color Class Symbol Character / Frame Actual value Green White Setpoint White Black Control output Cyan Black Alarm Red White Warning Yellow Black System fault Black Yellow Operation call, substitute value Blue White



Switching states

Color Class Symbol Character / Frame Off Gray Black Error Red White Not Ready Violet White Ready Light blue Black On Blue White Switching Yellow Black Running Green Black Local mode Yellow Black Single mode Cyan Black

Operational states

Color Class Symbol Character / Frame Automatic White Black Manual White Black Single mode Cyan Black Local mode Yellow Black Unlocked mode Orange Black

Number format The number formats are formed automatically using limit values and number type. The display with comma or decimal point depends on the language. (German = comma, English = point)

Limit value for the number Number format Absolute value >= 0.1 to <10 +/-1.2345 Absolute value >= 10 to <100 +/-12.345 Absolute value >= 100 to <1000 +/-123.45 Absolute value >= 1000 to <10000 +/-1234.5 Absolute value >= 10000 to < 1000000

+/-12345

All other cases +/-1234e+/-12



Analog value representation The analog values are displayed as floating-point values as follows:

values: max. five digits, sign and decimal point

overflow "*****"

leading zeros: are suppressed

invalid values: gray (e.g. for AS failure)

decimal point: can be defined using the property setting

status colors : the background color of the output field is changed depending on the status value. (alarm, warning, life zero, service)

Operator authorization The operator authorizations are specified for each operator control. The following authorizations are provided:

Monitoring PCS7 level 4 is needed for:

invocation of the faceplate Process operator control PCS7 level 5 is needed for:

manual operation changing the operating mode changes to setpoints

High process operator control

001 User administration 002 Authorization for area 003 System change 004 Monitoring 005 Process controlling 006 Higher process controlling 007 Report system 008 Archive controlling 018 Modify warning limits 019 Modify alarm limits 020 Modify switching limits 021 Controller parameters 022 Object parameters 023 System operations 024 Interlocking signals 025 Enter recipe data 026 Read recipe data 027 Write Service data

The PCS7 can be used to specify these operator authorizations for each area. This means that the picture hierarchy also affects the operator authorizations . Every user can be given different operator authorizations for each area. Operator groups can also be formed.



Representation types of the objects The picture modules have various representation types. The user can choose between the following views:

Symbol Faceplate Secondary dialogs (diagnosis, information)

Symbol The symbol is the simplified view of the associated AS module. The symbol can contain the following information in accordance with the representation type:

Plant identification (TAG) Symbolic status display of the AS module Setpoint, actual value Limits Annunciation / operating status display

The following diagram illustrates the symbol of a picture module.

Representation types:

1 = Bitmap 2 = Setpoint dialog high dialog 3 = Setpoint / actual value dialog 4 = Manipulated variable dialog mini dialog

2 3

4

1



Faceplate The faceplate provides a detailed view of the associated AS module. The following diagram illustrates the faceplate for a damper.

The faceplate has the following structure:

Heading lines: The heading line contains the plant identification and the associated comment for the AS module.

Module status display: This shows in plain text the status of the AS module assigned to the picture module.

Object function operator commands:

Use for direct process control

Depending on the module states and authorizations, the operator control elements are made visible and activated for the user.

Invocation buttons for secondary dialog :

Six buttons can be used to specify different secondary dialogs or commands in conjunction with the object. The secondary dialogs can contain the following items depending on the type:

Diagnosis Display AS module diagnosis

Info Object-related information (only with ODI AddOn)

Limit value Display and setting of the limits for measured values and setpoints

Parameter Parameter settings such as GAIN, TV, TN, etc.

Trend Display of the WinCC curve window

Alarm Display of the WinCC message window



Maintenance Information and parameter settings for maintenance personnel

The individual secondary dialogs are always visualized together with the faceplate.



Diagnostic dialog The diagnostic dialog has the following structure:


Interface word display: This displays the interface status of the AS module assigned to the picture module.

Input signal states These are indicated using colored circles.

Signal state: "0" = gray "1" = green

To indicate the preferred signal states always needed to start an object, these interfaces are listed in "green" with a "dark gray background".

Process parameter operator control: Process parameter output values are displayed with black lettering on a gray background; process parameter input values are displayed as a white, inset box with the value shown black.

Parameter field: This displays the hardware signal states of the object.

Operating time acquisition: Depending on the object type, the running times are displayed in hours or as the number of operations.

A pushbutton can be used to reset this display; this reset time is also visualized.

Module outputs: The output signals important for diagnostic evaluation are displayed together with their status.

Releases: Depending on the object type, function or annunciation releases are visualized.

Faults: Colored squares indicate faults.

Signal status "0" = gray (no fault) "1" = red (fault)

Object function operator control: Invocation keys for input-output assignment, service manual, help dialog, printing window permit the invocation of secondary applications that display detailed information on this particular object. ("Diagnostic" AddOn needed)



Display example:

Damper diagnostic dialog



Limit value dialog The limit value dialog has the following structure:


Operator control range: This dialog is used to set lower and upper limits for the setpoint. The setting is made using a slider or with direct value input. A bar display shows the setpoint within its limits.

Invocation / operator control buttons: Help, Save, Close The Transfer button sends the changed limit values to the AS.

Sample display:

Damper setpoint limits



Parameter dialog The parameter dialog has the following structure:


Process parameters: This dialog is used to set the controller parameters. A yellow frame shows the currently active PID parameter set.

Curve window: A curve window displays the setpoint, actual value, and the manipulated quantity.

The Ruler button displays a ruler and the associated display of the values for W,X,Y at this ruler position.

Sample display: Controller

Controller parameter table



Operator control and monitoring with picture modules

Where does operator control take place? Operatable objects are shown with cursor presentation-change, if these surfaces are contacted by the cursor. Thereby object symbols, value-presentation-fields or complete dialogs serve for dot sensitive surfaces.

Furthermore after a short cursor dwell time over the object, the tool tip text is displayed.

Symbol operation: If there are buttons or input fields in the object, the specific programmed functions are executed with a singleclick on these elements The faceplates (input fields) are displayed there as panels with a white background. The panels with a gray background are display-only panels and cannot be changed.

By clicking the different mouse buttons on any object you can trigger the following functions.

Left mouse button

Single click On a symbol Open faceplate On a jogging

button Change value by one decade

On a value panel A bar cursor indicates readiness for input or (value shown in red during the change) an input dialog is opened

Double click On a jogging button

Change value by a tens decade

Press and move Change value using slider The limits for changing the setpoint are displayed left and right above the slider button

Middle mouse button Single click No function

Right mouse button Single click Open the object help window or, if available,

the property box

Operator control windows or info-boxes must always be closed by the operator (no automatic closing after command triggering).



Faceplate operation: In a faceplate, only object-specific operations which are necessary for the process control are possible.

Left mouse button

Single click On a button A continuation dialog is opened or a command is sent to the PLC

On a jogging button

Change value by one decade

On a value panel A bar cursor indicates readiness for input or (value shown in red during the change) an input dialog is opened

Double click On a jogging button

Change value by a tens decade

Press and move Change value using the slider until the setpoint limits are reached

Middle mouse button Single click No function

Right mouse button Single click No function

What is concealed behind the dialog buttons?

Limits: Setpoint limit setting Help: Operation description Diagnosis: Presentation of PLC data like process parameters and states Information: Presentation of local labels, annunciation-system information, user info-texts Close: Close the dialog box



Diagnosis dialog - Operations Only process-parameter inputs and button operations are possible in this dialog.

Left mouse button Single click On a button A continuation dialog is opened or a command is

sent to the PLC On a value field A bar cursor indicates readiness for input or

(value shown in red during the change) an input dialog is opened

Limit-value dialog - Operation See diagnosis dialog

Parameter-table dialog - Operation See diagnosis dialog

Group-state dialog - Operation No additional operations other than "Close".



How are operator commands entered? To avoid incorrect operation to the largest possible extent, the operator must always confirm process commands and parameter changes (two-level operation). The entered value is written to the corresponding entry of the AS module only when this confirmation has been made (exception: jogging operation).

How are numeric input fields used? Enter the new value into the operatable field, or click on the Up/Down buttons.

The "old value" always appears for a value input field. "Return" must be used to terminate the "new value input".

Press the "ESC" key to cancel a "new value input".

Result: The software checks the plausibility of the entered value. If the limits are undershot or exceeded, a warning box is output or the input value is displayed flashing together with the violated limit. The value is the written in the AS module when it lies within the limits. If a bar display is provided, this adapts itself to the newly selected value.

Value changes are subject to a specific operator authorization level and can be performed only when the operator possesses this right. This ensures that only a certain operator group can perform these parameter changes, if required.

The operator authorization is not automatically revoked.

How are jogging keys used? In jogging operation, click on the provided keys. The value changed by the corresponding delta values is then written into the AS module without confirmation.

Special processing: "single click" represents a change to the value by "a decade" of the value "double click" represents a change to the value by "a tens decade" of the value.

The value can be changed only as far as the limit value; it is not possible to enter a value that lies outside these limits.

The authorization prompt is also active here.

How is the slider used? When a value is changed using the slider, the "new value" is always shown in the associated input field. The numeric values appear in red. Coarse positioning is performed by selecting the slider button with the cursor and moving the slider button while keeping the left mouse button pressed. A single click on the arrow keys on the left and right side of the slider can be used to make a fine adjustment to the input value. The input value is limited by the lower and upper setpoint limits, which appear over the arrow keys. "Return" must be used to terminate the "new value input".



Who can operate? The operation of process values and changes to parameters is possible only with specific user authorization. The authorization levels are assigned during the login of the associated user and specified in WinCC.

The picture modules use parameter-dependent authorization levels, in particular:

004 Monitoring 005 Process operator control

018 Modify warning limits 019 Modify alarm limits 020 Modify switching limits 021 Controller parameters 022 Object parameters 023 System operations 024 Interlocking signals 025 Enter recipe data 026 Read recipe data

The assignment of the authorization levels is described for the individual picture modules.

Who can monitor? When an operator has control authorization for a plant section, he can monitor all picture modules present in this plant section.

Logging of operations The WinCC annunciation system records every process operation/parameterization. The following values are passed to the annunciation system:

Time of the operation (date, time) Message type Incoming message Parameter name Old value New value Batch designation Plant identification Area Batch name Command text Name of the logged in operator Unit



Message class Assignment of messages according to their cause. The SIMATIC process control system uses the following message classes:

Process messages that are initiated when process-specific monitoring values are reached or violated (e.g. alarm, warning, upper/lower tolerance, general process messages).

Control system messages issued by the control system (system messages), by the peripherals (fault in the field) or for preventative maintenance.

Operator control messages that warn the operator that he needs to intervene for certain processes (e.g. operator control to confirm a manual step control to continue) or operator control logs.

The table shows the possible message classes and their meaning

Message class Meaning

AH High High Alarm

WH High Alarm

WL Low Alarm

AL Low Low Alarm

TH Tolerance High

TL Tolerance Low

F Process Fault (Field)

S Control System Message (System)

ALF PLC Control System Fault

M Preventitive Maintenance (Maintenance)

PM Process Message

OR Operator Request

OM Operation Message



Infoserver - Description

Display

Information Dialog The information dialog is available only with the "Information server" add-on and is organized as follows:

Header lines: The header lines display the general location designations and the installation location of the object with the plant structure.

Registers: They contain standard information about - Input/output descriptions with overview plan key - MCC descriptions with overview plan key - AS hardware and software modules with overview plan key - Service inputs for Loop in Alarm, etc.

User notes: The user is also given the capability to store his own information text.

Message output: The object-related messages are output in a message window.

Sample display:

Drive set-up information dialog



Operator Control This dialog provides the control room operator only with information text input and key operations.

Given special operator authorization, additional definitions can be entered in the "Service" register.

Click on a register to display its parameters in the foreground.

Left mouse button

Single click on a key To open a secondary dialog or switch a register, or to execute message line functions

on the notes field A bar cursor indicates readiness for input

Center mouse button

Single click No function

Right mouse button

Single click No function

What do the secondary dialog keys initiate?

The keys are assigned to icons, the descriptions follow from left to right.

Diskette: Save the user notes and service entries (no secondary dialog) Sound input/output: Dialog with sound recording and replay mechanisms (USER) Location plan: Display of the exact position of the object in the works (USER) Service manual: Descriptions for trouble-shooting for this object (USER) Video guide: Video description for trouble-shooting (USER) Circuit diagram: Circuit diagram of the object (not displayed) Function plan: Locking logic for this object (not displayed) Help: Description of the contents and the operation of this dialog Exit: Close this dialog.

Each register contains a key that can call the hardware drawings on this topic.

Input/output assignment:

Assignment of the input/output cards (cabinet assignment)

MCC field: Assignment of the MCC cabinet (cabinet assignment) AS hardware: Construction of the cabinet in which the AS is installed which this object

belongs to (cabinet assignment).



How are the user notes entered? – Place the cursor on the user notes field and "single click". – Enter the text with line-feed + Ctrl at the end of the line.

Once the text has been entered, "single click" on the "Diskette key“ (1st on the left) to save.

Which operations are available in the message window? The functions of the 12 icons that appear in the message window command line are listed below:

1. Select message lists 2. Select short-term archive 3. Select long-term archive 4. Scrolling on/off 5. Specify selections 6. Output log 7. Go to the start of the message list 8. Go to the end of the message list 9. Select the next message line below 10. Select the next message line above 11. Information text for the selected message line 12. Comment for the selected message line.

In the "Scrolling OFF" state, the horizontal scrollbars (below the messages) can be used to display additional message line information.

Which inputs are possible in the Service register?

1. Loop in Alarm picture name that is invoked from the alarm line.

2. Special sound information file 1, USER application multimedia, e.g. sound recording

3. Special sound information file 2, USER application multimedia, e.g. sound output for text files

4. Location plan coordinates, USER application multimedia, e.g. position of the object in the works

5. Video file designations, USER application multimedia, e.g. maintenance guides

6. User manual, USER application multimedia, e.g. starting guides for the group...

7. Spare

8. Spare



Configuring 1. You need a license to process the user archive.

2. To create the user archive: - Open user archive in the WinCCExplorer - Project -- Import -- Select File: d:\CEM_V5\UA\C_INFO.UAP - Click Load File.

3. Enter/edit user archive project data:

The following section describes the structure of the Excel import files in which the project data must be entered.

- The Import function can only be used to import new data records. i.e. first export the complete contents of the user archive and then delete.

- Then copy the sample import file or edit the previously exported file and associated project structure in Excel.

- Important: ID and Obj_ID must always be numbered consecutively.

Field designations:

GL_ = General Location

G_ = General Parameter

I_ = Input Register

M_ = MCC Register

H_ = Hardware Register

Structure of the user archive in the Excel structure: A = ID B = Object_ID C = Plant identifier (AKZ) D = GL_Complex E = GL_Plant F = GL_Plant_Zone G = GL_EQUIPMENT H = GL_Location_object I = GL_ Location_LocalSwitch J = G_Loop_in_Alarm K = G_Infotext L = G_Sound1 M = G_Sound2 N = G_Draw_Position O = G_Video P = G_Document Q = G_Grouplist (blocked from the user) R = G_Spare2 S = I_Building T = I_Location U = I_Area V = I_Cabinet W = I_Rack_Q X = I_Slot_Q Y = I_Rack_I Z = I_Slot_I AA = M_Building _I AB = M_Location



AC = M_Area AD = M_Cabinet AE = M_Feeder AF = M_Fuse AG = M_Bimetall AH = H_Building _I AI = H_Location AJ = H_Area AK = H_Cabinet AL = H_Rack AM = H_PLC_Name AN = free AO = USER_NAME AL = ERSTELLUNGS_ZEITFORMAT (CREATION_TIMEFORMAT)

4. Import project data - Select C_Info (or new file) – click Import - "Runtime data" icon must not be selected - The C_Info archive appears in the editor - Select -- Runtime Data -- Import --- click "Save" icon - Maintain the following sequence in the import mask

1. Select archive -- C_Info 2. Select file -- d:\cem_V5\UA\C_INFO.csv select – click Open key 3. Click Import key

- The " Import completed successfully" dialog must appear after the import.

- Select "Runtime data" icon -- the user data must be displayed.

5. Release Information dialog call in the configuration file of the corresponding module type (refer to Motor)

[Caption]

T1=Start T2=Stop DB1= DB2= DB3=Help DB4=Diagnosis DB5=Information (the dialog cannot be invoked if "Information" has been deleted) DB6=Cancel



Message Line Functionality

Display

Message line functions

A message line can contain the following information (from left to right): Incoming date/time of the message Plant identifier Fault type Message text Fault class. (P = process, E = electrical, M = mechanical, S = safety (emergency off)) Value output for special messages.

The message line displays only non-acknowledged messages from the selected plant sections.

A newly arrived message - Always appears immediately in the message line (even when operations are being performed on the previously displayed message). - Produces an acoustical signal that continues until it is reset by clicking an acknowledge key.

If several messages arrive quickly in succession, the acoustical signal for the latest message is output.

The acoustical signal can be activated/deactivated in a parameterization box.

Color attributes The messages are displayed in the following colors depending on the message class and message state:

Alarm Warning Oper. / Change.

Sys

Message arrived white / red black / yellow black / blue white / violet

Message sent white / light green white / light green - black / light green

Message arrived. Acknowledged.

black / pink black / light yellow - white / dark pink

Message sent. Acknowledged.

white / dark green white / dark green - white / dark green



Operator Control The three additional keys placed at the right of the message line initiate the following functions:

key L - left mouse button (SC) - Invoke alarm picture (Loop in Alarm). This is the process picture in which the faulty object is displayed.

- right mouse button (SC)- Select plant selections for message output, and enable or disable the sound.

key I - left mouse button (SC) Invoke information dialog for the object. key Q - left mouse button (SC) Acknowledge pending messages until the message line is empty.

When a message is acknowledged, the next non-acknowledged messages move up and an acknowledge telegram is sent to the automation unit from which the message came.

Plant section selections for the message line If no selection has been made, all messages are output by default.

If only messages from specific plant sections are displayed in the message line, this plant section must be moved from the left-hand listbox into the right-hand listbox. (Double-click on the required entry)

Operator stations with the same selected plant sections mutually acknowledge their messages.

Activate sound for this station.



Call object information dialog Object information is the information that belongs to the associated object (motor, damper, measured value,...) and is not linked to the message entry. An entry in the information dialog has a fixed assignment to the object and can also be written or read from a process picture.

Information dialog for the message line

Configuring 1. The Loop in Alarm picture designation must be stored in the information server for each object.

2. The name of the sound file can be stored for the instances in CFC, in message text 10. If no text has been entered there, the standard sound file, as defined in c_config.cfg, will be used.



Extended Diagnosis with the Interlock Module

Display When an interlock protective circuit is present, the corresponding interface is indicated with a blue point in the diagnostic dialog of the associated module type.

The interlock dialog displays the input parameter name of its logical state and the subsequent interconnection.

In an error situation, the input signal is displayed with a red background.

For the control room operator meaningful designations should be chosen for the input parameters.

Operator Control: A single click on the corresponding interface designation opens the Interlock dialog.

Clicking on the "Close" key terminates this dialog.

Further functions are not enabled.



Configuring

AS: CFG Plan editing example:

The assignment of instance names is particularly important when the Interlock module is used.

Depending on the "main object", the name is formed as follows.

For example, C_DRV_1D motor with plant identifier "FK11/E001" should be given an interlock protective circuit on the input interface "ESVG".

The name of the interlock module instances consists of:

FK11/E001 = main object _ESVG = interface description 1-3 = number of the interlock modules, max . 3 units

i.e. FK11/E001_ESVG1 is the name of the first interlock module.

Please note: - Correctly select the interconnection logic (red background means error) - Assign the signal designations for the control room operator with understandable text.

OS: No further parameterization is necessary.

However, the module must be mapped (i.e. be visible in the OS variable management).



Adapter Module for Non-CEMAT Modules

Display No user interface

Function

The C_ADAPT can connect "non-CEMAT modules“ to CEMAT groups and paths. In the case of faults of the "non-CEMAT module", this is also displayed on the collective display for group / path. When a status call is made, the TAG and the module comment from the "non-CEMAT modules" are displayed in the status messages window.

Configuring

Method of operation

Input interfaces

FAULT Pointer Initial state 0-signal

This input must be connected with an output of the non-CEMAT module. The output of the non-CEMAT module must have the 1-signal for a fault. NOTE: Only FBs with an instance-DB can be interconnected.

FT_NACK Fault not acknowledged Initial state 0-signal

When the non-CEMAT module has an output that indicates 1-signal for a non-acknowledged fault, you can connect this output with FT_NACK. For 1-signal at FT_NACK, a red flashing light indicates a started group / path.

AMZS Fault locking for the group Initial state 0-signal

A 1-signal on EMZS locks the display of the fault on the group fault lamp (red).

Typical application

Refer to C_DRV_1D EMZS interface.

Links

The failure of the drive is represented as a collective fault in the status display of the associated group / path. The Status Call function for group or path displays the fault details. To ensure this function, each drive must at least be interconnected with a path or group to which it belongs with regard to signaling.

GR_LINK1 Associated group/path

The GR_LINK1 interface of the drive must be connected with the R_LINK interface of the path or the G_LINK interface of the group.



GR_LINK2 Associated group/path

If the drive belongs to two different paths or groups, the GR_LINK2 interface must be connected with the second path/group.

MUX_LINK For several groups/paths

If the drive belongs to more than two paths or groups, the C_MUX module must be connected upstream. C_MUX has 5 inputs (GR_LINK1 to GR_LINK5) for connection with the groups/paths and an output (MUX_OUT) for connection with the MUX_LINK interface of the drive.

Note: Under no circumstances can the MUX_IN interface be used for the direct interconnection with group or path. It is used exclusively for interconnection with the MUX module.

Example: Non-CEMAT module using C_ADAPT assigned to a CEMAT path module.



Output interfaces

P_ERROR Parameterization error

The FAULT input must be connected with an output signal of the non-CEMAT module. The non-CEMAT module must be a FB that has an instance DB.

No inputs, outputs or flags may be switched to the FAULT input, otherwise P_ERROR indicates -1.

INST_DB Instance DB of the non-CEMAT module

You may only switch signals to the FAULT input from FBs that have an instance DB. The C_ADAPT cannot recognize when you interconnect an FC. To allow you in the case of any problems to test whether the correct module has been interconnected, the C_ADAPT displays the number of the instance DB.

Time behavior

The ADAPT module and the non-CEMAT module must be called before the associated path or group.

Any called C_MUX modules must run prior to this module.

Signal behavior

The module does not issue any messages.

Commands

There are no commands.



Edit CFG file No additional parameterization is necessary to permit the display of "non-CEMAT" modules in the group status call.

In this case, only the plant identifier and the comment are displayed (no fault type).

However, if the "third-party module" has a status word with defined states, these states can be written in separate configuration files.

In this case, proceed as follows.

Open the C_CONFIG.cfg file in the d:\CEM_V5\CONFIG directory and extend the following area with the new module name and associated configuration files.

[CEMAT]

MissingObject=unknown object

; *** The CEMAT-specific and non-CEMAT-specific objects can be listed here***

; known CEMAT objects

Types=C_SELECT,C_COUNT,C_DRV_1D,C_GROUP,C_ANNUNC,TE_CTRL,C_RUNNT,C_SILOP,C_MEASUR,C_VALVE,C_DAMPER,C_ROUTE

;Unknown objects

;Objectname=file name without language identification without extension) e.g.

SIM_ADAP3=SIM_ADAP3

e.g. SIM_ADAP3 is the module name and SIM_ADAP3_007.cfg the configuration file for German (_009 =English).

Build SIM_ADAP3_007.cfg with the following structure.

; This is an example file of a SIMATIC block of an subcontractor to show this object in the CEMAT Group/Route-Status

[Control]

; The name of the variable, which is an equivalent

; to the CEMAT Status variable

StatusVariableName=STA_MAR (module-specific output parameter name)

[Fault]

;Visible, Attribute,Comment,Bit,Fault Class

1,ABC1,Error1,1,M (module-specific bit 1 error message)

1,DEF2,Error2,2,E (module-specific bit 2 error message)

1,GHI3,Error3,3,P (module-specific...... error message)

1,JKL4,Error4,4,M (module-specific...... error message)



Multimedia Interfaces

Display The display is linked to a function and thus depends on the associated application.

The application video and maintenance manual were implemented as a sample application.

All additional applications depend on the end user, because it is not known how, for example, MCC plans or circuit diagrams are present or where these are saved.

Configuring Example : Maintenance manual.

Edit CFG file The following parameter changes are needed to enable the "neutral interface for multimedia applications" application program.

Open the module-type-specific file, e.g. C_DRV_1D_007.cfg, in the d:\CEM_V5\CONFIG directory and edit the (Programs) area as follows:

Make keys visible by setting the xxxxxBUTTON = 1 parameter

Specify the application program name with path. The following program parameters: Plant identification User name Language identification are transferred.

The VB sources for a sample program are stored under Tools\Sourcen\Video.

[Programs]

SOUND OUTPUT = d:\cem_V5\bin\Sound.exe SOUND OUTPUT BUTTON = 0 LOCATION = d:\cem_V5\bin\Location.exe LOCATION BUTTON = 0 USER MANUAL = d:\cem_V5\bin\c_doc_reader.exe USER MANUAL BUTTON = 1 VIDEO = d:\cem_V5\bin\c_avi_player.exe VIDEO BUTTON = 1

To change the editor program of C_doc_reader.exe, open the - c_config.cfg file in the d:\cem_v5\config directory - and edit the corresponding entries under

[AdditionalPrograms]

; This document reader will be started if you pressed the manual button ;( via the 'C_DOC_READER' program)

;DOC_Reader=notepad.exe DOC_Reader=winword.exe



Enter user files: The C_doc_reader.exe application reads the name of the DOC or TXT file from the information server.

You can enter this name in the information dialog of the object in the Service register under Manual. e.g. d:\cem_V5\docu\maintenancemanual.doc



CEMAT Object Browser

Display Object tree with AS devices as root. Then branch to Object types and then to Object display.

Double-click to initiate the object operation.



Configuring A key must be configured in a process picture or a function toolbar and the following function call included.



CEMAT Message Dialog

Display

Structure The message list window consists of three areas. 1. Toolbar message window 2. Message list 3. Selection input dialog.

Toolbar message window The toolbar message window displays 8 icons whose functions are described under Operator Control.



Message list structure Depending on the message class, the message list provides the following information: (from right to left)

For alarms, warnings, system and operational messages

Column text Description Incoming time With date / time

Plant identifier As defined for Object

Event (fault type) Depending on the object fault types (e.g. operational)

Message text As defined for Object

Value Used only for certain messages (object message text)

Fault class E:electrical, M: mechanical, P: process, S: safety (emergency off)

Message note Identification that a note exists for this message

For operator messages

Column text Description

Incoming time With date / time

Plant identifier As defined for Object

Fault type Depending on the object fault types (e.g. operational)

Message text As defined for Object

Operator control Operator, new value, old value, dimension

Message note Identification that a note exists for this message

Color attributes Depending on the message class and message state, the messages are displayed in the following colors: Alarm Warning Oper. /

Change System

Message arrived white / red black / yellow black / blue white / violet

Message sent white / light green

white / light green

- black / light green

Message arrived. Acknowledged black / pink black / light yellow

- white / dark pink

Message sent. Acknowledged white / dark green

white / dark green

- white / dark green

Listing of the fault classes

Electrical E

Mechanical M

Safety (emergency off switch) S

Process-conditional P



Selection input mask

Refer to Operator Control



Operator Control Call CEMAT message dialog: Use the key with the blue "C“ in the general toolbar.

.

Operate toolbars: 1. Auto-Scroll On/Off If the "Auto Scrolling" option is activated, the most recent message is always selected in the message window. The visible area of the message window will be moved if necessary. If the "Auto Scrolling" option is not activated, a newly arrived message is not selected. The visible area of the message window does not change. The specific selection of message lines is possible only when "Auto Scrolling" is not activated.

2. Selection Specify the selection criteria for the messages to be displayed in the message window. Although the messages that satisfy these criteria are not displayed, they are archived.

3. Log functions Function to create paper-based documentation.

4. Start of the list Select the first of the currently pending messages. The visible area of the message window will be be moved if necessary. The button can be operated only when the "Auto Scrolling" function has been deactivated.

5. End of the list Select the last of the currently pending messages. The visible area of the message window will be be moved if necessary. The button can be operated only when the "Auto Scrolling" function has been deactivated.

6. Next message Select the next message relative to the selected message. The visible area of the message window may be moved. The button can be operated only when the "Auto Scrolling" function has been deactivated.

7. Previous Select the previous message relative to the selected message. The visible area of the message window will be be moved if necessary. The button can be operated only when the "Auto Scrolling" function has been deactivated.

8. Infotext Opens a dialog to enter information text.

9. Comment Opens a text editor to enter comments.

In the "Scrolling OFF" state, the horizontal scrollbars (below the messages) can be used to display additional message line information.



Operate selection area

Grouping Individual points Description

Archives Fetch process message window Display the currently pending messages.

Fetch short-term archive Display the messages archived in a short-term archive.

Long-term Display all sent and acknowledged messages, operational messages and change messages.

Message classes

No selection Alarm Warning Tolerance AS control system alarm OS control system alarm Process messages Operational message Operator requests Operator messages

Selection using the accompanying criteria. Combinations of the message classes can be selected.

If no message class is selected, messages for all message classes are output.

Search criteria Plant section Select using drop-down menu.

Plant identifier (AKZ) Direct input or SC with the right mouse button in the input field.

Event Direct input.

Fault class Select using drop-down menu.

Time interval Date input fields from – to Time input fields from – to

Input fields for date/time with a maximum time range of 48 hours.

Keys for time adjustments Change the time by one hour.

Save Search criterion name Name to define a stored search criterion.

General operations

Update This key must be clicked after every selection change.

Acknowledge Acknowledge each page individually.

Alarm picture This key is enabled only when one message line is selected. After being clicked, the process picture that displays the faulty object (motor, measured value,....) is called.

Information This key is enabled only when one message line is selected. After being clicked, the information dialog of the object is opened.

Important: The Update key must be clicked after each new selection.



Within the message list: - Scroll forwards (by line) - Scroll backwards (by line) - Scroll in the direction of older messages - Scroll in the direction of newer messages - Selection of a message line by clicking it with the left mouse button.

When a message line is selected - An alarm picture can be selected - A message note can be entered - An object-information dialog can be opened - This message is acknowledged (only in the current alarm list, multi-line acknowledgements possible).

Search criterion definition

Plant identifier selection using the structure overview

Call: Click with the right mouse button on the Plant Identifier (AKZ) input field.

The AS and object type can be used to select the corresponding object.

Configuring No further configuring necessary.



Storable Message Selections

Display

New search criterion name

Operator Control See above

Configuring No further configuring necessary.



Technical questions regarding the PCS

Q&A Question Answer

Is a maximum outage time of 2 hours guaranteed?

Our plant concept with redundant OS stations, servers and process bus and the reliable, easily replaceable PNK SIMATIC S7-400 forms the basis for high availability.

This is supplemented with our service product with guaranteed response times.

- Direct service with a powerful remote maintenance tool and access to the automation system via modem and a telecommunications connection.

- The remote maintenance permits access to all relevant components in the control system and thus a fast fault correction.

- On-site service by a known configuring / commissioning engineer from Siemens.

Details of the requirements to be met by the fault immunity.

The offered products satisfy the requirements of the EU regulations 89/336/EWG. "Electromagnetic Compatibility". SIMATIC products are designed for use in the industrial area and satisfy the requirements of the interference radiation in accordance with EN 50081-2: 1993 and the interference immunity in accordance with EN50082-2: 1995

Can small controllers be integrated using Profibus DP? Diagnosis?

Profibus DP can include small controllers in the automation level as slaves. The form and size of the diagnostic functions depend on the type of the associated small controller. The routing functions from Step 7 can be used with the engineering station to perform the diagnosis.

Details of the start-up times and the set-up time for OS stations.

Reliable details for the start-up times can be provided currently only for systems with PCS7 in Version 5.2.

Start-up times:

OS client for running OS server typically 5 min., max. 7 min.

OS Server typically 5 min., max. 10 min.

Set-up time for an OS station :

30 minutes to replace the hard disk and the installation of the system software and application software. Prerequisite is the availability of a current system backup (image copy) on an external data medium.

What are possible solutions for OS stations external to the control room?

The WinCC Web Navigator functionality used for island operation satisfies this requirement.

Process pictures are called using the browser function. The process pictures of the control system are used here.



Q&A Question Answer

Which servers are required for what? Which data is stored?

Servers as OS servers (Online Server) are needed between the PNK level and the PFK level. Each server is provided as a redundant server pair with automatic archive matching.

The following data is maintained on the servers:

Object variables and data in the so-called object engine, OE

Alarms, warnings, messages, etc., in the message archive

Measured values in cyclical archives

Recipes, operational data, etc., including user archives.

Is the failure of every bus component recognized? Which are not recognized?

Yes, for the components supplied as standard (communications processors for the PC stations and the AS systems).

If products other than those recommended by us are used for the network components, the failure of these components can also be determined.

Is the complete functionality of Profibus DP or DP/PA used?

Profibus DP or DP/PA is used for coupling the distributed peripherals ET200S, converters, weighing systems and intelligent field devices (Profibus PA). Because the associated bus clients determine the usable functionality, no general statement can be made. In the case of systems from third-party manufacturers, in particular , the functionality must be determined in each specific case.

How many operator control levels are possible?

A maximum of 99 operator control levels and 128 users are possible.

Can process sectioning be realized easily without additional effort?

Yes, through the specification of user rights or the assignment of process pictures to an OS station.

A corresponding user and rights administration is a system component and contains predefined user/rights assignments for the most common usage.

Can the color be changed for the complete symbol (e.g. bucket elevator) when the operating mode changes?

Yes

Is there an animated function plan display of the application program (CFC/SFC)?

Yes, for CFC and SFC.

The animation for the CFC display is currently possible on the engineering system.

The SFC display and animation can be invoked at any time in the operator stations in the normal operator control and monitoring mode!

Is the operator control and monitoring level essential for the operation of the process level?

No, the control program with all interlocks and safety functions for the associated drives, controllers, measured values, etc., runs independently in the associated AS S7 400.



Q&A Question Answer

Can the availability of the system (MTBF) for the defined environment conditions be specified?

The availability of the complete system depends on the MTBF times (mean time between failures) of the associated components.

When the components offered or recommended by us are used, the complete system has an availability of 99.7%.

MTBF of some important components:

Hard disk 1,000,000 hours

Monitor SCM 2196 – I excl. CRT 50,000 hours incl. CRT 20,000 hours

SIMATIC S7-400 CPU 13 – 14 years

SIMATIC peripherals ET 200 ... 28 - 57 years

Can new stations be included during running operations?

Which steps are necessary?

Yes! The following steps must be performed:

- configure and parameterize station on the engineering system

- interconnect station

- possibly load station

- load new project data to the OS servers.

(The redundant servers must be loaded alternately, run down and restarted.)



Q&A Question Answer

The type of potential separation for binary and analog inputs and outputs must be described.

ET 200 S peripheral module

The 2DI DC 24 V and 2 DI AC 230 V digital inputs are potential separated using optocouplers between channels and backplane bus with a common reference potential.

Refer to the section in the ET 200S manual (from page 11 - 7 and 11 - 15) in register 7.3 of the tender folder.

The 2 DO Relay digital outputs for 24 DC / 230 V AC are individually potential separate per channel (can be delivered from 07.99).

Refer to the section in the ET 200S manual (from page 11 - 39) in register 7.3 of the tender folder.

The 2 DO digital outputs 24 VDU, 2 A (alternative) are potential separate using optocouplers to the backplane bus with common L+.

Refer to the section in the ET 200S manual (from page 11 - 37) in register 7.3 of the tender folder.

The comment on the ET 200S analog modules is contained under register 1.3 in the tender folder.

For technical data, refer to the section from the ET 200 S manual (from page 12 - 68, 12 - 75, 12 - 91) in register 7.3 of the tender folder.

As described in register 1.3 of the tender folder, we offer the analog modules of the ET 200 M as an alternative.

For technical data, refer to the section from the ET 200 M, Ex manual (from page 3 - 73, 3 - 79) in register 7.3 of the tender folder.

Size of the switch-on rush of the power supply units?

The power supply units of the SIMATIC automation systems limit the switch-on current.

NAMUR recommendation Part 1 from December 1990

The requirements to be met by the power supply must be specified.

For OS stations, monitors, printer

Rated value 230 V AC permitted range: 200 – 240 V AC

50 – 60 Hz

For SIMATIC automation systems

Rated value 230 V AC permitted range: 170 – 264 V AC

47 – 63 Hz

or

Rated value 24 V DC permitted range: 20.4 – 28.8 V DC

How does the startup of a process station proceed after a failure? Duration?

The startup of the SIMATIC automation systems proceeds automatically as provided by the firmware.

The startup of the servers and OS stations proceeds automatically as provided by the startup routine.

Duration: typically 5 minutes



Q&A Question Answer

The definition of the loading (base load + application program) and the calculation of the processor loading (base load + application program) per station must accompany the tender.

Maximum cycle time for each PLC?

Loading tests produced an average loading of 35% for the OS stations.

The cycle time should be considered as a relevant quantity for the loading of the S7 400 automation system.

This depends on the number of implemented objects and can be calculated from this.

A limitation to the number of objects maintains a maximum cycle time of 200 ms.

The size for main memory and reserve must be specified.

Main memory for PC stations 512 MB

Loading typically 75%

Main memory for S7 400 : CPU 416-3 2 x 1.6 MB

Loading typically 60%

The hard-disk size and reserve must be specified.

Hard-disk size for PC stations currently 30 GB

Maximum 2 GB are reserved for the system software and the project data.

The remainder is available for archives and other data.

What is the refresh frequency of the monitor? Screen size?

Size: 21“

Resolution: max. 1600 x 1200 pixels at 75 Hz

used 1280 x 1024 pixels at 85 Hz

Refresh frequency : 50 – 120 Hz

Which operating modes are provided?

The CEMAT Standard for cement works contains the operating modes:

AUTOMATIC, INDIVIDUAL START (locked) and LOCAL OPERATION. Refer to the description in the blue CEMAT Objects folder.

Are all switch-on conditions checked prior to the actual start of a sequence chain?

The switch-on readiness for a group or a path is displayed in the group/path symbol.

Detailed information can be requested at any time using the so-called status call for groups and paths. In this case, the message archive with its not corrected alarms is not queried but rather the actual status of the plant.

For example, although a switched-off motor circuit-breaker in a stationary plant (subplant) does not produce an alarm, it can be recognized immediately at the group or path symbol as missing interlock. The status call shows the complete message text. All interlocks not defined as standard using modules are recorded using message modules and thus can be recognized as text in the status call.

This avoids "test starts".

Can all symbol names be chosen freely for lock types and signal names?

As part of PCS7/CEMAT V5, the symbol names can be chosen freely subject to the permitted special characters and the maximum length.

The CEMAT Standard largely defines the signal names.



Q&A Question Answer

Is it possible to display the overview picture with a marking of the location of the applied main picture?

In the CEMAT Standards, the picture selection is normally available using pull-down menus that are available for each plant section.

However, it is possible to mark a specific area of a picture and assign it a button for a picture selection.

Step sequence display with status display. Are the input/output conditions for the previous, current and subsequent step displayed? If not, what is the form of the display?

In the CEMAT Standard, the control of the drives is made primarily as a logic control with higher-level groups and paths.

The modules have interfaces for switch-on, operation, protective locks, and switch-on, switch-off commands.

Switch-on sequences can be configured in a clear form using changeable switch-on delays from the control system.

Switch-off locks (switch-off sequences) can also be configured in the same work step (or later) using switch-off delays.

The status of a module of the logic control can be viewed online.

However, CEMAT V5 based on PCS7 also provides the capability of step sequence control.

SFC allows the easy and user-friendly configuring of step sequences and their inclusion in CFC. SFC step sequences can be visualized and, when necessary, operated using the normal user interface on the operator station.

The detailed states of the steps and transitions can be invoked using a zoom function.

Standard module display in the reverse-documentation as black box?

Standard function modules from the PCS7 and CEMAT libraries are displayed as black box with the associated parameters (I/O interfaces).

Any unneeded parameters can be switched as invisible.

Because the engineering system always serves as the data source for all OS and AS systems, the reverse-documentation function is not necessary for PCS7/CEMAT V5. Thus, changes are always performed on the engineering system, documented and then transferred to the corresponding station.

Thus, the project documentation is always up-to-date.

Are service pictures provided for the weighing equipment?

Yes.



Q&A Question Answer

Are the screen times observed?

Screen updating and response times.

Updating of an applied picture with:

50 dynamic objects typically < 1 sec. max. 1 sec.

200 „ „ „ < 1 sec. max. 1 sec.

Apply a new picture with:

50 dynamic objects typically < 1 sec. max. 3 sec.

200 „ „ „ < 2 sec. max. 5 sec.

Call measured value curves typically 2-3 sec. max. value depends on the total volume of the measured value archiving.

Fetch logs typically 5-8 sec. max. 10 sec.

Selected page fetching of message archives typically 2-3 sec. max. value depends on the selection criterion

Response times for alarm messages and operator control functions related to the associated PNK typically 1 sec. max. 2 sec.

The possible maximum expansion for PNK, field buses per PNK and OS stations must be specified. The load and time requirements of the tender must be observed.

Maximum expansion for a control system with CEMAT V5 based on PCS7

PNK (S7 400) previously 16 max. 32

L2-DP lines depending on the 2-4 loops integrated on CPU type per PNK the CPU max. 10 additional lines using CP 443 interface cards

Online server max. 6 redundant server pairs

Operator station max. 16 client/multiclient connections per server pair

when multiscreen is used (2 monitors per client), the number of monitors is limited to 20 per server pair!

Where is the timestamp of an event assigned? Resolution?

The timestamp for the event message is assigned in the automation system S7 400 (PNK).

The resolution corresponds to the cycle time, namely with max. 200 msec.

Connection of third-party system

Bus system/protocol Industrial Ethernet with TCP/IP protocol

Coupling procedure for third-party computer OLE for Process Control; OPC

Database communication SQL



Q&A Question Answer

Which data is present in the operator station, process station, engineering system, couplers, etc.? How is the comparison made for multiple copies of data?

Control program and the process states for drives, valves, controllers, etc.

Object variables and object descriptions

Alarms, warnings, messages, etc.

Measured values

Recipes, plant data

Process pictures

Engineering data

In the automation systems (AS) S7 400.

Thus, the ASes can operate independently without operator control and monitoring level

In the Data Manager

In the message archive on the OS server

In the measured value archive (up to 7 days) on the OS server

In user archives on the OS server

On the OS server and optionally on the clients (improved performance for the time needed to change pictures)

On the engineering system or on a separate server

The message archives and user archives are maintained in a Sybase database.

The measured value archives are stored as dBase files.

Multiple copies of the data are not maintained. The exception is the redundant data management on the OS servers with automatic archive comparison.

Is the loading level of the RAM batteries in the PNK monitored and reported in the case of failures?

Yes, using an optical display on the PNK and a system message to the control system.



What kinds of system status displays are possible? For remote I/O?

The following status displays are possible:

Representation in lists or graphically? Self-configuring?

On the operator stations: – Additional display for objects in the process pictures – Status call for groups and paths – Status display for SCF step sequences – Status display of the system components (distributed peripherals, PNK, servers, PFK) in system overviews (graphics)

On the engineering system

All functions of an operator station and in addition:

Status display of all signals and locks in CFC plans

All known status and diagnostic functions from S7 / Step7

Which criteria can be used to freely customize standard lists?

Plant data reports can contain counter values, measured values, consumption values, and messages. These can be freely grouped as Excel sheets.

These functions must be implemented using the information module.

How is the alarm suppression realized?

Are secondary alarms generally avoided?

If not, which are not avoided? What is the maximum number of secondary alarms that can occur?

Is the alarm acknowledged just once in the complete system?

How is the alarm tracked from the alarm line?

An important point in the CEMAT philosophy is the plausibility logic for events, messages. Principle: only the initiating signal is reported.

Every module contains a plausibility logic. The signals for each module are best linked together with the "message release" signal interface. The user connects the message release with the states belonging to the drive / measuring point, such as emergency off, signal voltage protection or also process signals, such as pump-off limit value exceeded, wait time expired, etc. The results are unique messages, no "message flood". Meaningful information in the message archive!

The acknowledgement (horn) is performed once per complete system. The alarm acknowledgement of the message line is performed for each pending line. The acknowledgement in the alarm list is made for the marked messages!

Trackball/mouse is used on the pending alarm in the message line to select the associated process picture.

Further information about the S7 cabinet installation location or motor outgoing feeder panel is available in the information screen forms of the faulty object.



Is each individual lock condition displayed?

All lock conditions in SCF step sequences can be displayed online on the OS stations.

The lock conditions in CFC plans can currently be displayed online only on the engineering system.

Because the operator can obtain all necessary information about the status displays and diagnostic pictures of the objects, the status call of the groups and paths, and the message system, the operator is not subject to any information restriction.

How many characters are available for display of the field lengths of:

• alphanumeric symbol names?

• the associated designation?

Field length for the symbol name: 32 characters

Field length for the designation text: 40 characters

Which CAE functions does the system contain?

Hardware configuration (HW-Config.) for the configuration and parameterization of all hardware components, such as racks, CPUs, CPs for communication, Profibus lines, I/O modules, etc.

Technological display of the plants in the form of a tree structure.

Graphical conversion of the procedure processes in open- and closed-loop control functions using CFC (Continuous Function Chart) function display.

Here, predefined functions and technological objects (from libraries) are displayed and connected graphically.

Creation of step sequences using SCF.

Here, step-controlled processes are created and parameterized graphically.

CFC and SCF can be directly combined and connected with each other.

Both editors generate the necessary program code for the PNK and the data for the PFK.

Powerful test and diagnostic functions are available for both editors.

Do outputs assume the safe operational state when the complete station or, for example, the CPU fails?

All outputs of the SIMATIC peripherals assume the OFF state (O-signal) for power failure, bus failure, CPU failure. Faults at the output modules themselves can cause them to remain in the ON state (1-signal).



How is the control system protected against unauthorized accesses during remote diagnosis and maintenance?

RAS Service (Remote Access Service) from Microsoft or the remote control software pcANYWHERE from Symantec are used for the remote diagnosis.

Access rights with password protection are assigned in both cases.

A so-called call-back variant can be used to protect the establishing of the connection.

Finally, the operator can expressly establish the physical connection between modem and control system only at the time of the remote diagnosis.

Is only standard hardware used?

Are additional manufacturer-specific components used? Which?

Only standard hardware is used.

Are commercially available relational databases used? If yes, which ones?

Which operating system?

Sybase Anywhere is used on the OS servers for object data, messages and user archives.

DBase for the measured value archiving.

The operating system is Microsoft Windows NT 4.0

How many communications interfaces can be realized at a process station? Does this reduce the number of fieldbus interfaces?

An automation system S7 400 can be equipped with communications modules (CPs) for all communications tasks that arise in practice.

CPs are available for

− Industrial Ethernet with ISO / OSI, TCP / IP and MAP 3.0 communication

− Profibus with DP, PA and FMS communication

− Serial point-to-point couplings

− Web-connection with integrated S7-Webserver.

The maximum number of employable interfaces depends on the selected S7 hardware and the system configuration.

How many components can be connected to an operator station?

2 monitors

1 keyboard (standard)

1 mouse or trackball

1 printer

can be connected to an OS station.

Is the application software checked by the manufacturer on a manufacturer's in-house system or must the target hardware be used?

Manufacturer's systems or the target systems can be used for the engineering.

The test of the application software and the Factory Acceptance Test (FAT) must always be performed on the target hardware.

CEMAT Reference Manual Glossary

CEMAT Reference Manual

Glossary


Copyright � Siemens AG. All Rights Reserved. 2 - 1Edition: 02.06.1998P:\INA_VD\cemat\DOKU\V500\Englisch\Referenz\GLOSSARY\GLOSSARY\02_Glossary.doc

Glossary

Table of Contents

Glossary 3A ............................................................................................................................. 3B ............................................................................................................................. 3C ............................................................................................................................. 4D ............................................................................................................................. 4E ............................................................................................................................. 5F ............................................................................................................................. 6G............................................................................................................................. 7K ............................................................................................................................. 7L.............................................................................................................................. 7M............................................................................................................................. 7O............................................................................................................................. 8P ........................................................................................................................... 10Q........................................................................................................................... 10S ........................................................................................................................... 10T ........................................................................................................................... 11


Copyright � Siemens AG. All Rights Reserved. 2 - 3

Glossary

AActivateHere: The elementary operator actions that affect a control component (Example: pressing akey/button).

AKZ (Plant Identification)The customer's plant identification for an object. A plant identification is unique throughout thesystem (works). Examples of a customer's plant identifications:

01KM034 is a motor

01KM805 is a measuring point

The plant identification in CEMAT can have a maximum length of 19 characters.

AG (PLC)Programmable Logic Controller (= automation unit). The SIMATIC S5 units 155U with CPU948 and 115U with CPU 945 series are used for CEMAT V4.

BBitmapHere: Graphic element used to build a process diagram.

BridgeA bridge is an amplifier that amplifies and forwards all arriving signals (telegrams) in anetwork. The bridge can also forward these signals to different networks (e.g. subnets).

Bridges in � control systems with double bus and � engineering station are used in CEMATto permit access from the engineering station to stations on the other bus.

Glossary CEMAT Reference Manual

2 - 4 Copyright � Siemens AG. All Rights Reserved.

CCEBASSCEMAT Base Interface; data block interface in the SIMATIC S5. The CEBASS contains allinformation that the associated object block stores (e.g. FB for non-reversible drive). Thestatus words, counters, process parameters and visualization data for � OIS and � MIS arestored in CEBASS. Its also contains the command interface for the object.

CEMATProduct designation for the automation system from SIEMENS for cement works.

Coming Time, Going TimeThe PLC inserts this time when the event telegram is formed.

Control SystemA control system is an automaton system used to control a production process. Theproduction process can cover both a complete works (from the quarry through to the packingunit) or just some arbitrary subprocess (e.g. cement grinding section). Several controlsystems are used to realize the complete system in the second case.

Up to 9 control systems, each with a maximum of 16 automation units, can be used as acomplex for CEMAT-V4.

DDBData block in an S5/ S7 automation unit.

DDEDynamic Data Exchange; dynamic data exchange between different Windows (NT)applications.

Diagram selection for alarmAn assigned (configured) mimic diagram appears when a key is pressed.

Diagram selection for informationA window with information for the object appears when a key is pressed.

DPData Processor; The DP is a PC that performs the data preprocessing for � MIS. Every �AG can be connected to a DP. If redundancy is required, an AG is also connected with 2 DPs.



EENG� Engineering station

Engineering StationCEMAT station for the configuring task. An engineering station can be used to both performconfiguring work using � CEMAT CASE and also create process diagrams.

Event ArchiveSeveral event archives exist. The event class can be used to control messages in specificevent archives.

Event AttributeThe event attribute controls the display (color) of a message. It can be configured per class orobject.

Event BlockAn event line consists of several event blocks.

Event FormatThe event format describes the layout of a message for the display. Also refer to event block.

Event ClassThe event class represents a classification of messages. If necessary, this can also be usedto control the messages in various event archives.

- Alarms,- Operator input messages, - Change messages- System messages- Warning messages- Group/path status messages- Status header message (is the message of the selected group or path)

Event TextThe event text is the object text. This text is designed to be multilingual.

Event LineThe event line is the ASCII string that is visible on the upper screen edge.

Event TimeThe event time is the time that is also visible in the event line/archive.

Event StatusThe status of a message (coming, going, acknowledged)



FFaultWe designate a fault as being a state that interrupts the production operation.

Examples:

All fuses have been removed from the drives (no electrical switching readiness (ESB)), or ameasured value has exceeded upper limit 2. The base functions generate an alarm messageif a fault occurs during the production operation.

No alarm message is generated if a fault occurs while there is no production operation!

Fault Type No.An object can generate various messages. The fault type no. encodes the fault cause

Example for the E-block:

No. Fault Type Explanation

0 ESS Contactor fault

1 ESB No electrical switching readiness

2 EVO Drive has not been set to automatic (localoperation)

3 EBM Bimetal protective relay triggered

4 ESD Tachometric relay triggered

9 EGE No longer fault (all faults have been removed)

Fault ClassIt is possible to classify messages according to additional criteria.

Examples:

E Electrical faultsM Mechanical faultsP Process faultsS Safety switch (emergency off, pull-wires)

Fault LocationInformation for each object can be specified on the installation location; building, room,switching cabinet, etc.

FBFunction block in an � AG. Function blocks are used to realize, for example, a motor controlblock (E-block; E indicates a non-reversible drive).



GGroupA group is a CEMAT object. A group can consist of several drives, dampers, measuredvalues. The user determines which objects are to belong to a group; he groups them asoperation sections. The operator then starts or stops a complete operation section using agroup.

GroupingCombining several objects to a new object. All � operations that apply to the new objectaffect the original (single) objects as a group.

KKCSKiln Control System; CEMAT functions for furnace control.

LLayoutDrawings (graphics) created with lines, here mainly process diagrams.

MMessageA message for CEMAT is a collective term for all types of messages.

Alarm messages are generated from the basic functions, such as motor, damper,measured value, annunciation module when a fault causes the production to bestopped. Please note that a "fault" does not necessarily produce an alarm message.There is also no alarm message when the process has stopped.

Change message if a process parameter (e.g. a limit value) is changed in the controlroom, the Measured Value base function generates a change message that includesboth the old value and the new value (normalized values).

Operator input message (process alarm). If, for example, a � group starts, the Groupbase function creates a process alarm.

System message. A system message can appear as an alarm message. It is amessage that is created from the safety monitoring functions. Example: bus fault.

Group status and path status messages. It is possible to request a group or a path tooutput their status in the form of messages. In this case, select a group or a path onthe screen and then press a key. The status messages are the result. The messages



are discarded as soon as the screen has been deselected. This function can bereinvoked at anytime.

Measured Value (Analog Value)Measured values are usually designated as being the measurement values read with analoginputs. A measured value can also be computed with a program.

The measured values are present as normalized analog values (value range (0-4095) units)in the PLC.

The values are always represented as physical values (i.e. with scale begin and end, and adimension) on the output devices, screens and printer. The operator control and monitoring orthe MIS stations are responsible for the conversion of the normalized values into physicalvalues.

MISManagement Information System. This is an information system that operates on the basis ofa PC with which it is possible to make consumption and operating data reports, static faultmessage evaluation, mathematical evaluation of curves, etc.

OOperator Control and Monitoring� Operator Control and � Monitoring, i.e. the � control room

Operator ControlHere: An action by the user that influences the operation of some item of technical equipment(system, device, machine) or initiates the execution of a function.An immediate effect is typical.

OperatorAn operator in the � CEMAT sense is the control room operator, i.e. a person who monitorsthe process and who can change the process parameters.

ObjectAn object for the customer is, for example, a motor, a damper, a measured value, or anactuator. We represent these objects as CEMAT objects. Examples:

Motor is realized with an E-block (an S5-FB for motor control)

Damper is realized with a K-block (an S5-FB for 2 direction dampers)

Measured value is realized with a UM-block (an S5-FB for measuring points)

Actuator is realized with an R-Function (S5-FBs for control)

We access a unique object with a numeric code in an SMR PLC.

Examples:

Object Type No. Object No.1 17 E-block 171 122 E-block 1226 35 UM-356 223 UM-223 etc.

Refer to object type no. and object no.



There are also timers, flags, and counters in an S5. We refer to these objects as S5 objects.These S5 objects normally remain hidden from a customer.

Object AttributesObject attributes are all variables and descriptions that belong to the object. These are theprocess variables and process parameters in the SMR PLC in CEBASS.

Object DescriptionThe object description is everything that belongs to an object and does not lie within the SMRPLC in � CEBASS. This can also be referred to as a data record description.

Examples:

- Scale begin, scale end, dimension of a measured value- The AKZ (plant identification)- The object text- General information such as:

- the building and room in which the object is located- the circuit diagram for the object- the function plan for the object- performance data for the object

Object List (Motor Components Measuring Point List)The objects (motors, dampers, measuring points, single signals, etc.) are entered into anobject list at the beginning of the configuring. An object appears here for the first time. Atleast the plant identification (AKZ) and the object text must be entered,

Example:

01KM034 AIR SUPPLY CHANNEL TO SILO 1AKZ Object text

This list arises during the configuring with CEMAT-CASE and contains the complete objectdescription.

Object TextThe object text is descriptive text for the object, such as conveyor belt to silo 1 or temperaturefurnace entrance. This object text appears, for example, in the signal designations or in thealarm event line. This text for CEMAT can have a maximum length of 40 characters.

Object Type No.This number designates the object type (refer to the table)

No. Type

1 E-block

2 Damper

4 M1 event block

5 M2 event block

6 UM (measuredvalue)

7 Valve

etc.



ODBCOpen Database Connection

PPathA path is a CEMAT object. In the same manner as the group, a path can consist of severaldrives, dampers, measured values. Paths can be used to realize, for example, varioustransport directions.

Process Parameter (PP)Process parameters are � object attributes.

Examples:

- Monitoring time for contactor confirmations of a motor- Upper limit 2 of a measured value- KP gain of a controller

These process parameters initially occur during the definition of an object in the configurationphase (default settings). These values can be modified from the control room during theoperations phase. (refer to CEBASS)

Process VariableThese are also object � attributes.

Examples:

- Status Visu (states of the object for the visualization)- Normalized analog value of a measuring point- Interface word (user program interface to the standard function)

(refer to CEBASS)

QQCSQuality Control System

SServiceA service is a process that runs in the background and often also provides applicationprograms with an interface to other processes. The services required for � CEMAT arestarted automatically during the Windows NT start-up. If required, the user can manually startor stop them later.



Signal Designation (Signal Name)The signal designation in CEMAT consists of two parts:

plant identification of the object to which the signal belongsand the signal short identification

A defined delimiter is placed between these two parts. ( - or . or / ). The customer defineswhich delimiter is to be used.

Examples:

01KM034-ESB Switching readiness of the motor01KM034-ERM Confirmation from the motor contactor 01KM034

Signal Short IdentificationThis is a part of the signal designation and indicates the type of the signals. It is a 3 or 4-character abbreviation and is placed in the signal identification after the delimiter. The signalidentifications are defined for the standard signals.

Examples:

ERM Confirmation from the motor contactorEVO Local switch for the motorKWE1 End switch in the CLOSED direction for a damper.

The customer must define the signal identifications for the "special signals" for a project.

Examples:

RL Pull-wire switch of a conveyor beltSL Belt-skewing switch of a conveyor belt

SMR PLCA PLC that runs in one of the base functions. Open-loop control, measured value processing,closed-loop control.

TTrendCurve representation without archive component, i.e. without representation of the valuesprior to the diagram selection time.

TSAPTransport Service Access Point.

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