deckblatt mmi v3 - siemens · guide the current manual ... planning the process control interface...

Copyright © Siemens AG. All Rights Reserved.

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

Systemspecifikation

Engineering Manual

CEMAT-CS VERSION 5 Engineering Manual

Introduction 1

Preparations 2

Installation of a PCS 7 Project 3

Assignments 4

Engineering Examples 5

PLC Engineering 6

PLC-PLC Coupling 7

OS Engineering 8

WinCC Server 9

WinCC Multiclient 10

Project administration 11

12

Graphic Templates 13

Tips & Tricks 14

Update-Information 15

Register Objekt 2 15tg. /Register_Projektierungshandbuch_engl.DOC/1

Engineering Manual_V5 Introduction

Copyright Siemens AG. All Rights Reserved. 1 - 1 Ausgabe: 25.02.03 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\01_Introduction.doc

Introduction

Content Introduction 1

General ...................................................................................................................2 Documentation structure.........................................................................................3 Guide.......................................................................................................................5

Introduction Engineering Manual_V5

1 - 2 Copyright Siemens AG. Alle Rechte vorbehalten.

General You have here the Engineering Manual for CEMAT V5. This manual should support you in performing the work required to configure your plant.

The Engineering 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


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 Engineering Manual_V5

1 - 4 Copyright Siemens AG. Alle Rechte vorbehalten.

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



Guide The current manual is divided into the topic areas: Installation, Engineering and Project Administration.

The engineering of CEMAT plants is done with the Engineering Tool PCS 7. With PCS 7 the following steps are performed.

- Configuring the hardware

- Creation of the S7-programs, including logic diagram and documentation

- Transferring the PLC/OS Connection data

Engineering Manual V5 Preparations

Copyright Siemens AG. Alle Rechte vorbehalten. 2 - 1 Ausgabe : 24.01.2002 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\02_Preparations.DOC

Preparations

Content Preparations 1

Verification of the Standard......................................................................................2 Verification of the received documents....................................................................3 Project Structure ......................................................................................................3

Assignment of the Objects into PLCs .........................................................3 Determine the number of PLCs required....................................................3 Structure of the plant from different views ..................................................3

Plant Designation System........................................................................................4 Field/name lengths and naming conventions for PCS 7 ............................4 Designation rules for CEMAT .....................................................................5 Permitted Special Characters .....................................................................6 Definition of the signal identifications..........................................................6

Definition of Object Types........................................................................................7 Planning the Process Control Interface ...................................................................8

Configuration Guidelines ............................................................................8 What is shown WHERE and HOW? ...........................................................9 Designation System for the process pictures ...........................................11

Preparations Engineering Manual V5

2 - 2 Copyright Siemens AG. All Rights Reserved.

Verification of the Standard Per plant the responsible engineering department must define the project definition. Henceforth these unique definitions are valid for all PLCs of the plant.

Especially if the engineering is done at different locations and for supplementary plant extensions it has to be insured that the original project definitions are used.

Definitions for the Engineering:

- Name of the PC Stations

- Definition of AS Numbers

- Addressing of the AS and PC Stations (MAC Addresses, TCP/IP Addresses, Profibus)

- The designation system of the plant tags (charts, modules, signals)

- Variable names

- Names of the WinCC pictures

- Rules for the generation of scripts and actions

- Engineering rules (Customer standards, Teamwork)

- Definitions for the documentation of a project

Definitions for the Runtime-Project:

- The operation surface (Division of the screen, Font style and –size, Language in Runtime, Representation of the objects)

- The operation concept (Picture hierarchy, operating philosophy, user rights, permitted keys)

- The color definition for the annunciations, Limit values, Status, Font etc.

- The communication (Communication type, Actualisation cycles)

- The volume of project data (Quantity of alarms, Archive values, Curves, Clients etc.)

- Message and archiving procedure

There are now various forms of the CEMAT Standard. Ensure that the project standard meets the requirements of your plant (MCC / plausibility, local switches, operation).

Caution: Subsequent changes in the function block parameters need a reload of the PLC. This means PLC Stop!



Verification of the received documents The received documents for the project must be examined, verified and if necessary completed. These are:

- Object list

- Signal list (with or without absolute addresses)

- Plant Topology (Building, Location)

- Process view (Plant, Unit, Function)

- Electrical view (MCC, Panel, Feeder, Bimetal, Fuse Rating)

- Panel Structure (I/O-Panels, Rack, Slot, Card, Address)

- Group/ Route/ Drive assignments

Project Structure

Assignment of the Objects into PLCs - Sensible (technological) division of the objects

- Communicate as little data as possible between the individual PLCs

- If possible, do not separate groups

Determine the number of PLCs required - Maximum number of objects per PLC

- Maximum number of signals per PLC

- Make allowance for reserves

- See table for module data in the reference manual, objects, chapter 1, General.

Structure of the plant from different views - Plant topology (Locations)

- Process view (Technological structure)

- Control system view (Control systems, PLCs, I/O-Panels etc.)

- Electrical View (MCC)



Plant Designation System

Field/name lengths and naming conventions for PCS 7 Object Length Comment

Chart 22 The following characters are not allowed: \ / . ” %

Chart comment 255 All ANSI-characters are allowed.

Run time group 22 The following characters are not allowed: \ / . ” %

Task 22 The following characters are not allowed: \ / . ” %

Block type 8 Fixed by STEP 7

Instance comment 80 All ANSI-characters are allowed.

Parameter name 24 Fixed by STEP 7. The 1st character cannot be a number (0 - 9).

Parameter comment 80 All ANSI-characters are allowed.

Instance name 16 The following characters are not allowed: \ / . ” %

Global variable 24 Characters are fixed by the symbols editor, all characters are allowed, also blank and special characters without ”.



Designation rules for CEMAT

Name of the PC Station Special characters are not allowed in the PC Name

Important Note: In Cemat V5 the underscore “_“ is not allowed in the Station Name. Otherwise the Server-Prefix for MultiClients can not be identified.

Plant view One of the most important decisions at the beginning of the engineering of a Cemat V5 Project is the structure of the plant view. You have to decide, if the name of the hierarchy folder should be included in the object tag or not.

It also has to be decided, which hierarchy level should be used as “OS Area”. The OS Area is used as selection criteria to filter the messages in the alarm line and (if it is engineered in that way) to acknowledge the specific area.

In Cemat V5 the messages in the alarm line can be filtered dependent on the OS Area, which means that only the alarms are displayed which proceed from the selected OS Area.

With the acknowledge of the alarm line the acknowledge signal is sent similarly to all PLCs and all dynamic faults are acknowledged (this is the default setting!). With an adaptation in the engineering it is possible to send the acknowledge signal only to the PLC from which the alarm was proceeding. This needs an assignment of the OS Area to the PLC.

e. g. Raw Mill = AS1 Kiln = AS2 Cement Mill1 = AS3 Cement Mill2 = AS4

Important: It is not possible to acknowledge only a part of the PLC, always all faults of a PLC are acknowledged. This implies that for an area specific acknowledgement the OS Area corresponds with the PLC. The OS Areas names must be unique.



Module tags The designations of the modules depend on the settings in the plant view of the PCS 7 project.

The module tags contain at least the chart name and the instance name.

The maximum length of the module tags is 20 characters.

Note: The name of the motors, dampers, valves, groups, routes, selections and controllers should not be more than 13 characters. Names for Annunciations and measuring values can reach a length of 20 characters (if a separator and an extension of max. 6 characters is added to the name of the main module).

The maximum length of the comment is 40 characters.

Example:

Motor Tag: 331-BC1/M01 Tag of the annunciation module for the rope switch: 331-BC1/M01-RS01

Signal names The maximum length for global symbols in PCS 7 is 24 characters. The signal names für the inputs and outputs of the CEMAT modules should be derived from the module tags.

The maximum length of the signal comments is 80 characters.

Fault Text The fault text is defined in the CFC at the function block and for the operation annunciations in the CFG file in directory D:\CEM_V5\CONFIG. For most of the standard function blocks there is a fixed fault text assignment which cannot be changed per instance. For Annunciation modules C_ANNUNC the fault text must be entered per instance.

Permitted Special Characters The following special characters are permitted:

"-" "+" "#" "_" "=" "<" ">" "!" "&"

Some special characters are rejected while entering it in PCS 7. Some other special characters are converted during transfer of PLC/OS connection data into a $ sign.

Definition of the signal identifications Definition of unique abbreviations for all the signal types in the project.



Definition of Object Types The definition of object types (e. g. bucket elevator, belt conveyor) with all the associated modules and interlocks will save engineering effort. Approved solutions can be used several times, whenever the function is required.

In chapter „Engineering Examples“ of this manual you find solutions for special tasks.



Planning the Process Control Interface

Configuration Guidelines Summary of the steps required to create the process control interface:

Description of the action Executor

1 Determine which plant sections of the process are to appear on the screen.

Customer / project management

2 Divide the complete plant into subprocesses that are to appear together in a diagram.


3 Determine the general rules for the process diagram creation.

Project management

4 Process diagram assignment for the menu entries. Refer to the next pages

5 Determination of the general representation rules for the plant.


6 Determination of the color assignment, blinking, font size and form.

Customer / project management refer to the default picture

7 Determination of the operation philosophy. Customer / project management CEMAT standard

8 Determination of the representation of operable objects.

Customer / project management CEMAT standard

9 Determination of the representation for typical process-relevant elements.

Customer / project management CEMAT standard

10 Design the process diagram layout on paper or drawing program or directly using Visual Basic.


11 Determination of the directories / file names for process diagrams, key assignments, graphical modules, etc.

CEMAT standard



What is shown WHERE and HOW? Complete plant overview Representation: Schematic representation of the complete plant

Content: Overview of the production plant with global status display from the running plant sections

Operation: Selection of a production section / a subplant

System monitoring, plant configuration diagrams Representation: Schematic representation of the complete control system

Content: Overview of the network connection of the individual control system devices with global status display of the individual components.

Operation: Selection of an individual component for detailed analysis

Plant sections: Representation: Material flow of a complete production plant without secondary aggregates

and details

Content: Display of all physical variables relevant for the process control.

Operation: Start and stop of the plant Specification of set points Assignment of recipes Invoke overviews for flow diagrams, measured values, closed-loop controllers, curves Tabular measured value listing

Process diagram overviews: Representation: Schematic representation of the diagram hierarchy with group states

Content: Overview of the production plant with display of the operational groups/paths

Operation: Selection of a process diagram

Grouping overview Representation: Tabular representation of the measured values, closed-loop controllers,

curves

Content: Overview of the grouping of the measured values, closed-loop controllers, curves either general or operator-specific

Operation: Selection of a group diagram



Groups, routes, selection overview Representation: Tabular representation of the plant-specific groups, routes, selections

Content: Overview of the states of the production plant

Operation: Selection of the process diagram in which the groups, routes, selections are displayed

Process diagrams: Representation: Representation of the plant sections with all aggregates

Content: Display of the operational modes, measured values, states, curves, filling levels

Operation: Selection, operation of individual aggregates and diagnosis, information and object parameter invocations

Detail diagrams: Representation: Representation of the individual aggregates

Content: Display of the operational modes, measured values, states

Operation: Selection, operation of individual aggregates and diagnosis, information and object parameter invocations

Help: Representation: User’s guide for the CEMAT system

User’s guide for the plant User key assignment

Content: Explanations and examples of the system handling.

Operation: Complete table of contents and search key control



Designation System for the process pictures

Introduction • Overview area:

psu_xxzz.pdl = Process diagram - system overview

• Overview diagrams: pau_xxzz.pdl = Process plant overview pbu_xxzz.pdl = Process diagrams overview pmu_xxzz.pdl = Process measured values overview pru_xxzz.pdl = Process controller overview pku_xxzz.pdl = Process curves overview pgu_xxzz.pdl = Process groups overview pwu_xxzz.pdl = Process routes/selection overview pzu_xxzz.pdl = Process recipes overview

• Process/Detail diagram: pb_xxyzz.pdl = Process diagram d_ttxyzz.pdl = Detail diagram



Process Plant Overview

Designation: pau_xxzz.pdl

Used for:

- Representation of the material flow for a complete production plant (without secondary aggregates and details).

- Display of all physical variables relevant for the process control.

Possible operating commands:

- Start and stop the plant, - Specification of set points, - Assignment of recipes - Invocation of overviews for process diagram, measured value, controller or curve

Process Diagrams Overview

Designation: pbu_xxzz.pdl

Used for:

- Schematic representation of the diagram hierarchy with group states.

- Overview of the production plant with the display of the operational groups/routes.


- Selection of a process diagram

zz: Serial diagram no.

pau: Process plant overview

xx: Plant section identification (no. 1-99 or ZM, RM etc.)


pbu: Process diagrams overview




Process Measured Values Overview

Designation: pmu_xxzz.pdl

Used for:

- Schematic representation of the measured value bar chart diagram hierarchy with the assignment allocation by the AKZ (plant identification)


- Selection of a measured value bar chart diagram

Process Controller Overview Diagram

Designation: pru_xxzz.pdl

Used for:

- Schematic representation of the controller bar chart diagram hierarchy with the assignment allocation by the AKZ (plant identification)


- Selection of a controller bar chart diagram



pmu: Process measured values overview

pru: Process controller overview diagram





Process Curves Overview Diagram

Designation: pku_xxzz.pdl

Used for:

- Schematic representation of the curve diagram hierarchy with the assignment allocation by the AKZ (plant identification)


- Selection of a curve diagram

Process Groups Overview Diagram

Designation: pgu_xxzz.pdl

Used for:

- Tabular representation of the plant-relevant groups with the group states of the production plant.


- Selection of the process diagram that shows the group.



pku: Process curves overview diagram

pgu: Process groups overview diagram





Process Routes/Selection Overview Diagram

Designation: pwu_xxzz.pdl

Used for:

- Tabular representation of the plant-relevant routes/selections with the routes/selections-states of the production plant.


- Selection of the flow diagram in which the routes/selections are represented.

Process Control Diagrams

Designation: pb_xxyzz.pdl

Used for:

- Representation of the plant sections with all aggregates and - Display of the operating modes, measured values and states.


- Selection - Group Start/Stop - Operation of single aggregates - Diagnostic, information and object parameter invocations

zz: Serial diagram no. 1-99

pb: Process control diagram



y: Overview diagram no. 1-9

pwu: Process routes/selection overview diagram




Process Detail Diagrams

Designation: d_tt x y zz.pdl

If the detail diagrams are not to be nested, dialogs can also be configured instead of the diagrams.

Used for:

- Representation of single aggregates or subcontrols with operating modes, measured values and states.


- Selection - Group Start/Stop - Operation of single aggregates - Diagnostic, information and object parameter invocations

Bar Charts System diagram with group selection mask

Curve Diagrams System diagram with group selection mask

y: Process diagram no. 1-9

d: Process detail diagrams

tt: Plant section identification (no. 1-99 or ZM, RM etc.)

x: Overview diagram no. 1-9

zz: Serial diagram no. 1-99

Engineering Manual V5 Installation of a PCS 7 Project

Copyright Siemens AG. Alle Rechte vorbehalten. 3 - 1 Ausgabe : 24.01.2002 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\03_PCS7_Project.DOC

Installation of a PCS 7 Project

Content Installation of a PCS 7 Project 1

General ....................................................................................................................3 Installation of PCS7 .................................................................................................4

Language ....................................................................................................4 Installation of the software for PCS7 ..........................................................4 Installation of Softnet IE S7 Basic Software ...............................................4

Installation of the CEMAT Software.........................................................................5 File Structure............................................................................................................5 Adaptation in PCS 7 for CEMAT..............................................................................6 Create a new PCS7 Project .....................................................................................7

Create a new PLC and define Hardware....................................................7 Create a new OS ......................................................................................17

Plant Structure definition (Plant view)....................................................................18 PLC Configuration..................................................................................................21

Copy Standard Symbols and blocks into the PCS 7 Project ....................21 Preparations for programming with the CFC ............................................21 Copy the system chart into the PCS 7 Project .........................................24 Loadable PLC-Program ............................................................................24

OS Configuration (Single-User System) ................................................................25 Selection of Project Type Single-User System.........................................25 Base data -> Split Screen Wizard.............................................................25 Base data -> Alarm Logging Wizard.........................................................30 General changes in the alarm logging......................................................35 Computer properties .................................................................................38 Tag Management......................................................................................42 Add User rights .........................................................................................43 CEMAT specific preparations ...................................................................45 Adaptations in the standard pictures for the message system.................46 General Screen structure..........................................................................50 Picture Tree Manager ...............................................................................51

OS Configuration (Server-Project).........................................................................53 OS Configuration (Standby-Server-Project) ..........................................................53 Redundancy Settings in the Server-Project...........................................................54 OS Configuration (MultiClient) ...............................................................................55

Base data -> Split Screen Wizard.............................................................55 Base data -> Alarm Logging Wizard.........................................................59 Computer properties .................................................................................62 Tag Management......................................................................................66 Add User rights .........................................................................................66 CEMAT specific preparations ...................................................................67

Installation of a PCS 7 Project Engineering Manual V5


Adaptations in the standard pictures for the message system................. 68 Generating and loading of the Packages .............................................................. 73

Creating of a package in the Server Project............................................. 73 Loading of the Packages in a MultiClient Project: .................................... 74 Selection of a Preferred Server ................................................................ 75 Trigger for Action AcknowledgeHorn........................................................ 76 Selection of area specific rights................................................................ 77 Picture navigation on the MC ................................................................... 78

Project-Download .................................................................................................. 79



General This chapter describes the configuration of a PCS 7 project at the Engineering Station (ES).

At the Engineering Station the PCS 7 project is created, engineered, tested and administrated and at the end it is downloaded to the Stations (PLC, SERVER, MC).

Before the CEMAT Project can be created the complete installation of PCS 7 incl. the necessary licenses for PLC and OS engineering and the installation of CEMAT is required on the ES.

Steps 1-3 must be carried out at the beginning of the engineering. Steps 4-8 will be carried out after the engineering is completely or partly finished.

Procedure to Create a PCS 7 Project:

1. Creating a Project After the installation of PCS 7 and CEMAT the PCS 7 Project can be created with all PLCs and OS and the Plant Structure (Plant view) can be created.

2. PLC Configuration After that follows the configuration of one (ore more) PLCs. The description you find under “PLC Configuration” Now the PLC Engineering can be started.

3. OS Configuration as Single User Station After that an OS-Project has to be configured as a Single-User System. This OS-Project will be used for test (and commissioning) on the Engineering Station itself. After this step the OS Engineering can be started.

The following steps you better do not perform subsequently. You better wait until the engineering is partly or completely finished or the plant is commissioned:

4. OS Configuration as Server To create a Server-Project the already existing OS-Project will be copied and modified (e.g. Single-User System -> Multi-User System).

5. OS Configuration as Standby-Server After the creating an OS-Project as a Standby-Server this must be assigned to the Server.

6. OS Configuration as MultiClient The OS-Project for the MultiClient can be created of the Engineering Station or on the MultiClient itself. For administration purpose we recommend to create the MultiClient Project on the ES and to download the Project to the MC Station.

7. Creating/ Loading the Server-Package To provide the Server data to the MultiClients in the Server-Projects a so-called Package has to be created which is loaded in the MultiClient-Projects afterwards. Both steps are carried out on the Engineering Station.

8. Project Download The S7-Programs are downloaded to the PLCs. The OS-Projects are transferred via Project-Download to the different OS Stations (Server, Standby-Server and MultiClient).



Installation of PCS7 The following description assumes that the operation system windows NT4.0 is installed on the Engineering Station.

Caution: The character “_” is not allowed in the Computer name!

Language The installation of the language of the individual systems is described in the document „Engineering with PCS 7“. The languages English, German and the language of the corresponding country is installed.

Installation of the software for PCS7 Please, always use the actual installation instructions which are delivered with the PCS 7 installation CD.

Installation of Softnet IE S7 Basic Software Softnet is required if no CP1413 or CP1613 is available. Please, always use the actual installation instructions which are delivered with the PCS 7 installation CD.

For the installation please select Softnet-S7 Basic V3.1.



Installation of the CEMAT Software Start the delivered Setup Programs from the CD and follow the instructions on the screen.

Installation directory: 'D:\CEM_V5\BIN'.

Enter the key for project standard 000 = CEMAT 006 = Dyckerhoff 007 = Heidelberger Zement

Reboot the PC.

File Structure After running the Setup the CEMAT specific files are located in drive D, directory CEM_V5.

D:\Cem_V5 \Bin CEMAT IndustrialX Controls \Bitmaps CEMAT V4 Bitmaps \Config Configuration Files \Docu Documentation in PDF format \Sounds Sound files for alarms \Tools \Terminator To close all PCS 7 applications \ua User Archive default \Video Video files \web html pages \WinCC \GraCS CEMAT Standard pictures and bitmaps \Library WinCC project functions for CEMAT \Pas WinCC project functions for CEMAT \Siemens WinCC standard functions for CEMAT

The CEMAT libraries ILS_CEM and PRO_CEM (only available if project standard is not ‘000’) are installed in the PCS 7 system directory and will be found after the installation under

C:\Siemens\Step7\S7libs



Adaptation in PCS 7 for CEMAT 1. Install the Fonts "wingdng3.ttf" under Control Panel -> Fonts -> "Install new Font“.

You will find this fonts in directory "d:\cem_v5\tools\windng3.ttf"

2. Copy all files under d:\Cem_v5\WinCC\Siemens to c:\Siemens

3. Adaptations in the Config-Files (uner D:\Cem_V5\Config) should be carried out on the Engineering Station and the transferred to all other Stations.

Make sure that all the modified Config-Files are saved additionally to a backup directory, because these files will be overwritten in case of a CEMAT Upgrade!

Open file C_Config.cfg and define under [ServerPrefix] the allotted Server for each PLC. The server name must be identical with the definition under Server Data (WinCC-ProjectName_Server-PCName.)

Example: [ServerPrefix] ;PLC No. = ProjectName_PCName ;e.g.: 1=OS1_SRV1291 1=E518283D_E518283D 2= 3= 4= 5= 6= 7= 8= 9= 10= 11= 12= 13= 14= 15= 16= 17=E518281D_E513888D 18= 19= 20=

In the example above the data from PLC 1 and PLC17 are displayed

Those declarations are required for the following functions:

- acknowledgement of alarms by the means of the variable SYSPLCx on a mc

- to build the list of servers for the plant (C_PlantSelection)

- opening of the „Info Dialog“ from the alarm-line.

4. Adaptations in the LMHOSTS file. Descriptions see Chapter 14, “Tips and Tricks”.



Create a new PCS7 Project Define a directory where all the PCS 7 projects will be stored in the future. We don’t recommend to use the default directories under D:\SIEMENS\STEP7\S7Proj. We recommend to create a separate directory on D drive.

Use Options -> Customize to select the new directory under ‘Storage location for projects‘. Use directory D:\PROJECTS to save your PCS 7 projects.

In the SIMATIC Manager create a new project using File -> New.

Select New Project and define the project name. Check the Storage location (it should be the previously selected directory.

Create a new PLC and define Hardware For each PLC:

Select project and use right mouse button to insert a new object. Select SIMATIC 400 Station and rename it (e. g. PLC03).

Select the station and open the HW Config Editor. Add all elements of your PLC Hardware and parameterize.

On the following pages you find all the settings you have to follow in the Configuration of a PLC.



Define AS Hardware Select form Hardware Catalog -> SIMATIC 400 -> RACK-400 the Rack you want to use for your PLC and drop it to the sheet. Select a power supply, CPU and a CP according to your hardware configuration.

When dropping the CPU create a new PROFIBUS and connect it.



Settings in tab Start-up:

Under “Start-up after Power ON” Warm Restart must be selected



Settings in tab Cycle/Clock Memory:

Enter the Scan Cycle Monitoring Time. 2000ms is a recommendation.

Enter the Minimum Scan Cycle Time of 100ms

Select Clock Memory. The memory Byte must be 0



Settings in tab Memory:

These are the minimum values for Local Data per each priority class. You have to check the required local data after completing the user program and modify the local data values if necessary.

Bigger CPUs probably have more memory for local data.

Please set the maximum Communication Jobs to 1800 if the type of CPU allows this.



Settings in tab Memory:

The PLC synchronization type should be as Slave

Note: The PLC is always working with winter time!



When dropping the CP443 connect the same to the Ethernet bus. If no Ethernet bus exists, create a new Ethernet bus and connect it to the CP443. Define the Ethernet Address for the PLC, e. g. 08.00.06.01.12.01 (MAC Address).

Properties for Ethernet interface:



Under Options you have to activate the time-of-day synchronization:



Define the I/O Periphery and parameterize:



Enter the properties for the analog input and analog outputs cards:

Save and Compile the hardware definitions and load it to the PLC.

Rename S7-Program Back in the SIMATIC Manager you see the elements of the Hardware Configuration (CPU, CP) under each PLC Station. Below this you find the Program Container for the elements. For better identification we recommend to rename the S7 Program Container for the CPU (e. g. P_PLC03).



Create a new OS For PC Station:

Select project and use right mouse button to insert a new object. Select SIMATIC PC Station and rename it (e. g. Station name).

Caution: The character “_” is not allowed in the Station names!

Select the Configuration of the Station and open the HW Config Editor.

Select the appropriate WinCC Application and drop it into your project. If a CP is available also insert this into your project.

Save the HW Config. This creates an OS-Project for the station. You should rename this OS-Project afterwards in the Simatic Manager into the real station name. Underscore is also not allowed here.

Under “OS Configuration (Single-User System)” you find the steps you have to follow in the Configuration of a Single-User Station. We recommend to create an OS-Project as a Single-User Station which is used for the Engineering and to test the engineering data on the ES.

To avoid the repetition of all steps for the Server-Project, this can be created by copying the OS-Project for the Single-User Station. After copying the project some modifications are required which you find under “OS Configuration (Server-Project).

Under “OS Configuration (Standby-Server-Project)” you find all the required settings for a Standby-Server Project.

Under “OS Configuration (MultiClient)” you find all the settings which have to be performed for a MultiClient Project.



Plant Structure definition (Plant view) In the component view of the SIMATIC Manager the Stations were inserted and the plant configuration was defined. Now you have to use the plant view of the SIMATIC Manager to structure the plant according to technological criteria.

For the technological structure the plant designation system and the message philosophy are very important. Refer to point “Designation rules for Cemat” in chapter 2 of this manual (Preparations).

Example:



The names of the hierarchy folders can be limited for maximum number of characters. The names can be included completely or partly for the designation system.

The settings for max. number of hierarchy folders, max. number of characters, include in designation you will find if you select a hierarchy folder with the right mouse button and use Options -> Plant Hierarchy -> Customize.

For a Cement plant 3 hierarchy folders should be (more than) enough.

The OS Area is used in Cemat to filter the messages in the alarm line. In the Runtime you can select from which OS Area messages should be displayed.



Before you can add a CFC, you have to make the PLC and OS Assignment. Select the hierarchy folder and go the object properties and assign in folder PLC and OS assignment the chart folder for the assigned PLC and the assigned OS.

All Elements you add to this hierarchy folder will be assigned to this PLC/OS. If you pass the Selected Assignments to the Lower-level Objects, the subordinated hierarchy folders get the same PLC/OS Assignment.

Important: Please create new CFC only in the plant view. They will automatically be stored in the chart folder of the assigned PLC. CFC which are created in the component view are not assigned to any hierarchy folder in the plant view!



PLC Configuration

Copy Standard Symbols and blocks into the PCS 7 Project The CEMAT Standard Library ILS_CEM contains the S7 Program ILS_CEM, which has the Standard Symbols and the blocks for CEMAT, ILS_PTE and ILS. For project standards with key unequal to ‘000’ the library PRO_CEM contains the project specific blocks. (For project key = ‘000’ the library PRO_CEM does not exist.)

- Copy first the symbols from ILS_CEM into the S7 Program Container of your PLC.

- Copy all blocks from ILS_CEM into the block Container of your PLC.

- Copy all blocks from PRO_CEM into the block container of your PLC (overwrite the existing blocks).

Preparations for programming with the CFC Select the CPU S7 Program (e. g. P_PLC03).

The S7 Program contains three Folders: Sources, Symbols and Blocks. You have to insert one more folder for Charts using Insert New Object -> Chart folder. Select the Chart folder and insert a new object of type CFC.

Define illegal Ranges for CFC blocks:

With a double-click on CFC1 the CFC editor will open. To define the illegal ranges to Options -> Customize -> Compilation.



DB 1 to 999 FC 0 to 1800



Copy the blocks for CEMAT, ILS and ILS_PTE into the chart folder:

In the CFC-Editor go to Options -> Block types. Select the blocks from the offline block folder and copy it into the chart folder:

List of blocks, which have to be copied into the chart folder: Absolute Symbol Task Absolute Symbol Task FB1001 C_DRV_1D OB1 FB1052 C_PLC_SEND OB1 FB1002 C_DAMPER OB1 FB1053 C_PLC_RECEIVE OB1 FB1003 C_DRV_2D**) OB1 FB1054 C_PLC_PLC OB1/OB35 FB1004 C_ANNUNC OB1 FB503 TE_VSLCT OB1*) FB1006 C_MEASUR OB1 FB513 TE_CTRL OB35*) FB1007 C_VALVE OB1 FC527 OB100_SYS1 OB100 FB1009 C_ROUTE OB1 FC528 OB1_SYS2 OB1 FB1010 C_GROUPE OB1 FC529 OB35_SYS1 OB35 FB1011 C_SILOP OB1 FC530 OB35_SYS2 OB35 FB1013 C_SELECT OB1 FC1001 C_SPEEDM OB35 FB1015 C_COUNT OB35 FC1011 C_SPCNT OB35 FB1016 C_RUNNT OB1 FC1017 C_MUX OB1 FB1020 C_FB_PLC OB1 FC1088 C_PUSHBT OB1 FB1026 C_MEAS_I OB1 FC1102 OB1_SYS1 OB1 FB1031 C_DRV_SIMO_2D**) OB1 FC1103 C_OB1SY1 OB1 FB1032 C_DAMP_SIMO**) OB1 FC1018 C_ADAPT OB1

*) This block can also be called from a different Task.

**) The blocks C_DRV_2D, C_DRV_SIMO_2D and C_DAMP_SIMO are not available for all Project Versions of CEMAT. Please check PRO_CEM library for availability of the blocks!

After this close the CFC1 and delete it.



Copy the system chart into the PCS 7 Project In the chart folder of the CEMAT library ILS_CEM you will find the system chart SYSPLC00. This system chart is required once in each PLC.

First define in the plant view a hierarchy folder for the system chart. Then copy the system chart from the library into this hierarchy folder. Change the name of the system chart according to the PLC number (e. g. SYSPLC02).

The system block C_PLC_PLC is only required, if the PLC-PLC-Coupling of CEMAT is used. In this case the CP-Address of the CP443 for Bus A and Bus B (e. g. 16372 and 16376) must be entered into the parameters BUS_A_AD and BUS_B_AD. Parameter PLC_NO must have the PLC-Number of the own PLC. The function block is called in the once in the restart (AS_RESTART) and once in OB1 (MAIN_TASK). For detailed description see chapter PLC-PLC-Coupling.

Loadable PLC-Program Once the configuration settings have been made in the system chart the PLC Program is loadable and executable.

Warning: To start the PLC with the Programmer only Warm Restart is allowed!

After these steps you can start with the PLC Engineering. In chapter 6 of this manual “PLC Engineering” you find some additional advises.



OS Configuration (Single-User System) The WinCC Project (OS-Project) for the Single-User System was already defined with the SIMATIC Manager. The following settings have to be carried out in the OS-Project, which means you have to open WinCC. This can be done directly from the SIMATIC Manager through selection of the OS with right mouse button and Open Object of from the Start Menu under Start -> Simatic -> WinCC -> WinCC Control Center 5.1.

Important: The following steps must be carried out from the beginning in the engineering language which is used for the project. If you change the language afterwards the language dependent setting have to be performed again. The language settings in SIMATIC Manager are not consistent with the settings for WinCC!!

Selection of Project Type Single-User System Generating a new OS-Project of type “WinCC Application“ automatically a “Multi-User System is created. As there is usually no server licence available on an Engineering Station we recommend to change the setting to Single-User System.

In the Windows Control Center select the Project name and go to Properties, Folder General in order to select Type Single-User System.

Base data -> Split Screen Wizard With the Split Screen Wizards screen configuration and the resolution for the OS Project will be initialized and configured. The Split Screen Wizards must always run at the beginning of the engineering of a new OS Project, because in Runtime mode WinCC uses the data which have been generated through the Wizard. The Split Screen Wizard defines the @Screen.PDL as start picture

The Split Screen Wizard is called from folder Base Data in the control center.



Screen resolution for a Single-User-Project In the first dialog the screen layout is fixed. Please select the layout for screen resolution SIMATIC Standard 1280*1024.

Screen resolution for a Multi-User-Project (Server) In the first dialog the screen layout is fixed. Please select the layout for screen resolution SIMATIC Server 1280*1024.



Multi-VGA In the next screen of the Wizard the desired monitor configuration is selected. Please select a single monitor system.



Display of the selected Configuration for a Single-User-Project The third page shows the actual settings for the screen configuration. With „Finish“ the OS Project will be configured with the previously selected values.

Display of the selected Configuration for a Multi-User-Project (Server) The third page shows the actual settings for the screen configuration. With „Finish“ the OS Project will be configured with the previously selected values.



Split Screen Wizard - Generation The generation dialog shows all steps of the screen configuration of the OS.

At the end of the generation the OK Button is shown and must be pressed.



Base data -> Alarm Logging Wizard The Alarm Logging Wizard generates a complete message system for the actually open OS project. The wizard guaranties that the message system is configured in conformity with PCS 7. Parameters have to be changed only in the Alarm Logging Wizard. If you run the Alarm Logging Wizard a second time the previously defined settings are used.

The Alarm Logging Wizard is called from folder Base Data in the Control Center.

Generating the message windows The first dialog allows to modify the default settings for the column width in the message window. The Connection of the Signal Module is not required because the alarm sound is generated via sound file.



Activation of Control System Messages The second dialog is used to enable or disable individual process control system messages. A control box displays the status of the messages.

Use the control box „System Messages“ to incorporate predefined messages in the system. These messages are imported into the alarm system upon activation of the control box.

Use the control box „Filter messages area-specific“ to filter Runtime messages depending on the status of the user authorization matrix. If the control box is activated, messages are filtered according to the user. If the control box is deactivated, all messages are displayed.

Please use the default settings.

Use the control box „Do not display the warning for the area-specific filtering again“ to deactivate the following dialog:

Confirm with OK.



Assignment of output channels The following Dialog appears only if the Signal Module is connected. The output channels of the Signal Module are assigned to the message class. It is specified which signal is to be activated for each individual message class.



Overview In the following overview all elements are listed according to the settings of the dialogs before. With „Finish“ all elements of the message system are created.



Message Wizard - Generation The generation dialog shows all steps of the configuration of the message system.




General changes in the alarm logging Select the „Alarm Logging“ in the WinCC Explorer and use right mouse button to open the alarm logging editor.

Click on the plus symbol in front of Message blocks

Select System blocks - Use right mouse button to click on „Date“ and select properties - Change the following settings: Date: Four-Digit Day.Month.Year

- Use right mouse button to click on „Time“ and select properties Time: H/M/S (deselect Milliseconds)

Select User text block - Use right mouse button to click on „Origin“ and select properties - Change the following settings: Change „Origin“ to „Tag“ Length = 22 Flashing = off

- Use right mouse button to click on „Event“ and select properties - Change the following settings: Length = 20 Flashing = off

- Use right mouse button to click on „Free 1“ and select properties - Change the following settings: Change „Free 1“ to „Tag Comment“ Length = 42

- Use right mouse button to click on „Free 2“ and select properties - Change the following settings: Change „Free 2“ to „FCL“ (Fault class) Length = 2 Flashing = off

Select Process value blocks - Use right mouse button to click on „Process_Value_1“ and select properties - Change the following settings: Change „Process_Value_1“ to „Old value“

- Use right mouse button to click on „Process_Value_2“ and select properties - Change the following settings: Change „Process_Value_2“ to „New value“



Message classes and message types Click on the plus symbol in front of Message classes

Change the settings for „Alarm“, „Warning“, „PLC Process Control System Messages“, „Process Message“, „Operator Input Messages“ according to the following table.

- Use right mouse button to click on „Alarm“ and select properties Go to folder „General Information“ and select „Properties“ button to change the colors. Go to folder „Acknowledgement“ to change the acknowledge parameters.

The colors and message types have to be changes as follows:

Message

class Message

Type Came in Went out Acknowledged

Text

color Back-ground color

Textcolor

Back-ground color

Text color

Back-ground color

Must be ackn.

Come in must be acknowl.

Flashing

Alarm H L

white red black green black pink yes

yes off

Warning H L

black yellow black green black light yellow

yes yes off

PLC System

Message

Failure white red black green black pink yes

yes off

Process Message

Process white red black green black pink yes yes off

Operator Input

Message

black turquoise no no off

The acknowledge philosophy for the message classes „Alarm“, „Warning“, „PLC Process Control System Messages“ and „Process message“ has to be configured as follows:

- Acknowledge Came In: yes

- Acknowledge Went Out: no

- Flashing on: no

- Only initial value: no

- Messages without status Went Out: no

- Separate Acknowledge key: no

- By means of single acknowledge: yes



Create the short-term archive for diagnosis In the Alarm Logging Editor use right mouse button click on Archives and then select Add/Remove. In the next dialog both Archives have to be selected. The short-term archive appears.

Double-click on the short-term archive and change the properties as follows:

Double-click on the long-term archive and change the properties as follows:

Archive includes: 8 Days

Exit the alarm logging editor and save the changes.



Computer properties The following configuration settings are valid for the Engineering phase of a WinCC Project. During the commissioning of the WinCC Project a special configuration has to be performed.

Select the Icon Computer - Select the computer name in the right part of the window. - Use right mouse button to click on the computer and select Properties.

General computer properties In the folder „General“ the basic settings for the computer are shown. The split screen wizard has already entered the computer name. The computer name can be seen under Start -> Settings -> Control Panel -> Network. Changes are not required as long as you work with the same computer.

As Computer Type the Server is selected.




Computer Startup In the computer startup list all the applications are selected which will be started with the activation of the runtime mode.



Computer Parameters In the folder Parameters the settings for the Language at Run Time and the disable keys are configured. The language at run time depends on the project. At the operator station all key combinations are disabled, to prevent the operator from reaching the operating system of the operator station.



Graphics-Runtime For each Computer the following settings in Graphics Runtime have to be done. Normally these settings have automatically been generated by the Split Screen Wizard before.



Tag Management Open the Tag Management and add the following internal variables:

Name: C_AcknowledgeHorn Datatype: Unsigned 32-Bit Value Project-wide update

Per PC Station, whose OS-Project will be created based on the Master-OS-Project (ES, SERVER, Standby-SERVER), you have to add an additional internal variable:

Name: C_<ComputerName>_AlarmSound (<ComputerName> must be replaced according to your PC name) Datatype: Signed 16-Bit Value Computer-local update

Before the next step the transfer of PLC-OS Connection data has to be performed once (otherwise the SIMATIC S7 PROTICOL SUITE is not available).

In the WinCC Explorer click on the plus symbol in front of Tag Management - Select SIMATIC S7 PROTOCOL SUITE - Use right mouse button to click on Industrial Ethernet and select System Parameter - Select Cycle formation by PLC - close with OK



Add User rights In the WinCC Explorer click open the User Administrator and add the rights from No. 18 according to the following list:

Select the user specific rights.



The following table shows how the user rights are assigned to the Cemat Functions: No. Comment Function 1 User Administration WinCC Function 2 Authorization for Area WinCC Function 3 System change WinCC Function 4 Monitoring WinCC Function 5 Processcontrolling e. g. start and stop groups or drives, selection and

deselection of routes.... 6 Higher

Processcontrolling e.g. Change of Controller modes Closed loop control/ open loop control, Internal/External

7 Reportsystem WinCC Function 8 Archive controlling WinCC Function 18 Modify warning limits

Measuring value

19 Modify alarm limits Measuring value 20 Modify switching limits Measuring value 21 Controller Parameters Modification of the Controller parameters for TE_CTRL

and TE_VSLCT 22 Object parameters Change process values and Release options in the

diagnostic picture 23 System operations Special Functions: e.g. Release Functions 24 Interlocking signals Special Functions: e.g. Service for measuring value,

non-interlocked single-start 25 Enter Recipe Recipe 26 Read Recipe Recipe 27 Modify Info-Dialog Info-Dialog Tab 1-3 (Object data) 28 Object-Info

Parameters Info-Dialog Tab 4 (System settings)



CEMAT specific preparations Before you start with the generation of the process pictures you have to copy the Cemat Functions in to your Project. These are Global Script Actions, Project Functions, Standard Pictures and Bitmaps. Please proceed as follows:

- Close the WinCC Explorer

- Copy the Global Scripts from 'D:\CEM_V5\WinCC\Library' into the PCS 7 Project ...\wincproj\<OS>\Library'.

- Copy the Global Scripts from 'D:\CEM_V5\WinCC\Pas' into the PCS 7 Project ...\wincproj\<OS>\Pas'. On PC Stations without message line (e. g. Server) you have to delete the file PlaySoundForAlarm.pas.

- Copy from ''D:\CEM_V5\WinCC\GraCS' all Objects into the PCS 7 Project ...'wincproj<OS>\GraCS' The following standard pictures contain adaptations for CEMAT. The existing pictures must be overwritten by the pictures from the CEM_V5 directory.

@Overview1.pdl Overview @AlarmOneLine.pdl Alarm line @Buttons11.pdl Button keys1 @Buttons12.pdl Button keys2 @Buttons13.pdl Button keys3 @PTN0.pdl Template for Picture Tree

- Open the WinCC Project.

- Open 'Global Script' and regenerate Header. (Menu Options -> Regenerate Header)



Adaptations in the standard pictures for the message system For the acknowledge functions in CEMAT (acknowledge alarm, acknowledge horn) the pictures for alarm line and button keys were adapted. The pictures have been copied into your project in the step “ CEMAT specific preparations”. Dependent on your plant configuration and the message philosophy additional modifications have to be performed in these pictures.

You must modify the acknowledge button function in the alarm line and the button keys to send the acknowledge signal of the relevant PLC.

The following functions are available:

AcknowledgeAlarm(<PLC-No.>) Acknowledge fault AcknowledgeHorn(<PLC-No.>) Acknowledge horn

or

C_AcknowledgeAlarm(<PLC-No.>,<“System chart“>) Acknowledge fault C_AcknowledgeHorn(<PLC-No.>,<“System chart“>) Acknowledge horn

The first two functions AcknowledgeAlarm and AcknowledgeHorn can be used if the name of the plant view hierarchy folder is not included in the designation system. The function uses the variables of the System chart SYSPLCxx and therefore the PLC-No. must correspond with the number of the System chart.

Example:

AcknowledgeAlarm(13) and AcknowledgeHorn(13) sends the acknowledge signal to SYSPLC13.

The function C_AcknowledgeAlarm und C_AcknowledgeHorn must be used if the name of the plant view hierarchy folder is included in the designation system. You must add the name of the system chart to the function (including the name of the hierarchy folder).

Example:

The name of the Hierarchy folder „RM2“ is part of the designation system which means the system variables start with RM2/SYSPLC13....... The functions must be adapted as follows: C_AcknowledgeAlarm(13,“RM2/SYSPLC13“) and C_AcknowledgeHorn(13,“RM2/SYSPLC13“)

Caution: There are different functions for Server and MultiClient which means the pictures cannot be copied from the Server to the MultiClient.



In the WinCC Explorer select the Graphics Designer and double-click on @AlarmOneLine.pdl.

- Select Button34 (the only button in the picture) - go to Properties, Register Event - Select Mouse and double-click on “Press left”

To acknowledge alarms and horn one additional line must be added per PLC:

Add code: AcknowledgeAlarm(<PLC-No.>) or C_AcknowledgeAlarm(<PLC-No.>,<“System chart“>)

- Select Button34 (the only button in the picture) - go to Properties, Register Event - Select Mouse and double-click on “Press right”



To acknowledge the horn one additional line must be added per PLC:

Add code: AcknowledgeHorn(<PLC-No.>) or C_AcknowledgeHorn(<PLC-No.>,<“System chart“>)



In order to allow the acknowledge of alarm and horn from the button keys the standard pictures for button keys have to be modified as well.

@Buttons11.PDL Button15 (acknowledge horn) and Button16 (acknowledge alarm) @Buttons12.PDL Button2 (acknowledge horn) and Button16 (acknowledge alarm) @Buttons13.PDL Button15 (acknowledge horn) and Button16 (acknowledge alarm)

In the WinCC Explorer select the Graphics Designer and double-click on @Buttons11.pdl.

To acknowledge the horn one line has to be added per PLC:

- Select Button15 or Button2 (horn symbol) - go to Properties, Register Event. - Select Mouse and double-click on “Mouse Action”

Add code: AcknowledgeHorn(<PLC-No.>) or C_AcknowledgeHorn(<PLC-No.>,<“System chart“>)

- Select Button16 (acknowledge alarm symbol) - go to Properties, Register Event. - Select Mouse and double-click on “Mouse Action”




Add code: AcknowledgeAlarm(<PLC-No.>) or C_AcknowledgeAlarm(<PLC-No.>,<“System chart“>)

The same changes are required for the pictures @Buttons12.pdl and @Buttons13.pdl.

Caution: Don’t forget to save the modified standard pictures. If you have to start the split screen wizard again the standard pictures will be overwritten.

General Screen structure The general screen structure was created from the split screen wizard according to your settings.

The start picture is always @screen.pdl The following PDLs are assigned to this @OVERVIEW1.pdl as Overview range @1001.pdl as Working range @Buttons11.pdl as Buttons

The @OVERVIEW1.pdl can be adapted respecting number of area selection buttons and collecting fault annunciations.

Please take care that this PDL has to be saved because if you run the Split Screen Wizard the PDL will be overwritten.



Picture Tree Manager To create the picture tree the process pictures must be available. It is sufficient to create empty process pictures. The description for the generation of the process pictures you find in chapter 8 “OS Engineering”.

Creating the Picture Tree It is possible to create the picture tree automatically from the plant view during PLC-OS-Connection data Transfer or to create it manually in the WinCC Project. This description shows the manual way.

The Picture Tree Manager is used to define the hierarchy for the process pictures.

The Picture Tree Manager is opened from the WinCC Explorer.

The empty Picture Tree Manager appears:

In the field for „Hierarchy of the containers and pictures“ use Menu or right mouse button to insert new containers in different levels. (The length of the container names can not be fixed, because a proportional character set (Arial) is used. You have to check in Runtime weather the text fits.) To each Container a Picture has to be assigned. The pictures must exist before. All unassigned pictures, shown in the field „Unassigned containers and pictures“ can be moved into a container (with pressed right mouse button).

The fist level shows the menu buttons of the Split Screen Wizard. In the first level there will be a maximum of 16 pictures. The amount of pictures in the lower levels is free.

All pictures which use the complete process range of the screen must be included in the hierarchy. Picture windows (e.g. Header line) are not included into the hierarchy.



Example for a Picture tree manager:

Language change To provide an online language change of the container names (button text ) you have to do as follows:

Start Picture Tree Manager PTM and complete the hierarchy. Write the Container names in the language which is set in the Control Center.

Save Picture Tree Manager and exit.

Change language for the Control Center.

Open Picture Tree Manager again. (The container names will be shown in the 1st language.) Translate the container names and save again.

Each change in the Picture Tree Manager has to be carried out in both languages.

Caution: Theoretically it is also possible to make the translations in the text library. We don’t recommend to do so, because in case of a mistake the Picture Tree Manager cannot be started again.



OS Configuration (Server-Project) The configuration of an OS as a Server-Project mainly corresponds with the Configuration of a Single-User System and it is therefore not described in detail.

To avoid the repetition of all steps for the Server-Project, it is easier first to complete the engineering and test the engineering data on the engineering station and then to copy the complete OS-Project in the SIMATIC Manager. After copying, still in the SIMATIC Manager modify the name of the PC Station and the Name of the OS-Project. Don’t modify the computer name in the Server-Project (Computer Properties). The computer name will be replaced automatically during the download.

Caution: If the OS-Project on the ES contains Archives in Dbase Format, you have to delete all files from directory PDE in the generated Server-Project. If this is not done old archives will be transferred to the Server Station during Server Download.

The following modifications are required to change the copied Single-User System into a Server-Project:

1. Change the OS-Project from Single-User System to Multi-User System. Don’t delete the Startup list!

2. Run the Split Screen Wizard to change into Server view (evtl. a different resolution is required, if the monitors are not able to handle the high resolution).

3. Under Global Scipts: Delete file PlaySoundForAlarm.pas (because the Server doesn’t have an alarm line). If the file is deleted in the NT Explorer, Header must be generated again!

4. In the Network-Configuration the new OS-Project must be connected to the H1 Bus and the correct Ethernet Address (MAC-Address) must be given.

5. Select Target OS In the SIMATIC Manager select the Server-Project and use Object Properties, folder Target OS and Standby OS Computer to select the Path to the Target OS Computer.

OS Configuration (Standby-Server-Project) The Standby-Server-Project doesn’t contain any data. There is only a reference to the Master- Server-Project. The following settings have to be performed.

1. In the Network-Configuration the Standby-Server-Project must be connected to the H1 Bus and the correct Ethernet Address (MAC-Address) must be given.

2. Select Target OS In the SIMATIC Manager select the Standby-Server-Project and use Object Properties, folder Target OS and Standby OS Computer to select the Path to the Target OS Computer.



Redundancy Settings in the Server-Project After the Server-Project and the Standby-Server-Project are configured, in the Server-Project the corresponding Standby-Server-Project must be selected and the redundancy settings have to be performed.

1. Select the Server-Project in the SIMATIC Manager and select in the Properties under Target OS and Standby-OS the corresponding Standby-OS.

2. Open the Server-Project and carry out the redundancy settings: - Select the Redundant Partner Server. - After selecting the options according to your requirement activate the Redundancy.



OS Configuration (MultiClient) The OS-Project for the MultiClient can be created on the Engineering Station or directly on the MC Station. To improve the administration of the project data we recommend to create the OS-Project on the ES and to download the project to the MC Station.

The following settings have to be performed in the OS-Project.

Important: The following steps must be performed from the beginning in the engineering language which is used for the project. If you change the language afterwards the language dependent setting have to be performed again. The language settings in SIMATIC Manager are not consistent with the settings for WinCC!!

Base data -> Split Screen Wizard With the Split Screen Wizards screen configuration and the resolution for the OS Project will be initialized and configured. The Split Screen Wizards must always run at the beginning of the engineering of a new OS Project, because in Runtime mode WinCC uses the data which have been generated through the Wizard. The Split Screen Wizard defines the @Screen.PDL as start picture

The Split Screen Wizard is called from folder Base Data in the control center.



Screen resolution In the first dialog the screen layout is fixed. Please select SIMATIC Standard 1280*1024.

Multi - VGA In the next screen of the Wizard the desired monitor configuration is selected. Please select a single monitor system.



Display of the selected Configuration The third page shows the actual settings for the screen configuration. With „Finish“ the OS Project will be configured with the previously selected values.



Split Screen Wizard - Generation The generation dialog shows all steps of the screen configuration of the OS.




Base data -> Alarm Logging Wizard The wizard guaranties that the message system is configured in conformity with PCS 7. Parameters have to be changed only in the Alarm Logging Wizard. If you run the Alarm Logging Wizard a second time the previously defined settings are used.

The Alarm Logging Wizard is called from folder Base Data in the Control Center.

Activation of the messages Use the control box „Filter messages area-specific“ to filter Runtime messages depending on the status of the user authorisation matrix. If the control box is activated, messages are filtered according to the user. If the control box is deactivated, all messages are displayed.

Use the control box „Do not display the warning for the area-specific filtering again“ to deactivate the following dialog:

Confirm with OK.



Assignment of output channels In the following dialog the output channels are assigned to the message class. It is specified which signal is to be activated for each individual message class.



Message Wizard - Generation The finish button starts the configuration of the message system. Only Step 10 is executed.




Computer properties The following configuration settings are valid for the Engineering phase of a WinCC Project. During the commissioning of the WinCC Project a special configuration has to be performed.

Select the Icon Computer - Select the computer name in the right part of the window. - Use right mouse button to click on the computer and select Properties.

General computer properties In the folder „General“ the basic settings for the computer are shown. The split screen wizard has already entered the computer name. The computer name can be seen under Start -> Settings -> Control Panel -> Network. Changes are not required as long as you work with the same computer.

As Computer Type the MultiClient is selected.

Caution: The Computer name corresponds with the computer name of the Engineering Station. Don’t change the name now. During the Project-Download the name is replaced automatically by the name of the MultiClient Station.



Computer Start-up In the computer start-up list all the applications are selected which will be started with the activation of the runtime mode.



Computer Parameters In the folder Parameters the settings for the Language at Run Time and the disable keys are configured. The language at run time depends on the project. At the operator station all key combinations are disabled, to prevent the operator from reaching the operating system of the operator station.



Graphics-Runtime For each Computer the following settings in Graphics Runtime have to be performed. Normally these settings have automatically been generated by the Split Screen Wizard before.



Tag Management Open the Tag Management and add the following internal variables:

Name: C_AcknowledgeHorn Datatype: Unsigned 32-Bit Value Project-wide update

For each PC Station with MultiClient Function you have to add an additional internal variable:

Name: C_<ComputerName>_AlarmSound (<ComputerName> must be replaced according to your PC name) Datatype: Signed 16-Bit Value Computer-local update

Add User rights In the WinCC Explorer click open the User Administrator and add the rights from No. 18 according to the following list:

Under OS Configuration (Single-User System) you find a table which shows how the user rights are assigned to the Cemat Functions. The user rights related to specific areas can only be configured after the package is loaded.



CEMAT specific preparations - Close the WinCC Explorer

- Copy the Global Scripts from 'D:\CEM_V5\WinCC\Library' into the PCS 7 Project ...\wincproj\<OS>\Library'.

- Copy the Global Scripts from 'D:\CEM_V5\WinCC\Pas' into the PCS 7 Project ...\wincproj\<OS>\Pas'.

- Copy from ''D:\CEM_V5\WinCC\GraCS' all Objects into the PCS 7 Project ...'wincproj<OS>\GraCS' The following standard pictures contain adaptations for CEMAT. The existing pictures must be overwritten by the pictures from the CEM_V5 directory.

@Overview1.pdl Overview @AlarmOneLine.pdl Alarm line @Buttons11.pdl Button keys1 @Buttons12.pdl Button keys2 @Buttons13.pdl Button keys3 @PTN0.pdl Template for Picture Tree

- Open the WinCC Project

- Open 'Global Script' and regenerate Header. (Menu Options -> Regenerate Header)



Adaptations in the standard pictures for the message system For the acknowledge functions in CEMAT (acknowledge alarm, acknowledge horn) the pictures for alarm line and button keys were adapted. The pictures have been copied into your project in the step “ CEMAT specific preparations”. Dependent on your plant configuration and the message philosophy additional modifications have to be performed in these pictures.

You must modify the acknowledge button function in the alarm line and the button keys to send the acknowledge signal of the relevant PLC.

The following functions are available:

AcknowledgeAlarmFromMC(<PLC-No.>) Acknowledge fault AcknowledgeHornFromMC(<PLC-No.>) Acknowledge horn

or

C_AcknowledgeAlarmFromMC(<PLC-No.>,<“System chart“>) Acknowledge fault C_AcknowledgeHornFromMC(<PLC-No.>,<“System chart“>) Acknowledge horn

The first two functions AcknowledgeAlarmFromMC and AcknowledgeHornFromMC can be used if the name of the plant view hierarchy folder is not included in the designation system. The function uses the variables of the System chart SYSPLCxx and therefore the PLC-No. must correspond with the number of the System chart.

Example:

AcknowledgeAlarmFromMC(13) and AcknowledgeHornFromMC(13) sends the acknowledge signal to SYSPLC13.

The function C_AcknowledgeAlarmFromMC und C_AcknowledgeHornFromMC must be used if the name of the plant view hierarchy folder is included in the designation system. You must add the name of the system chart to the function (including the name of the hierarchy folder).

Example:

The name of the Hierarchy folder „RM2“ is part of the designation system which means the system variables start with RM2/SYSPLC13....... The functions must be adapted as follows: C_AcknowledgeAlarmFromMC(13,“RM2/SYSPLC13“) and C_AcknowledgeHornFromMC(13,“RM2/SYSPLC13“)

Caution: There are different functions for Server and MultiClient which means the pictures cannot be copied from the Server to the MultiClient.



In the WinCC Explorer select the Graphics Designer and double-click on @AlarmOneLine.pdl.

- Select Button34 (the only button in the picture) - go to Properties, Register Event - Select Mouse and double-click on “Press left”


Add code: AcknowledgeAlarmFromMC(<PLC-No.>) or C_AcknowledgeAlarmFromMC(<PLC-No.>,<“System chart“>)

- Select Button34 (the only button in the picture) - go to Properties, Register Event - Select Mouse and double-click on “Press right”



To acknowledge the horn one additional line must be added per PLC:

Add code: AcknowledgeHornFromMC(<PLC-No.>) or C_AcknowledgeHornFromMC(<PLC-No.>,<“System chart“>)



In order to allow the acknowledge of alarm and horn from the button keys the standard pictures for button keys have to be modified as well.

@Buttons11.PDL Button15 (acknowledge horn) and Button16 (acknowledge alarm) @Buttons12.PDL Button2 (acknowledge horn) and Button16 (acknowledge alarm) @Buttons13.PDL Button15 (acknowledge horn) and Button16 (acknowledge alarm)

In the WinCC Explorer select the Graphics Designer and double-click on @Buttons11.pdl.

To acknowledge the horn one line has to be added per PLC:

- Select Button15 or Button2 (horn symbol) - go to Properties, Register Event. - Select Mouse and double-click on “Mouse Action”

Add code: AcknowledgeHornFromMC(<PLC-No.>) or C_AcknowledgeHornFromMC(<PLC-No.>,<“System chart“>)

- Select Button16 (acknowledge alarm symbol) - go to Properties, Register Event. - Select Mouse and double-click on “Mouse Action”




Add code: AcknowledgeAlarmFromMC(<PLC-No.>) or C_AcknowledgeAlarmFromMC(<PLC-No.>,<“System chart“>)

The same changes are required for the pictures @Buttons12.pdl and @Buttons13.pdl.

Caution: Don’t forget to save the modified standard pictures. If you have to start the split screen wizard again the standard pictures will be overwritten.



Generating and loading of the Packages

Creating of a package in the Server Project To make the Server data available for the MultiClient, a so-called package must be created in the Server-Project and loaded in the MultiClient-Project.

To create the package open the Server-Project on the Engineering Station and select from context menu „Server data“ the option „Create...“

The physical name must match with the Server-Name. The symbolic computer name is used as file name, e. g. SRVW1_SRVW1.pck.

Once the package is created a message box appears. Confirm this with o. k.

Creating and loading of packages can be performed in Runtime (RT) as well as in the Configuration System (CS). After changing of the engineering data on the server projects the packages have to be recreated. Using the „Update“ function the MultiClient is getting refreshed with the modified packages.

Close the Server-Project.



Loading of the Packages in a MultiClient Project: To load a package into a MultiClient, open the MultiClient-Project on the Engineering Station and use context menu of Server data and select Menu option „Loading“.

- In the "Open"-Dialog select the Server-Project and within that the computer name (in this case this is the name of the Engineering Station). There you find a folder “Packages”.

- In the folder Packages select the package-file (.pck) and click on "open". The Serverdata will be copied into folder „packages“ and is available in the MultiClient.

To select the standard server, use context menu of Server data and select menu option Standard server...

- Select the standard server for the components Alarms, SSM and User Archive.



Selection of a Preferred Server To distribute the load for the servers uniformly it is useful to connect a part of the MultiClients to one Server and the other part to the Standby-Server.

Therefore a Preferred Server must be configured under Serverdata -> Configure ...

Example:

If the preferred Server is stopped the MultiClient automatically switches to the Partner-Server. Once the preferred Server runs again, the MultiClient automatically switches back to the preferred Server.



Trigger for Action AcknowledgeHorn After loading the package(s) the Global Script Action ‘Acknowledge Horn‘ has to be adapted. Please follow the instructions:

- Open the action ‘Acknowledge Horn‘.

For each Server install one new Trigger with cyle ‘upon change‘.



Select the variable C_AcknowledgeHorn from the Tag Management of the corresponding Servers.

Selection of area specific rights Area specific rights can only be set after the MultiClient knows the areas, which means it is only possible after the package was loaded.

Consequently the area specific user rights must be set now.

Open the User Administrator from the WinCC Explorer and select the area specific rights.



Picture navigation on the MC For a MultiClient it has to be distinguished between three different kinds of operations:

Operation of all Server Pictures of the MultiClient from the overview range.

Combine one or more pictures from one ore more servers to one picture (picture-in-picture techniques)

Designing pictures which contain variables from different servers (these pictures are not selectable from the picture tree The selection is only possible with „picture by name“ or with a button function)

Overview range:

Hardcopy of the @Overview1.pdl of a Multi-Client.



Project-Download The Project-Download is used for the actualization of the OS-Data for Server, Standby-Server and MultiClient from the Engineering Station. All Engineering steps including creating and loading of the packages have to be performed previously on the Engineering Station.

A Project-Download is required if variables have been changed or if the Picture Tree has been expanded. The Project-Download is not necessary if e. g. only Pictures have been modified or Bitmaps have been added. These changes can directly copied into the target system(s).

The following description shows the procedure, if for example new objects have been added in the PLC and these objects shall be monitored on the Operator Stations (MultiClients).

1. To actualize the Tag Management a Transfer of PLC-OS Connection data (mapping) has to be performed. The transfer must be carried out into the OS-Projects of ES and Server.

2. Still on the Engineering Station you must open the Server-Project and create a new Package. After that close the Server-Project.

3. Now open the MultiClient Project on the Engineering Station and load the Package. Close the MultiClient Project.

4. After that you must close the OS-Project on the Server Station. First close the WinCC Explorer (if it is not already closed) and second the Runtime. The Standby-Server will be MASTER, the MultiClients will be switched to the Standby-Server.

Important: After closing the WinCC Project on the Server Station you have to wait for at least 2 minutes. During this time the project is still „used“.

5. Now you can carry out the Project-Download from the Engineering Station to the Server Station. The Server-Project on the Engineering Station must remain closed. The Download is carried out from the SIMATIC Manager.

Very important: After the Download is finished you have to wait another minute before you open the OS-Project on the Server again. The download seems to be completed but the data is still in use. If you don’t wait you probably won’t be able to open the OS-Project on the Server any more.

6. After both Servers are running again, the Redundancy Manager starts actualizing the Server data. If possible wait until the procedure is finished.

7. Now you can close the OS-Project on the Standby Server Station. First close the WinCC Explorer (if it is not already closed) and second the Runtime. The Server will be MASTER, the MultiClients will be switched to the Server.

Important: After closing the WinCC Project on the Standby-Server Station you have to wait for at least 2 minutes. During this time the project is still „used“.

8. Now you can carry out the Project-Download from the Engineering Station to the Standby-Server Station. The Download is carried out from the SIMATIC Manager.

Very important: After the Download is finished you have to wait another minute before you open the OS-Project on the Standby-Server again. The download seems to be completed but the data is still in use. If you don’t wait you probably won’t be able to open the OS-Project on the Standby-Server any more.

9. If a default Server is selected for the MultiClient, the MultiClient automatically switches to the default Server as soon as it is available.



Further Information to the Project-Download you find in the FAQ „Using the Project-Download Function in PCS7 V5.1“ from 3.1.2002 (Beitrags-ID: 7675576 in PCS7).

Engineering Manual V5 Assignments

Copyright Siemens AG. Alle Rechte vorbehalten. 4 - 1 Ausgabe : 04.05.1998 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\04_Assignments.doc

Assignments

Content Assignments 1

Assignments FB, FC, DB.........................................................................................2 Memory, Timer, Counter ..........................................................................................4

Assignments Engineering Manual V5


Assignments FB, FC, DB

FB FC 000 PCS7 499

001 PCS7 400

500 ILS 799

500 ILS 799

800 SISTAR 999

800 SISTAR 999

1000 CEMAT 1199

1000 CEMAT 1199

1200 WATER 1399

1200 WATER 1399

1400 SUGAR 1599

1400 SUGAR 1599

1600

1600 User 1799

User 2047

1800 CFC-Tasks 2047 *

Engineering Manual V5 Assignments


DB UDT 001 PCS7 399

001 ILS 499

400 User 599

500 SISTAR 999

600 all Technologies 999

1000 CEMAT 1499

1000

1500 WATER 1999

2000 SUGAR 2499

CFC-Instances 2500 User

4095

4095

Assignments Engineering Manual V5


Memory, Timer, Counter

Memory 0000.0 PCS7 0000.7 0001.0 ILS 0099.7 * 0100.0 CEMAT 0199.7 0200.0 **User 2047.7

** The biggest memory address depends on the selected CPU

ILS and CEMAT Standards don‘t use Timers and Counters

* Please consider that the quantity differs from CPU type to CPU type. The above mentioned numbers refer to CPU 416-2.

Engineering Manual V5 Engineering Examples

Copyright Siemens AG. All Rights Reserved. 5 - i Ausgabe: 07.05.1998 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\05_Engineering_Examples.doc

Engineering Examples

Content

Engineering Examples i General ....................................................................................................................2

Basic Rules .................................................................................................2 Connection rules and recommendations ....................................................3

Examples .................................................................................................................4 Unidirectional Drive, Sporadic Operation ...................................................4 Start Unidirectional Drive ............................................................................5 Stop Unidirectional Drive ............................................................................6 Local Unidirectional Drive ...........................................................................7 Single Start mode .......................................................................................8 Start-up warning in the Single Start Mode..................................................9 Calculated Values .......................................................................................9 Limit Value Evaluation of Measured Values .............................................10 Group Start-up warning ............................................................................12 GBVG Group Operation Interlock .............................................................13 GEVG Group Start Interlock .....................................................................14 GRAZ Group Feedback Off ......................................................................15 GREZ Group Feedback On ......................................................................17 Group Start/Stop .......................................................................................19 Impulse Processing...................................................................................20 Damper with Middle Position ....................................................................21 Damper Positioner ....................................................................................22 Damper with Torque switch ......................................................................23 Wagging....................................................................................................23 Ventilator Damper .....................................................................................24 Annunciation Modules...............................................................................26 Annunciations, Alarm Interlocks ...............................................................28 End Limit Switches (Limit switch of the Damper) .....................................29 Star-Delta Starting; Slipring Rotor with Starter Motor...............................29 Route change without interrupt.................................................................30 Automatic Route change ..........................................................................34

Engineering Examples Engineering Manual V5


General This description should provide support in the solution of control problems using the CEMAT software.

In part 2 we show you the correct connections for the basic functions.

Please adhere to these recommendations that have proved themselves in practice.

In the function diagrams of this description, the following letter codes are used to define the CEMAT object types:

Code Object type Block name E Unidirectional drive C_DRV_1D

K Damper C_DAMPER

V Valve C_VALVE

M Annunciation module C_ANNUNC

UM Measuring value C_MEASUR

W Route C_ROUTE

G Group C_GROUP

AW Selection module C_SELECT

SP Silo pilot C_SILOP

CNT Counter C_COUNT

RT Running time C_RUNNT

Basic Rules It is essential to conform to the following basic rules.

Limit Switches The break contacts from these switches should be connected directly in the contactor control circuit. Connect the make contact elements to the AS inputs.

Binary Special Signals Signals such as belt drift switch, pull-rope switch, silo full must always be connected to an annunciation module. The module flag of the annunciation module (MAU) should then be used for the further use in the program.

Start/Operation Interlock of the Group To permit on status call-up the interlock setting to be displayed, such interlock signals (also internal flags) should be maintained on annunciation modules.

Damper Directions The following definition applies for the end position of the damper: direction 1 = closed direction 2 = open



Connection rules and recommendations

Selection and Route Module We provide two module types for selections:

• selection module

• route module

The selection module is particularly suitable for smaller branches, standby circuits, such as, transport into various destination silos.

Advantage:

• reduced configuration effort

• reduced program run-time

The classical route module is particularly suitable for long transport routes that use many drives. If route modules are used, an individual status call can be made for each route and so permit this diagnostic function to be invoked for each section.

The question whether a selection module, a route module or various groups should be used must be decided individually. This section merely describes the various possibilities.



Examples

Unidirectional Drive, Sporadic Operation If the start is not possible directly with GBE, WBE (because the drive is to operate sporadically in conjunction with the process signal), the start signal must be stored. This signal must be “0” in case of a fault.

S

R

EGBE

=>1GDE

&=>1

for GREZsignal

Prozess signal controlsthe drive

EBFE

EBVG

EST EVS

Applications: Heating probe Lubrication equipment Water pump

Note: Never switch a continuous signal on the EBFE. Not even a signal that becomes “1” immediately after being acknowledged.



Start Unidirectional Drive In automatic operation, the ON command from the group or route starts the unidirectional drives.

Only these ON signals, but no interlock conditions, are connected to EBFE.

Example:

=>1

G01/GBE

G02/GBE

W05/WBE

EBFE E

Note: A continuous signal must never be switched on the EBFE. After the acknowledgment of a fault condition, the start command must not be set immediately to “1” again. Refer to Unidirectional Drive, Sporadic Operation.



Stop Unidirectional Drive In automatic operation, drives are stopped with the negated ON commands from groups or routes, or with operation interlock.

Example:

E3

E2

E1

conveyor direction

EVS

EBVG

EBVG

EVS

EBFA

&

G01/GDE

G02/GDE

W05/WDE

EBFA

t

EBFA



Local Unidirectional Drive It is possible to have a classical local operation, i.e., the hardware circuit starts the drive (contactor control). The programmable controller in this case only receives the signal from the local switch that is switched to the EVO parameter of the C_DRV_1D. This signal must still be switched negated on the ELOC interface.

ELOC

EVO

signal from local switch

1

E

The local control realized in the programmable controller is used for the software solution.

The Start and Stop signals (of the local switch) are switched to the C_DRV_1D parameters.

Connect the ELOC interface (local activation) with the GLO signal of the group.

For the protection interlock, ensure that those signals that must always be active (e.g. pull-rope) are switched on the ESVG.

The protection interlock that is not to be active in local operation (e.g. belt drift) is switched on the ESVA.

&&

pull-rope 1

pull-rope 2

belt drift 1

belt drift 2

ESVG ESVA

E

M MMM

MAU MAU MAU MAU



Single Start mode In the Single Start mode, the individual drives can be started and stopped from the control panel (COROS terminal). It should be noted that all interlocks are effective. That is, the discharging drive must first run before a charging drive starts.

The Automatic and Single Start mode are formed by the group. The group must be switched to the appropriate mode (control panel operation).

We do not see any requirement for the single start mode in addition to the automatic operation and local operation.

The ....EIZ interface must be connected with the group’s GES signal for all drives (C_DRV_1D, C_DAMPER, C_VALVE).

G

GES

EEIZ EEIZ EEIZ EEIZ

E E E E

The following notes must be observed to permit a smooth transition from “single” operational mode to “automatic”.

a) Take the GDA or WBA for one group or one route.

EBFA GDAE

b) The following circuit should be used for multiple groups or routes.

EBFAE &G02/GDE

G01/GDE



Start-up warning in the Single Start Mode The group does not provide any start-up warning in the Single start mode.

After the individual start of a drive (C_DRV_1D, C_DAMPER, C_VALVE), the module starts the set wait time. The drive is started only after this time expires.

The HORN output signal is “1” during this wait time and can be used to control the horn and lamp.

Example:

> 1

IMP

> 1

A GLA

GHAA

G1/GLA

E2/HORN

E3/HORN

E4/HORN

G1/GHA

> 1

Calculated Values Certain values are calculated during the plant configuration, e.g., total amounts from subamounts, temperature or pressure average values.

The values and measured values that are read using AIs are analog values for which a measuring value module must be programmed.

To improve the readability, the calculation should be performed before the invocation of the measuring value module.

The measuring value module permits a simple inclusion of the calculated values in the HMI system.



Limit Value Evaluation of Measured Values The limit value signals are often used for start or operation interlocks of groups.

The following points should be observed:

• To prevent interlocks appearing on the group fault lamp, interconnect UMZS.

• If, for example, the alarm interlock is interconnected with GVG, the measuring value module provides alarm messages only for a running group.

• The status call-up can at any time be used to request pending annunciations (also for a stationary group).

•

a) Example: Silo full Warning for ’H’ Switch-off for ’HH’

UM

G

UMZS UAMV

H HH

GEVG GBVG

GVG

>1



b) Example: Pressure monitor

• Pump should switch on when the ‘L’ limit is fallen below and switch off again when the ‘H’ limit is exceeded.

• No annunciations should be created and the output of the group fault lamp should not be set if the limits 1 are violated.

• Annunciaitons should be created and the output of the group fault lamp should be set if the limits 2 are violated.

S

R

EGBE

GDA

& =>1for GREZ signal

EBFEEBVG

EST EVS

=>1

S R

UM

L H

RA_L RA_H

LOG0

LOG0



Group Start-up warning If a machine group (e.g., cement transport) is started, then signal horns and lamps warn the personnel in this area that machines are starting and so increased caution should be exercised while working in this area.

Every group module provides a start-up warning during start.

The GHA or GLA output signal of the group must be switched to the horn or lamp outputs.

Example:

>1

Output for common horn

G06/GHA

G02/GHA

G03/GHA

(starting alarm from group 6)





GBVG Group Operation Interlock Process signals used to disconnect a group are placed on the operational interlock (e.g., silo full or requesting group unavailable). The control panel operator must acknowledge such disconnections.

Note: To permit an alarm message to be created for the disconnection, this interlock must be maintained on an annunciation module.

Example:

G

M

1

GVG

GBVG

MAU

MAMV

Silo full LOG1

MST0 MMZS

1



GEVG Group Start Interlock The start interlock avoids a start-up warning being initiated for a non-operational group (e.g., route preselection must be made before the group start).

Example:

G M

&

1

W03/WVW

> 1

W02/WVW

W01/WVW

LOG0

LOG1

GEVG MST0 MMZS MAMV

Note: To permit a start interlock to be reported for a “status call-up”, start interlocks should be maintained on an annunciation module.



GRAZ Group Feedback Off A signal that uniquely specifies that the group is stationary (negated feedback of the group drives).

a) Group without routes

GRAZ

E04/EVS

E05/EVS

E09/EVS

&

b) Group with routes

WRA=0 means: Route is not selected or route has been selected but all associated drives are off.

&

GRAZ

W02/WRA

W01/WRA



c) Drives in several groups or routes

Drives that belong to several groups/routes must be interlocked for the group feedback with the GVG or WVW signal of the other group/route.

Example:

&

> 1

G02/GVG

EVS

drives in G01 und G02

&

EVS

drives only in G01

G01-GRAZ



GREZ Group Feedback On This signal indicates that the group is operating completely.

a) Group without route

• Feedback of the last drive in the connection sequence,

• if all drives are started in parallel: each the feedbacks of the last drives.

Example:

&

GREZ

E01/EVS

E02/EVS

E07/EVS

b) Group with routes

WRE=1 means: Route has been selected and is operating

Example:

&

GREZ

> 1 > 1

W01/WRE

W02/WRE

W17/WRE

W19/WRE

W20/WRE



c) Group with routes (subsequently startable)

The simple allocation of the route feedback to the group feedback does not suffice if additional routes or drives are to be subsequently started for an operational group. It must be ensured that the GREZ is set to zero on selection of the “new” route, because only then can the group be restarted.

Example:

&

GREZ

> 1 > 1> 1

W02/WVW

W02/WRE

W01/WRE

W01/WVW



Group Start/Stop It is possible to start or stop a group:

• from the screen (GPTS=0)

• with the classical panel keys (GPTS=1)

Note: The supplied state is: operation from the screen Interconnect GPTS interface with LOG1 if panel keys are to be used for test purposes (simulator box)!

A parallel operation may be required in limited circumstances. The following connections can be used for this purpose.

GTE

GTA

GPTS

G

GPTS

G

AW

AZE

panel enable

or

> 1



Impulse Processing Both the pulse length and pause length must be longer than the OB1-cycle for signals that are to be recorded from the cyclical program (OB1). As guidance value, it should be longer than 1.5 seconds.

OB 1 cycle

signal to berecorded

1,5 sec.

1,5 sec.

If the signals are recorded in the 100ms-OB cycle (time-controlled alarm processing), the pulse times and the pause times of the signal must both be longer than 150 ms.

There are signals that are created with a flag attached to the drive shaft and a BERO switch. Such signals, for example, have a short pulse and a long pause.

BERO-Signal

Such signals must not be wired directly to an input module.

The signals must be converted with C1-technic hardware circuits or with series-connected mini programmable controllers (binary converter) so that the programs can record them reliably.

E A

E

E

A

A

e.G.AG 100 U

E

E

E

processed signal AG 155 U

Open loopcontrolandClosedloop control

Such signals can occur in silo pilots or speed monitors.



Damper with Middle Position The damper module normally monitors two end positions. End position 1 = closed, end position 2 = open. In exceptional circumstances, there are also dampers with three end positions (open-middle-closed) used in the cement plants.

The following example provides a possible solution for the connections for a damper with middle position.

K1 K2ZU AUFMotor Nr.

"closed" key

"open" end position

"middle" key

KEB1

"middle" key

"closed" end position

"open" key

KEB2KAB1 KAB2

"middle" end position

S R

"middle" key

"closed" key

"open" key

> 1

&

> 1

& &

> 1



Damper Positioner Dampers are sometimes used as portioning organ and so must be controlled to a specific position. An exact positioning is achieved by controlling the damper in positioning operation. A measured value for the damper position is required.

The release of the positioning operation is achieved by applying a 1-signal at the KPOS and KTFG interface. The output ‘MV’ of the associated measured value must be transferred to the interface POS_IN.

The actuator run time, the setpoint limits, the minimum impulse length and hysteresis must be specified as process parameters for the damper.

LOG1

Meas. Val/MV

KPOS KTFG POS_IN

K1 K2Motor No.

This connection permits the operator to enter the numerical positioning value from the keyboard.

If the positioning value is to be specified from a primary controller, then a 1-signal must be applied at the KWEE interface. The controller output of the associated controller must be connected to the interface KWEX of the damper. For the 1-signal at the KWEE interface, the damper module reads the external setpoint.



Damper with Torque switch Should an operating damper be stopped on activation of the torque switch, these signals must be applied to the KDR1/KDR2 interface. The “torque failure” message will be output if the damper operates using torque.

K1 K2CLOSED OPENMotor No.

1 1

KDR1 KDR2

... /KDR2... /KDR1

Wagging The damper is returned to the initial position when the torque switch activates. There is then a new start attempt made in the chosen direction. This process is called wagging.

The number of start attempts (wagging actions) can be set as process parameter WAGG_NO.

If the selected end position even after the set end position is not achieved after the specified number of start attempts, the damper reports “mechanical failure”.

Damper connection when the activation of the torque is to result in wagging:

K1 K2CLOSED OPENMotor No.

1 1

KDR1 KDR2

... /KDR2... /KDR1

LOG1

KWED



Ventilator Damper Because larger ventilators may start only when the damper is closed, it is desirable to close the associated damper when the group is stopped.

The following function diagram shows how this problem can be solved. Even after a possible failure of the damper, a renewed stop command or group start can close the damper.

In Example a), the positioning of the damper is realized with the inching interface of the damper module. This solution is suitable for a conventional panel with keys and lamps.

In Example b), a positioner is used for the same task. This permits the numerical input of the position value and the exact positioning to the required value. The positioner is realized using the damper positioner function.

a) Interconnection of ventilator and damper during the positioning using panel keys:

&

KEB1

SR

> 1

GRUPPExy-GBE

GRUPPExy-GBA

EBFE

EVS

"closed" key

KHA1

KST1

EEVG

KTFG

KVS1

"open" key

KHA2

E ventilator

K1 K2CLOSED OPENMotor No.ventilator flap



b) Interconnection of ventilator and damper positioner

&

KEB1

SR

> 1

GRUPPExy-GBE

GRUPPExy-GBA

EBFE

EVS

KPOS

KST1

EEVG

KTFG

KVS1

Meas. Val/MV

POS_IN

E ventilator

K1 K2CLOSED OPENMotor No.ventilator flap



Annunciation Modules There are two distinct uses for annunciation modules.

a) Drive failures

Annunciations of drive failures that the drive itself cannot report. These are all signals that are switched to the protective logic (belt drift, pull-ropes, bearing temperature, etc.)

• The message should appear together with the disconnection of the drive and the annunciation module output (connect alarm activation and use the annunciation module output for the disconnection).

• Interconnect the annunciation release from drive and annunciation module with the same control voltage.

M

1

EST

ESVG

MAU

MST0

1

E

MAAT

pull-rope

control voltage

EMFR

MMFR



b) Process signal annunciations (interlocks)

Report process signals, such as silos level and other interlocks.

Please observe the following points:

• Because interlocks should not appear on the group fault lamp, interconnect MMZS with LOG1.

• To ensure annunciation and interlocks occur concurrently, use the annunciation module output signal for the interlock.

• If the alarm interlock is interconnected with, for example, GVG, the annunciation module provides an alarm message only for a running group.

The status call-up can at any time be used to request pending messages (also for a stationary group).

G

M

1

GDE *)

GBVG

MAU

MAMV

Silo full LOG1

MST0 MMZS

1

*) Refer to “Alarm Interlock”



Annunciations, Alarm Interlocks It is guaranteed for the drives modules that they produce a fault message only when they are “active”, that is

a) if the drive was running and detects a fault,

b) if the drive is faulty and is switched on, and

c) if the drive is in stand-by mode and has a failure.

The appropriate connectionprovided for the annunciation modules (C_ANNUNC, C_MEASUR) must itself ensure that an alarm is produced only when the associated plant section is active and the message is plausible. For drive failure messages, this is guaranteed by the interconnection of the alarm activation (MAAT).

For the annunciation of special signals and limit value annunciations, the MAMV/UAMV alarm interlock must be so interconnected that this annunciation is plausible. Depending on the technological function, the alarm interlock must be interlocked accordingly. Criteria for the plausibility of a message can be: group feedbacks, drive running signal, group states, etc.

Examples: a) A fault should produce an alarm only when the group has been started but not stopped.

MAMV

GDE

b) A limit value violation should be reported only when the group has been run up completely.

GDE

GBE

UAMV

&



End Limit Switches (Limit switch of the Damper) Limit switches must be wired directly in the contactor control circuit and so perform a hardware disconnection of the drive.

The signals passed to SIMATIC must not be used for the disconnection, but are required for interlocking and annunciation tasks.

This rule has to be followed for all positioning actions and end limit switches.

Star-Delta Starting; Slipring Rotor with Starter Motor For drives with star-delta starting or slipring rotor with starter motor, the “1” state can be achieved at much later time after applying the ERM signal (20-30 seconds).

The feedback time in seconds must be parameterized in the appropriate data word in the CEBASS-DB for such drives.

Note: In the local operation (local control using the AS), the Local-On push-button must remain depressed until the drive runs fully (ERM=1). The ERM signal provides the criteria for maintaining the On command. If the On command was stored immediately and the drive for some reason did not start, then dangerous operational states could arise, because the motor could start subsequently without the push-button being activated.



Route change without interrupt

E03

E01

K01

E02

Silo 1 Silo 2

Task: The change for charging into Silo1 or Silo 2 has to be without interrupt, i.e., the feeding drives should not be stopped during the switching operation.

Both air slide E02 and E03 must run while the damper is being moved. The part of the old transport direction that is no longer required is switched off only when the new direction has been traversed completely.

The following connection example provides a solution for a transport group with two routes:

The air slides E02 and E03 and the damper position K1 (direction silo 1) belong to route 1. The air slides E01 and E03 and the damper position K2 (direction silo 2) belong to route 2.

Operation: During the switching, the new route must be selected first and then the group started.

Whether the route selection and the group start takes place manually or automatically is not important.



&> 1 > 1

GEVG GREZ GRAZ

W01/WVW

W02/WVW

W01/WRE

W02/WRE

W01/WRA

W02/WRA

GDA GBE GRE GVG

> 1 1 &

G01/GRE

G01/GVG

E02/EVS

E01/EVS

K01/KVS1

WHVR WRAZ WREZ WVWA

WVE WBE WVW WUM

&

WEBW

> 1 1 & &

G01/GRE

G01/GVG

E03/EVS

E01/EVS

K01/KVS2

W01/WVE

LOG1

W02/WVE

WHVR WRAZ WREZ WVWA WVWL WUUS

WVE WBE WVW WUM

WEBW WNo. 2

direction silo 2

Function diagram:

&

WNo. 1

direction silo 1

&

W02/WVE

W01/WVE

WVWL

LOG1

WUUS

GNo. 1

Transport group



&

> 1

EBFE EBFA EBFE EBFA

EBVG

W01/WVW

EBVG

W02/WVW

W01/WBE W02/WBE

EVS EVS

KEB2KEB1

KBV1 KBV2

W01/WVW

KVS1 KVS2

&

W02/WVW

> 1

&

> 1

&

G01/GDA

> 1 > 1

W01/WVW W02/WVW

&

K01/KVS1

W01/WBE

&

W02/WBE

K01/KVS2

EBFE

> 1

E03/EVS

EBVG EEVG

EBFA

EVS

EVZ

No. 2

air slideENo. 3

air slideE

No. 1

directionSilo 1K1 K2

directionSilo 2

No. 1

air slideE



The connection example becomes clearer by considering the individual functions that must satisfy a change of routes without interrupt.

• The route change can only take place when the group is stationary or runs completely ⇒ refer to WHVR

• If a route was preselected and the preselection of another route is added, then the own preselection must be removed. ⇒ refer to WVWL and WUUS

• In case of a route change without interrupt the group has to be started while it is completely running (because the drives of the “old” route are still running). To permit the group to give the start command again, the “group feedback On / route feedback On“ must be removed. This is done by linking the route preselection WVE with the drive feedbacks. ⇒ refer to WREZ

• The old route is deselected automatically once the newly started route runs completely. ⇒ refer to WVWA

• The deselection of the “old” route stops the drives that are no longer required. ⇒ refer to EBVG from E02 and E03

• The disconnection of the complete group is performed only for group stop (use GDA signal) or for a fault if the switching has not been performed within a specified time. ⇒ refer to EBFA from E01



Automatic Route change Here the route change and start is not performed manually but with a process signal (e.g., silo filling level). The process signal (start condition) must be unique. If necessary, use an interlock to ensure that only one signal is pending!

Example:

&

> 1

Silo 1 - empty

Silo 2 - empty

Prozess signal 1 Prozess signal 2

&

Start condition formaterial transportto Silo 1

Start condition formaterial transportto Silo 2

&

> 1

W02/WRE

W01/WRE

Prozess signal 1

Prozess signal 2

GREZ GEBG

No. 1

Transport groupG

Prozess signal 1

WVWE

Prozess signal 1

WVWE

No. 1

direction Silo 1WNo. 2

direction Silo 2W

The process signal automatically preselects the route. ⇒ refer to WVWE

Note: The automatic group-On command must be supplied only when the GREZ signal of the group becomes zero (otherwise no start is possible). ⇒ refer to GEBG

Engineering Manual V5 PLC Engineering

Copyright Siemens AG. Alle Rechte vorbehalten. 6 - 1 Ausgabe : 24.01.2002 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\06_PLC_Engineering.DOC

PLC Engineering

Content PLC Engineering 1

Enter the signal list......................................................................................2 Enter the user program (CFC) ....................................................................3 CEMAT Functions.......................................................................................4 Invisible Module parameters.......................................................................5 Define the run sequence.............................................................................8 Compile CFC ..............................................................................................9 Download CFC............................................................................................9 Transfer of PLC/OS connection data........................................................10

PLC Engineering Engineering Manual V5


Enter the signal list The hardware signals can be entered directly in the hardware configuration.

They will be added to the Symbols list and can furtheron be used in CFC.

There is also the possibility to import the hardware signal list from an excel file.



Enter the user program (CFC) The program logic is written in the Control Function Charts. The CFCs are shown in the plant view and in the component view and can be edited from both views.

The CEMAT Standard functions are located in Folder CEMAT, ILS_PTE and ILS.

Open the CFC and drag the functions from the different catalogs. After you drag the module from the catalog go the object properties and start editing the name and comment.

Save the comment with Ctrl+C. In special object properties press button Messages... to edit the comments for the message lines. Now use Ctrl+V to paste the text. This will later be used for the annunciation system.

Draw the interlocks for the modules according to there function. You can use signals from the assignment list or connections to other modules.



CEMAT Functions

Drive functions C_DRV_1D Unidirectional drive C_SPEEDM Additional block for speed monitor supervision of drive C_DRV_2D *) Bi-directional C_DAMPER Damper C_VALVE Valve C_DRV_SIMO_2D *) Bi-directional drive for SIMOCODE C_DAMP_SIMO *) Damper for SIMOCODE *) The blocks C_DRV_2D, C_DRV_SIMO_2D and C_DAMP_SIMO are not available for all Project Versions of CEMAT. Please check PRO_CEM library for availability of the blocks!

Annunciation functions C_ANNUNC Annunciation module C_ANNUN8 Annunciation module with 8 Alarms C_MEASUR Measuring value

Control/Supervision C_GROUP Group module C_MUX Additional block for group/route C_ROUTE Route module C_SELECT Selection module

Controller functions TE_CTRL PID-Controller TE_VSLCT Set point Setter

Caution: CEMAT V5 has no special block for analogue output function. You have to use the PCS7 driver block CH_AO.

Silo pilot function C_SILOP Silo pilot C_SPCNT Additional block for counting pulses of Silo pilot

Information system C_RUNNT Runtime supervision (MIS) C_COUNT Counter block (MIS) C_MEAS_I Measuring value integration (MIS)

Special function C_ADAPT Adapter block to include non-CEMAT modules into group supervision. C_PUSHB Parameterization of a conventional Control Desk with Push Buttons and Lamps

The detailed description of the CEMAT Functions you find in the object description an in the only help.

All other blocks from the PCS7 standard library can be used as well.



Invisible Module parameters In the Object description you will find a list of the Parameters for all Objects as well as a detailed description of the programming rules.

For the CEMAT Modules by default only the module parameters which are usually used in most of the plants are set to visible. This means, if you drop a CEMAT Module to your chart, you will not see all the available parameters.

The invisible parameters can be switched to visible if required. This can be done generally at the FB itself (change of the Attribute S7_visible to ‚true‘) or in the CFC for each instance.

Note: With a Standard Update your attribute changes at the function block will be lost and must be performed again if required. The instances keep the original Settings.

Control desk pushbuttons The following interfaces will only be required if you want to use a conventional control desk with pushbuttons and lamps. In the default settings they are switched to invisible but they can be changed to visible if necessary.

Function DRV_1D DAMPER VALVE ANNUNC MEASUR ROUTE GROUP

Lamp test ELPZ KLP1 VLPZ MLPZ WLPZ GLPZ

Acknowledge EQIT KQT1 VQIT MQIT UQIT GQIT

Release signal GFGS

Pushbutton release WPTS GPTS

Pushbuttons WVT GTA GTE

Lamps ELS KL1 KL2

VL1 VL2

MLA WVL GZV GZS GZB

In connection with Control desk push buttons additionally the CEMAT block C_PUSHB must be called. This block allows the parameterization of Release button, Acknowledge button and Lamp Test button as well as an output for a Horn.



Module Parameters of C_PUSHB

Input parameters

FGS Release Button Basic State: 0-Signal The Release Button must be pressed together with Group Start, Group Stop, Route Selection etc. (2-Hand-Operation).

QT Acknowledge Faults Basic State: 0-Signal With a positive Edge on QT all dynamic faults in the PLC are acknowledged.

QT_H Acknowledge Horn Basic State: 0-Signal With a positive Edge on QT_H the horn gets switched off.

LP Lamp Test Basic State: 0-Signal Parameter LP is used to parameterize a Lamp Test button for Running/Fault Lamps of the drives, Annunciation lamps, Group status indications and Route selection lamps.

THUP Horn time in Seconds Basic State: 120 After this time the horn is switched off.

Output Parameters HORN Horn Output for an acoustical alarm in the control room.



Positioner function The following interfaces of the damper belong to the positioner function. In the default settings they are switched to invisible but they can be changed to visible if required.

Element Meaning Format Default Type Attr. HMI Permitted

Values

KPOS Positioner BOOL 0 I U

KWEE External setpoint ON BOOL 0 I U

KSNF Setpoint tracking BOOL 1 I U

POS_LZ Live Zero for position BOOL 0 I U

KWEX External setpoint REAL 0.000000e+000 I U

POS_IN Position value 0-100 STRUCT I U

W_OS Sollwert of OS (KWCO) REAL 0.000000e+000 I U +

KWUG Setpoint lower limit REAL 0.000000e+000 I U +

KWOG Setpoint upper limit REAL 1.000000e+002 I U +

SCB Scale beginning REAL 0.000000e+000 I U +

SCE Scale end REAL 1.000000e+002 i U +

UNIT Unit STRING[8] ‚%‘ I U +

TMIN Min. pulse length REAL 5.000000e-001 I U +

TM Actuator run-time REAL 3.000000e+001 I U +

AN Switch on of the dead zone REAL 1.000000e+000 I U +

AB Switch off of the dead zone REAL 1.000000e+000 I U +

X_POS_OS Damper position display REAL 0.000000e+000 O U +

KPO Positioner ON BOOL 0 O U



Define the run sequence Most of the CEMAT objects have to be called in OB1 (MAIN_TASK). The only exceptions are C_SPEEDM, C_SPCNT and C_COUNT. These types have to be called in OB35 (100MS_TASK).

Remember the sequence:

1. evtl. MUX 2. Annunciations and Drives 3. Corresponding Routes 4. Corresponding Groups

All modules in the CFC will be assigned to a (default) OB. The module which was defined last will automatically be the predecessor for the installation of the next module.

The so-called run-time editor allows the definition of Run-time groups and the modification of the run sequence according to the desired structure of the program.



Compile CFC Before you can download the program into the PLC it must be compiled. It will be transferred into a machine language (SCL). During compilation the program will be checked for errors and warnings. You can compile the complete program or only the changes.

Download CFC First the hardware definitions and the network configuration has to be downloaded into the PLC (if this was not done before).

The S7 Program has to be downloaded from the CFC. PCS 7 takes care of the right order of the loading procedure. Do not download the blocks! You will be asked for a complete download or to download only the changes. Changes in the interfaces of a function or function block will require a download of the complete program. This means a PLC stop.



Transfer of PLC/OS connection data Before you can use the objects in the Visualization system you must transfer the PLC/OS connection data. This function you can find in the SIMATIC Manager under Options.

After that the modules can be used in WinCC.

First select, which programs you want to assign to which operator stations:



Check for Network connections!

Select each PLC and press “Connection”

Select the network connection you want to use for the communication to WinCC



Finally select the transfer data and the transfer mode.

Don’t forget to deselect the picture tree, if you created the picture tree manually in the OS-Project. Otherwise it is overwritten!

Now press “Finish” to start the transfer.

Engineering Manual V5 PLC-PLC Coupling

Copyright Siemens AG. Alle Rechte vorbehalten. 7 - 1 Version : 28.02.2000 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\07_PLC-PLC-Coupling.doc

PLC-PLC Coupling

Inhalt

PLC-PLC Coupling 1 General ....................................................................................................................2

Complete Structure .....................................................................................2 Performance Data.......................................................................................3 Activation of Coupling .................................................................................4

Interfaces .................................................................................................................5 Initiation Bits and Receive Indicator for Coupling Job ................................5 Parameters for Coupling Jobs ....................................................................5

Configuration Example.............................................................................................8 Exemplary Description................................................................................8 CFC chart for example................................................................................9 Project work in the network settings .........................................................11 Project work for the system call of PLC PLC coupling .............................14

System Description ................................................................................................16 Diagnosis ..................................................................................................16 Structure of Double-Bus Interfacing of an Individual SMR-PLC...............17 Function of the Double-Bus ......................................................................17 Structure of the Test Telegram .................................................................17 Coupling from CEMAT S5 V X.X and other Control System or Third-Party PLCs .........................................................................................................18

PLC-PLC Coupling Engineering Manual V5


General

The PLC-PLC Coupling CEMAT-V5 (PC S7) enables the transmission of user data blocks (DB599 >= DB => DB 400) between SMR-PLCs. The communication is performed via Industrial Ethernet which can be designed as a double bus. The user configures the job parameters in CFC with the blocks C_PLC_SEND = FB1052 and C_PLC_RECEIVE = FB1053. The send job is initiated by setting the job bit TRIGGER and the reception is signalled through a receive bit RECEIVED.

Complete Structure

PLC20PLC03PLC02PLC01 . . . .Bus A

PLC20PLC03PLC02PLC01 . . . .Bus A

Bus B

Single bus:

Double bus:

Third-partyPLC04

Third-partyPLC01 . . . .

Third-partyPLC04

Third-partyPLC01 . . . .



Performance Data • 20 SMR-PLCs and 4 third-party PLCs (CEMAT V1.9, V2.0, V3.0 / V4.0 other control

system or third-party system).

• Transmission of CEMAT user data blocks (DB599 >= DB => DB 400).

• Max. transmission length = 600 Bytes.

• Initiation of the individual transmissions by setting the initiation bit TRIGGER in the send PLC.

• Signalling of the successful transmissions through a set message bit RECEIVED in the receive PLC.

• Coupling monitoring in case of parameterized coupling request.

• Individual user telegram monitoring for each of the 24 couplings: If the monitoring time is exceeded the receive DB can be deleted on request completely or partially.

• Diagnostics interfaces like:

- Global display for bus A and bus B from the point of view of each individual PLC: Bus is OK.

- Receipt OK (bus A or bus B) for each parameterized coupling job.

- Parameterization error for each parameterized coupling job.

- Status (bus A or bus B) for each parameterized coupling job.



Activation of Coupling By calling the blocks C_PLC_SEND = FB1052 and C_PLC_RECEIVE = FB1053 in a CFC chart, the user can parameterize his coupling jobs. As soon as a valid coupling job is parameterized the Coupling becomes active. You do not have to do anything else. To install a coupling job and then to activate it, the best is to proceed as follows:

If the links don’t exist, create the links with NETPRO. See chapter “Project network communication” page 11.

1. Parameterize the send parameters on the function block C_PLC_SEND = FB1052.

2. Parameterize the receive parameters in the corresponding PLC on the function block C_PLC_ RECEIVE = FB1053.

3. Programming the logic for initiation (SET TRIGGER).

4. Compile the CFC chart new and transfer the changes to the PLC. If the links already exits, the transfer is possible during running PLC.

Further possibilities like connection monitoring see page 16.



Interfaces

Initiation Bits and Receive Indicator for Coupling Job The user must set the corresponding initiation bit to activate the send job = TRIGGER and he can find out through a query of the corresponding receive bit = RECEIVED whether data have arrived. Is the RECEIVED bit used, after query the Bit REC_ACKN must be set. If the REC_ACKN bit is set, the Bit RECEIVED is reset. The initiation and receive bits are located in the parameter set of the FBs C_PLC_SEND and C_PLC_RECEIVE.

Parameters for Coupling Jobs All settings are made in the own PLC. There are no settings (like DB no.) for the partner PLC. The send parameters are made in the sending PLC. The receive parameters are made in the receiving PLC.

Parameters for the send job:

TO_PLC = PLC No. , to which the job is sended (1-24). DB_No = DB-No. in the sending PLC with the source data (400-599). OFFSET = start byte no. of the source area (0-65535). LENGTH = number of bytes of the source area (1-600).

Parameters for the receive job:

FROM_PLC = PLC No.,from where the job is received (1-24). DB_No = DB-No. in the receiving PLC with the destination data (400-599). OFFSET = start byte no. of the destination area (0-65535). TIMEOUT = watch dog time in seconds. DEL_BYTE = number of bytes which will be deleted, when the watch dog time is elapsed. (start byte is the start byte of the destination area).



PLC n

Send-DB1st byte

Sendinglength

SEND

Receive-DB

1st byte

Receivedlength

RECEIVE

Range to bedeleted incase of fault

DB_No:No. of the DB to be sent(DB599 >= DB => DB 400)

OFFSET:1st byte in send-DB

LENGTH:Length of the Send range

DB_No:No. of the DB (> 400) in whichreceived data are stored

DEL_BYTE:Number of bytes which are deletedfrom the 1st byte onwards in case theuser monitoring time is exceeded(RECEIVE_TIMEOUT_PLCx)

OFFSET:1st byte from receive-DB



Diagnosis Variable for Users A fault-free coupling is only possible if the parameterization error bits and fault bits have the value 0. Otherwise one must search for the fault and correct it using the additional information.

Diagnosis SEND in the parameter-set of FB C_PLC_SEND: BUS_A_FT = Fault during SEND on bus A to PLC x BUS_B_FT = Fault during SEND on bus B to PLC x ENG_ERR = Parametrize failure on SEND to PLC x COM_ERR = dynamic fault during SEND to PLC x E_ERR_CO = Error code for engineering failure for SEND to PLC x A_ERR_CO = Error code for SEND on bus A to PLC x B_ERR_CO = Error code for SEND on bus B to PLC x

Diagnosis RECEIVE in the parameter-set of FB C_PLC_ RECEIVE: BUS_A_FT = Fault during RECEIVE on bus A to PLC x BUS_B_FT = Fault during RECEIVE on bus B to PLC x ENG_ERR = Parametrize failure on RECEIVE to PLC x COM_ERR = dynamic fault during RECEIVE to PLC x E_ERR_CO = Error code for engineering failure for RECEIVE to PLC x A_ERR_CO = Error code for RECEIVE on bus A to PLC x B_ERR_CO = Error code for RECEIVE on bus B to PLC x R_LENGTH = Received telegram length in bytes COUNT_T = telegram counter

Parameterization Error-Codes Additional informationen for parameterization error in ENG_ERR_CODE: 0 = No error! 1 = Illegal DB (only > 400)! 2 = DB does not exist! 3 = 1st DW is not permitted! 4 = Send-DB is too short! 5 = Sending length is not permitted (max. 238 bytes)! 6 = Receive-DB for block delete during absence of user telegram is too short! 7 = Block length for block delete during absence of user telegram is not

permitted! 8 = Receive-DB is too short for received length! 9 = A send-DB is entered in the parameter-set for your own PLC! 10 = A receive-DB is entered in the parameter-set for your own PLC!

Status codes:

"AG_AG_KOMMUNIKATION".VERBINDUNG_x.FEHL_SEND_A Error code SEND Bus A

"AG_AG_KOMMUNIKATION".VERBINDUNG_x.FEHL_SEND_A Error code SEND Bus B

"AG_AG_KOMMUNIKATION".VERBINDUNG_x.ANZW_REC_A Error code RECEIVE Bus A

"AG_AG_KOMMUNIKATION".VERBINDUNG_x.ANZW_REC_A Error code RECEIVE Bus B

Additional information regarding error codes is available in the help (mark block and press „F1“) of FC50 (SEND) and FC60 (RECEIVE) or in the NCM S7 manual for Industrial Ethernet.



Configuration Example

Exemplary Description

PLC15

DB 410Byte 10

50 Bytes SENDEN

DB 411Byte 0

RECEIVE

Byte 59

Byte 19

PLC16

DB 420Byte 110

SEND

DB 401Byte 0

RECEIVE

Delete 10 bytesafter 8 sec. Incase of fault

Byte 159

Byte 19

20 Bytes

Initiation every secondNo deletion in caseof fault;set DB402, D1.0at receive

Transmission isto happen asoften as possible

Delete range in caseof fault; do notanalyse receive



CFC chart for example PLC 15:

PLC 16:



Please be careful during connecting the TRIGGER bit on the SEND block. Please do not use the LOG1 signal. The LOG1 signal would be reseted after a succesful SEND job.



Project work in the network settings Select in the SIMATIC Manager the CPU container and open NETPRO with double click on the connections.

Select the CPU -> you see the connection table:

Connection Local ID Partner ID Active connection setup PLC15 to PLC16 1A 19 yes PLC16 to PLC15 19 1A no

ID 1A = to PLC16

ID 19 = to PLC15



Select the CPU and choose with right mouse button „New connection“:

Connection Partner Station

Select the station to which the connection should be established, in our example the PLC 16.

Connection type

The connetion type is ISO-Transport-Connection

(Local) ID

The connection between the CPU program and the connection link is done by the (local) ID. For CEMAT exist the following rule:

ID Partner PLC 0xB PLC 1 0xC PLC 2 0xD PLC 3 0xE PLC 4 0xF PLC 5 0x10 PLC 6 0x11 PLC 7 0x12 PLC 8 0x13 PLC 9 0x14 PLC 10 0x15 PLC 11 0x16 PLC 12 0x17 PLC 13 0x18 PLC 14 0x19 PLC 15 0x1A PLC 16 0x1B PLC 17 0x1C PLC 18 0x1D PLC 19 0x1E PLC 20 0x1F PLC 21 0x20 PLC 22 0x21 PLC 23 0x22 PLC 24



TSAP For the connection setup is for every connection a local and a remote TSAP necessary. The ethernet adress allone is not enough for the connection setup. There are more than one connections possible betwenn two ethernet cards.

For CEMAT exist the rulel: local TSAP = remote TSAP For PLC-PLC-Connections is the TSAP „AG----AG“ (Hexadezimalcode: 41 47 2D 2D 2D 2D 41 47).

ACTIV / PASSIV

For PLC-PLC-Connections is defined: The communication partner with the smaller PLC no is activ for the connection setup.



Project work for the system call of PLC PLC coupling Open the hardware editor and check with „View -> Adress Overview“ the adresses of the CP443.

16372 = e. g. adress of Bus B CP

16376 = e. g. adress of Bus A CP



In the system chart SYSPLCxx the FB 1054 = C_PLC_PLC must be called on AS restart and in the cycle. The parameters for adress bus A, adress bus B and own PLC no. must be supplied. If bus B don’t exist, please set the adress to „0“. If the parameter PLC_NO = 0, then the PLC PLC coupling is switched off.

Adress of bus B CP e. g. = 16372

Adress of bus A CP e. g. = 16376

Own PLC number, e. g. = 15

FB1054 in cycle OB1 FB1054 in AS restart OB100



System Description

Diagnosis The variables table AG_AG_KOM_Diagnose provides an aid for the diagnosis of the PLC-PLC coupling.

Remedies in Case of Faults If the coupling does not work properly or not as expected one has to check the following:

• Is the bus interface CP443-1 inserted for bus A and bus B, respectively? Check: The bits 0.0 to 0.3 must be set to "0" in DB "00PLC_PLC_ENG"!

• Are the addresses of the CP443-1 correctly configured? The S7 hardware configuration and parameterization on FB C_PLC_PLC (FB1054) must be identical. The FB C_PLC_PLC (FB1054) must be called in the cycle (OB1) and during AS restart (OB 100)! Check: The bits 0.0 to 0.3 must be set to "0" in DB "00PLC_PLC_ENG"!

• Check the bus cable connection (Is the plug loose? Bus A or B mixed up?)

• Is the connection engineered and loaded to the PLC?

• Check the parameters on C_PLC_SEND (FB1052) and C_PLC_RECEIVE (FB1053). The output parameter ENG_ERR must be “0”. If the is a “1”, check the E_ERR_CO. (For error numbers refer to page 6) Check using the variables table "AG_AG_KOM_Projektierung":

• If there is no parameterization error, then check status of the connection! Check using the variables table ‘’AG_AG_KOM_Diagnose: (For error numbers refer to page 6) The status information must be 0!

• If no parameterization error exists and the corresponding connection is OK, then one must couple user telegrams. Check using the variables table ‘’AG_AG_KOM_Diagnose: Receive bit should be set to ‘1’ and/or initiation bit should be blinking. Check : Is the initiation bit set?



Structure of Double-Bus Interfacing of an Individual SMR-PLC

PLC

Bus A

Bus B

CPBus A

Addr.CPBus B

Addr.

Addresses of the CP 443-1

Function of the Double-Bus The PLC-PLC Coupling is designed for double-bus operation. Of course, it also functions when a single-bus is used. Generally, "Bus A" is the master bus; "Bus B" is (provided it exists) only monitored with regards to function and is used exclusively in the event of the failure of "Bus A" for user telegrams. As soon as "Bus A" functions faultless again "Bus B" switches back to "Bus A". This means there is no load distribution on "Bus A" and "Bus B". The reversing logic is on the sending side and triggers the user telegram on the respective bus system. On the receiving side both bus systems have equal rights and receive the incoming telegrams. By checking the telegram in the receive buffer one determines whether it is a test telegram or a user telegram. The user telegram is copied to the user receive DB.

Structure of the Test Telegram The test telegram for checking the connections is sent from the work-DB and consists of the length KF = 2 and the text KC = TEST.



Coupling from CEMAT S5 V X.X and other Control System or Third-Party PLCs Refer to the SIMATIC S5 PLC-PLC Coupling description Chapter 8

Engineering Manual V5 OS Engineering

Copyright Siemens AG. Alle Rechte vorbehalten. 8 - 1 Ausgabe : 19.02.2003 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\08_OS_Engineering.doc

OS Engineering

Content OS Engineering 1

Generation of Process Pictures ...............................................................................2 Default PDLs...............................................................................................2 Name definitions .........................................................................................6 Engineering of Picture Windows.................................................................6 Connect CEMAT Controls ..........................................................................7 Bitmaps .....................................................................................................20

Archive definitions..................................................................................................21 Message archive.......................................................................................21 Measuring value archive...........................................................................21 User Archives............................................................................................22

OS Engineering Engineering Manual V5


Generation of Process Pictures

Default PDLs In a PCS 7 Project the process pictures can be created in the plant view of the SIMATIC Manager or directly in the Graphics Designer. For a screen resolution of 1280x1024 the picture size has to be 1280x825.

Together with the CEMAT Standard Pictures, two default PDLs have been copied into your project during the Installation procedure. These pictures contain all the Controls available in CEMAT and a number of already prepared symbols.

To create the process pictures, open the default pictures and copy the symbol/control into the process picture. Controls can be represented in different views. The size of the controls is fixed and cannot be modified.

Caution: The default symbols were created based on normal standard (key=000). If you use a special standard version for your project (key > 000) you eventually have to adapt the symbols. Please check the module states in configuration dialog (status, colour) according to the object description, “module states” and correct the default symbols if required.

Together with the Cemat Standard PDLs 2 default Pictures have be copied into your project.

PP_CEMAT_DEFAULT.pdl

- Contains all available default symbols as well as all controls in the most usual view. - Contains the picture windows TOP01 to TOP12 (required for Web Clients). - Contains the Data Server (required for KCS).

PP_CEMAT_DEFAULT2.pdl

- Shows all possible views of the CEMAT Objects. (Most of the Cemat Controls can be represented in different views by changing property „CStyle“).

Caution: The Update Cycle for all symbols in the default PDLs is set to “User Cycle 1”. You have to adapt the value for the “Update Cycle 1” in the WinCC Explorer in the general settings of your project.



Elements of C_CEMAT_DEFAULT.pdl If a Web Client is used, you must copy the picture windows TOP01 to TOP12 from C_CEMAT_DEFAULT.pdl into all your process pictures. Without Web Client the Picture windows are not required.

For KCS the symbol of the DataServer has to be copied into the Process Picture.

PP_CEMAT_DEFAULT.PDL:



Elements of C_CEMAT_DEFAULT2.pdl Different views of the Cemat Objects (default symbols and controls)



Line Representation (short and long)



Name definitions

Picture Names See chapter preparations – Designations for the OS.

Object names The object names are created in the Engineering of the CFC. In the OS only selection of existing objects is possible. New Objects can not be created in WinCC.

Engineering of Picture Windows If picture window are used you must pay attention to the following:

If the picture windows are assigned to in a lower layer than the OCX the OCX probably shine through the picture window.

To keep the the OCX covered by the picture window the picture window has to be assigned to a higher layer than the OCX.

Example:

The OCX is assigned to layer 13. The picture window must be assigned to a layer >= 14.



Connect CEMAT Controls

Procedure for Group, Route and Selection There are 3 different styles for the group control, 4 styles for the route control and 5 styles for the selection control (can be set via property CStyle). Except the shown symbols there is a short and a long line representation.

- Duplicate the default control. - Double-click on the new symbol

- Select the tag of the corresponding object - Close with OK



Adaptations under Properties, Control Properties:

- tagname: Name of the selected object - Active: yes - CButtonLock: For different appearance of the faceplate for the object: Appearance for the faceplate of the group module: 0 – Standard 1 – Buttons_Invisible 2 – Quick_Stop 3 – Start_Stop 4 – Local_Auto 5 – Single_Auto 6 – Local_Auto_QuickStop 7 – Single_Auto_QuickStop Appearance for the faceplate of the route module: 0 – Standard 1 – Buttons_Invisible Appearance for the faceplate of the selection module: 0 – Standard 1 – Buttons_Invisible - ToolTipText: The Tool-Tip Text can be entered in one language - CAllowWinCCZoom: must remain „no“! - CShortDescription: This text will be displayed in the symbol. If this field is empty the object name (tagname) is displayed in the symbol.



- CStyle: Selection of the style for representation of the group/route and selection control (see PP_Cemat_default2.pdl) Styles for the group symbol: Dialog_Style – 1 (normal Symbol) Dialog_Style – 2 (long line representation) Dialog_Style – 3 (short line representation) Styles for the route symbol: Dialog_Style – 1 (normal symbol) Dialog_Style – 2 (small symbol without tag) Dialog_Style – 3 (long line representation) Dialog_Style – 4 (short line representation) Styles for the selection symbol: Dialog_Style – 1 (normal symbol) Dialog_Style – 2 (small symbol without tag) Dialog_Style – 3 (long line representation) Dialog_Style – 4 (short line representation) Dialog_Style – 5 (small Symbol – shows only selection/deselection) - CButtonText: Button text in line representation (only one language is possible!)

For the selection module it is possible to use small symbols for selection/de-selection (instead of using the control IX_SELECT). The connection is then done via variable “STATUS” like it is done for annunciation modules. An example for small selection symbols is also available in PP_CEMAT_DEFAULT.PDL.



Procedure for the Measuring Value There are 3 different styles for the control (can be modified via property CStyle). Beside the normal symbol, there is a long and a short line representation available. It is also possible to show the measuring value in an I/O field. This possibility can be used to increase performance, if the pictures are very crowded.

- Duplicate the default control. - Double-click on the new symbol - Select the tag of the corresponding object - Close with OK

Adaptations under Properties, Control properties:

- tagname: Name of the selected object - Active: yes - CComma: Number of digits behind the comma (default value is 0) - CTimeRange: Display range for the representation of the trend curve Time_1min – 1 Time_2min – 2 Time_3min – 3 Time_4min – 4 Time_5min – 5 Time_10min – 10 Time_20min – 20 Time_30min – 30 Time_60min – 60 - ShowUnit: With „yes“ the unit is displayed in the output field. - Font: Font and size of the output field can be modified. - ToolTipText: The Tool-Tip Text can be entered in one language. - CStyle: Selection of the style for representation of the control (see PP_Cemat_default2.pdl) Dialog_Style – 1 (normal symbol) Dialog_Style – 2 (long line representation) Dialog_Style – 3 (short line representation)



Including a Measured Value into a Process Value Archive In the WinCC Explorer please start the Tag Logging Editor and add the measured value as „new variable“ into the Process Value Archive. For each variable one can make individual adjustments (see PCS7-Description or Online-Help).

After that please save the new settings in the Tag Logging Editor.

One can call up the curve in runtime via the PCS7 button “Trend Curve” (parameterised curve pictures with one or more measured value curves) in the lower button line or directly out of the C_MEASUR faceplate using the “Curve” button.

Important note:

If you include a measuring value into a process value archive, you must not change the curve name, which is given automatically by the Tag Logging Editor! This curve name is created out of the symbol name (TAG) of the measuring value variable. Not allowed special characters will be removed automatically by the Tag Logging Editor and should therefore not be included in the symbolic names (CFC name, instance name).

If you change this name, the CEMAT faceplate can not find the archive data and will not display a curve, if one is pressing the “curve” button!



Procedure for the controller There are 6 different styles for the control (can be modified via property CStyle). Beside the normal symbol, there is two different line representations available.



- tagname: Name of the selected object - Active: yes - CComma: Number of digits behind the comma (default value is 0) - CTimeRange: Display range for the representation of the trend curve Time_1min – 1 Time_2min – 2 Time_3min – 3 Time_4min – 4 Time_5min – 5 Time_10min – 10 Time_20min – 20 Time_30min – 30 Time_60min – 60



- CStyle: Selection of the style of the controller symbol Dialog_Style – 1 (small Symbol) Dialog_Style – 2 (large Symbol) Dialog_Style – 3 (long line representation with more/less buttons) Dialog_Style – 4 (long line representation with slider) Dialog_Style – 5 (small symbol without tag – set point and actual value) Dialog_Style – 6 (small symbol without tag – only actual value) - ToolTipText: The Tool-Tip Text can be entered in one language. - CShortDescription: This text will be displayed in the symbol. If this field is empty the object name (tagname) is displayed in the symbol. - CAllowWinCCZoom: must remain „no“! - CAbloluteSteps: Normal steps for inching function are 1% and 10%. If absolute steps are required the absolute value can be inserted. E. g. 0,5 for ±0,5 and ±5.

Procedure for the Counter There is only one style for the control.



- tagname: Name of the selected object - Active: yes - CComma: Number of digits behind the comma (default value is 0) - ShowUnit: With „yes“ the unit is displayed in the output field. - ToolTipText: The Tool-Tip Text can be entered in one language.



Procedure for the Runtime There is only one style for the control.

- Duplicate the default control - Double-click on the new symbol - Select the tag of the corresponding object - Close with OK


- tagname: Name of the selected object - Active: yes - ShowUnit: With „yes“ the unit is displayed in the output field. - ToolTipText: The Tool-Tip Text can be entered in one language.



Procedure for Motor, Damper, Valve, Annunciation and Silo Pilot Motor, Damper, Valve, Annunciation and Silo Pilot are displayed as symbol in the process picture. The PP_Cemat_default.pdl contains a number of default symbols.

For motor, damper, valve and annunciation there are also controls available for short line representations.

Long line representation only exists for the damper (positioner function). To show the damper position in a normal process picture the following styles of the damper control can be used:

For the silo pilot there is also a control available, but only one style:



To use one of the default symbols in your Process Picture proceed as follows: - Duplicate the default symbol. - Open the configuration dialog

- Click on the variable folder (yellow button behind the variable)

Select from ES variables the desired object

- For Motors, Valves, Dampers Silo pilot select Variable „VISU_OS“ - For Annunciation Modules select Variable „STATUS“ - Change update time if required



- If different Bitmaps should be used they can be selected from the picture selection field The variable name is also used for the Tooltip text. Therefore: - Mark the text string for variable name (from the left side until the „.“) - Ctrl + C - Close Configuration Dialog with „OK“


- To enter a Tooltip Text select „Miscellaneous“ - Double-click on Attribute „Tooltip Text“ - Select the desired language and paste the object name with Ctrl + V into the value field - Save with „OK“



To use the control for motor, damper, annunciation module or silo pilot please proceed as follows: - Duplicate the default control - Double-click on the new symbol - Select the tag of the corresponding object - Close with OK

Possible adaptations under Properties, Control properties for motor and valve:

- tagname: Name of the selected object - Active: yes - CComma: 0 - ToolTipText: The Tool-Tip Text can be entered in one language. - CAllowWinCCZoom: must remain „no“!

Possible adaptations under Properties, Control properties for the annunciation module:

- tagname: Name of the selected object - CComma: 0 - ToolTipText: The Tool-Tip Text can be entered in one language. - CAllowWinCCZoom: must remain „no“!



Possible adaptations under Properties, Control properties for the damper:

- tagname: Name of the selected object - LanguageID: 1033 - CComma: 0 - CStyle: Selection of the style of the damper (see PP_Cemat_default2.pdl) Dialog_Style – 1 (long line representation) Dialog_Style – 2 (short line representation) Dialog_Style – 3 (large symbol with set point and actual value) Dialog_Style – 4 (medium symbol – only set point) Dialog_Style – 5 (small symbol without tag) - ToolTipText: The Tool-Tip Text can be entered in one language. - CAllowWinCCZoom: must remain „no“!

Possible adaptations under Properties, Control properties for the silo pilot:

- tagname: Name of the selected object - Active: yes - CComma: 0 - ShowUnit: With „yes“ the unit is displayed in the output field. - ToolTipText: The Tool-Tip Text can be entered in one language.



Bitmaps The bitmaps for the symbols are stored on all clients and servers in the standard directory (D:\CEM_V5\bitmap\). Symbols used for the project must be copied into the <WinCC-Project directory>\GraCS, otherwise they cannot be used in the OS Engineering. The master for the bitmaps is the Server. The distribution can be done with a batch file.

The bitmaps for the Symbols (Drives, Valves) from Version 4.12 of CEMAT can be used.

For Drives and Valves all bitmaps must exist, which are theoretically foreseen for the Symbol, even if the status is never used in Runtime. WinCC will give an error message if any of the bitmaps is not existing.



Archive definitions

Message archive The message system under PCS 7 is generated with the Alarm Logging Wizard. After running the Alarm Logging Wizard a few adaptations have to be performed (see Chapter „WinCC Project“).

For the archiving of the messages the storage package of PCS 7 is used (see PCS 7 Manual).

Measuring value archive The measuring value archive must be configured according to the PCS 7 Engineering Manual.

We recommend to save the measuring values in Dbase III format and not in the runtime database. Selection has to be made in Project Properties for Tag Logging:



User Archives There are 2 user archives for Cemat Functions.

The user archive C_INFO contains the object information (Info Database). This function is not available in CEMAT V5B. For CEMAT V5D see description under Reference – System, System description DIGNOSTIC (D)

The user archive C_DriveList contains the Group-Object-Lists (list of objects associated to a route or group). The function Group-Object-List is available with Cemat Version 5.02.



How to create the user archive for the Info Database In directory D:\Cem_V5\ua you will find the default files for the Info Database.

File C_INFO.uap contains the structure of the Info Database. File C_INFO.csv contains one line with example data.

The structure of the Info Database is as follows:



File C_INFO.csv contains one line (only header). The Info Data can be entered with Excel and then be imported into the user archive.

Procedure for the first entry of the Info Data (later modifications can also be performed in the runtime system):

1. Enter the Info Data in Excel (use file C_INFO.csv and append the object information) Please note that column A (ID), B (Obj-ID) and C (C_TAG) must be unique, otherwise import is not possible).

2. Open the User-Archive

3. Import the structure of the Info Database from C_INFO.uap

4. Save the structure.

5. Import the Runtime Data of the Info Database form C_INFO.csv

6. After that the Info Data are available in WinCC Runtime mode and can be modified online if necessary.

How to create the user archive for the Group-Object-List In directory D:\Cem_V5\ua you will find the default user archive for the Group-Object-List.

File DriveList.uap contains the structure of the Group-Object-List. The data for Group-Object-List are entered in runtime mode.

Import the structure of the C_DriveList and save:

1. Open the User-Archive

2. Import the structure of the Info Database from C_INFO.uap

3. Save the structure.

The structure of the Group-Object-List is as follows:

Engineering Manual V5 WinCC Server

Copyright Siemens AG. Alle Rechte vorbehalten. 9 - 1 Ausgabe : 24.01.2002 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\09_WinCC_Server.DOC

WinCC Server

Content WinCC Server 1

General ....................................................................................................................2 Installation of WinCC ...............................................................................................3

Maximize Throughput for Network Applications .........................................3 Language ....................................................................................................3 Installation of the software for WinCC ........................................................3

Installation of the CEMAT Software.........................................................................4 File Structure............................................................................................................4 Adaptation in PCS 7 for CEMAT..............................................................................5

WinCC Server Engineering Manual V5


General A maximum of 16 Multiclients can be attached to a Server. In the runtime one Multiclient can be attached to max. 6 Servers (in difference to a Client, which is connected to only one Server). That means in one picture of a Multiclient the data from max. 6 Servers can be shown.

This chapter describes exclusively the installation of a WinCC Server Station.

The installation and the engineering of the Server-Projects is performed on the Engineering Station. From the Engineering Station the OS-Projects are transferred to the Server Stations via Project-Download.



Installation of WinCC The following description assumes that the operation system windows NT4.0 is installed on the Visualisation Servers.


Note: NT-Server Licenses Please take care that sufficient NT Server Licenses are installed during your NT Installation. (min. 10). Insufficient number of NT Server Licenses can lead to sporadic interrupts in the communication.

Maximize Throughput for Network Applications To maximize the throughput for network applications select in the Control System under Network -> Service -> Server-> Properties -> Optimization the Option Maximize Throughput for Network Applications


Installation of the software for WinCC Please, always use the actual installation instructions which are delivered with the PCS 7 installation CD.

WinCC Server Engineering Manual V5





Boot the PC.

File Structure After running the setup the CEMAT specific files are located in drive D, directory CEM_V5.







3. Adaptations in the LMHOSTS file. Descriptions see Chapter 14, “Tips and Tricks”.

Engineering Manual V5 WinCC MultiClient

Copyright Siemens AG. Alle Rechte vorbehalten. 10 - 1 Ausgabe : 24.01.2002 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\10_WinCC_Multi_Client.DOC

WinCC MultiClient

Content WinCC MultiClient 1

General ....................................................................................................................2 Installation of WinCC ...............................................................................................2

Language ....................................................................................................2 Installation of the software for WinCC ........................................................2

Installation of the CEMAT Software.........................................................................3 File Structure............................................................................................................3 Adaptation in PCS 7 for CEMAT..............................................................................4 How to create a PDL Cache ....................................................................................5 Restrictions for a MultiClient ....................................................................................5

WinCC MultiClient Engineering Manual V5


General This chapter describes the installation of a WinCC MultiClient.

The MultiClient-Project is a WinCC Project which can be attached to more than one Server. Each MultiClient and the associated Servers have it’s own project. The engineering of a Server Project is performed at the Server Station, the engineering of the MultiClient project is performed at the MultiClient station.

A maximum of 16 MultiClients can be attached to a Server. In the runtime one MultiClient can be attached to max. 6 Servers (in difference to a Client, which is connected to only one Server). That means in one picture of a MultiClient the data from max. 6 Servers can be shown.

At the MultiClient no Configuration System functions regarding to changes of the Server Project can be performed, which means the engineering of the Server Project can be performed only at the Server Station and not at the MultiClient. The data from the Server Projects will be introduced to the MultiClient through reference lists (packages). Before the MultiClients can access the Server Data, packages have to be generated at the Server and loaded at the MultiClient.

Installation of WinCC The following description assumes that the operation system windows NT4.0 is installed on the OS Servers and Clients. It only contains a list of the components which have to be installed on the individual stations to run the visualisation task.


Installation of the software for WinCC Please, always use the actual installation instructions which are delivered with the PCS 7 installation CD.






Boot the PC.

File Structure After running the setup the CEMAT specific files are located in drive D, directory CEM_V5.


WinCC MultiClient Engineering Manual V5





3. Under D:\Cem_V5\Config you find the file C_Config.cfg. In file C_Config.cfg under [ServerPrefix] for each PLC the allotted Server must be defined. The server name must be identical with the definition under Server Data (WinCC-ProjectName_Server-PCName.) Example: [ServerPrefix] ;PLC No. = ProjectName_PCName ;e.g.: 1=OS1_SRV1291 1=E518283D_E518283D 2= 3= 4= 5= 6= 7= 8= 9= 10= 11= 12= 13= 14= 15= 16= 17=E518281D_E513888D 18= 19= 20=

In the example above the data from PLC 1 and PLC17 are displayed

Those declarations are required for the following functions:

- acknowledgement of alarms by the means of the variable SYSPLCx on a mc

- to build the list of servers for the plant (C_PlantSelection)

- opening of the „Info Dialog“ from the alarm-line.



How to create a PDL Cache To achieve shorter picture change times on a MultiClient, the server pictures can be copied to the MultiClient Station (PDL-Cache).

On the MultiClient Station under C:\Siemens\WinCC\Bin\PDLCache you have to create one directory per Server; where the directory name corresponds to the Server-Prefix-Name (WinCC-Projectname_ServerPC-Name). Into this directory you have to copy all files from the GraCS directory of the specific Server.

Restrictions for a MultiClient

- In case a new alarm appears, in the alarm-line, only the default sound (see C_Config.cfg) is played. Individual sounds (per message) are not possible!

- Opening of the Info-dialog from of the alarm-line is not working (only from the faceplate)

- In the Info-dialog the alarm list is displayed in smaller size.

- Restrictions within the plant selection from the alarm-line and with the object-browser. Those two functions pick their data from the relevant servers. In case that one or more servers are not available, Windows NT is waiting for 90 seconds. During this time the control and it’s mimic is „frozen“. If the operator tries to change mimics during this time, WinCC terminates with an access-fault. The operator has therefore to wait until the end of this 90s timeout.

Engineering Manual V5 Project administration

Copyright Siemens AG. All Rights Reserved. 11 - 1 Ausgabe: 07.05.1998 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\11_Project_Administration.doc

Project administration

Content

Project administration 1 Distributed Engineering..........................................................................................2 Saving the PCS 7 project.......................................................................................2

Project administration Engineering Manual V5


Distributed Engineering A PCS 7 project can be edited by more than one user. At the same time, however, only one user is permitted per S7 program.

If the situation demands that a project is created at different times or at different locations, you can break down a master project into subsections. You could, for example, assign a station or a program to each person involved. The procedure is analogous for distributing work on several operator stations.

See PCS 7 Engineering Manual, Chapter 1, Basics of PCS 7.

Saving the PCS 7 project To copy the PCS 7 project you always have to copy the complete project directory. Don’t try to copy only a part of it.

To save the PCS 7 project in a compressed form you have to use WinZip because of the long file names. WinZip is included in the PCS 7 packege.

If you want to save the PCS 7 project on a CD you shoul compress it first, otherwise you have to remove the wright protection from every file.

Engineering Manual V5 Graphic Templates

Copyright Siemens AG. Alle Rechte vorbehalten. 13 - 1 Ausgabe : 24.01.2002 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\13_Graphic_Templates.DOC

Graphic Templates

Content Graphic Templates 1

Graphic Templates Engineering Manual V5


The following pages show the existing Bitmaps. After the installation of CEMAT V5 these bitmaps are located in directory D:\Cem_V5\Bitmaps.

Engineering Manual V5 Tips&Tricks

Copyright Siemens AG. All Rights Reserved. 14 - 1 Edition: 31.03.2003 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\14_Tips_Tricks.doc

Tips&Tricks

Table of Contents Tips&Tricks 1

Important Notes and Tips for the Use of WinCC / PCS7 V5.0 ...............................3 MS Internet Explorer 5.0 ............................................................................3 OS server ...................................................................................................3 Terminal bus ..............................................................................................9 System loading, response times................................................................9 Lifebeat monitoring via OPC....................................................................10 Connection termination at the client ........................................................10 Confirmation of messages .......................................................................10 Time synchronization...............................................................................10 Standard server .......................................................................................10 General user errors..................................................................................11 "...EventState" variable updating .............................................................11 Internal variables on redundant servers: .................................................11 Messages about the connection status: ..................................................11 SCRIPT: When is which function the correct one?..................................12 Create PDL-cache on multiclient .............................................................12 Manual switching of the master standby server ......................................12 Activate Autostart.....................................................................................13 How to create an Icon to activate the Runtime........................................14

User Handling of the PCS7 OS System ...............................................................15 Initial situation ..........................................................................................15 Start the OS system.................................................................................15 Update user data during running operations ...........................................16 Update the OS software during running operations ................................17 Online updating of process pictures ........................................................18 Add another multi-client in the running system........................................19 Remove a multi-client in the running system...........................................19 Add another server pair to the running system........................................19 Remove a server pair in the running system ...........................................19 Shutdown the complete OS system.........................................................20 Restrictions ..............................................................................................20 Failure of a multi-client computer.............................................................20 Failure of a server computer....................................................................20

CEMAT Functions.................................................................................................21 CEMAT Annunciation list .........................................................................21 Area specific acknowledgement (from Cemat V5.02) .............................22 CEMAT Group Display.............................................................................23

2 • Table of Contents Projektierungshandbuch_S7

Tips&Tricks Engineering Manual V5


Important Notes and Tips for the Use of WinCC / PCS7 V5.0

MS Internet Explorer 5.0 The successful operation of WinCC requires the installation of the Internet Explorer IE5 . The minimum installation suffices. We recommend that you use the typical installation method. No additional settings are needed.

OS server

CPU loading The CPU loading of the server must be held on average below 50%. If the average loading is higher, the operating system can no longer properly clear memory fragmentation; this causes the computer to become increasingly slower, possibly ending with a system blockage.

For this reason, it applies to the client/server configuration since the PCS7-Version 3.1that the server can no longer be used as an operator station when more than 2 operator stations are connected. Consequently, only a static picture (e.g. "@ServerStaticScreen.PDL" ) should be used as the start picture in the continuous display on the server. During commissioning, a process picture or annunciation display can be shown for a short time for comparison purposes, the normal picture must be selected afterwards. An automatic picture change on the server computer or automatic operating sequences using test automatons on the server computer are not permitted.

The online configuring is not permitted on the server computer when more than 2 multi-clients are active. Similarly, the operation of other programs or even the copying of files on the server is not permitted during runtime operation.

Note: Even for a client computer, the rule applies that the average CPU load should lie below 50% in order to retain the system dynamics (caused by the operating system, see above).



Network settings WindowsNT 4.0 Server must be installed The network must be set to optimize the network throughput

Rather than a hub, a switch should be used A switch makes use of the telegrams to learn the Ethernet addresses of the connected terminals. Thus, the switch has the capability to block local data telegrams and directly switch connections from port to port.

Advantage: Because the local data transfer remains local and the local data traffic does not reach the backbone, there is a significant bus load reduction. This structuring of the data traffic increases the data throughput and the network performance.

It must be guaranteed that sufficient logical connections are configured. Sufficient licenses for concurrent connections must be set (recommendation for PCS7-OS: 10 licenses per connected client) per server on the server computers (Windows NT 4.0 Server). If further applications are to be operated in parallel, the number of licenses must be increased appropriately.



Create LMHOSTS file and enter all OS computers The corresponding NT computer names (NetBIOS names) are assigned to the individual IP addresses in this file. Each entry should consist of a single line. The IP address is entered in the first column, followed by the associated computer name. The address and the computer name must be separated by at least one blank or tabulator character. The "#" character is prefixed to normal comments.

The LMHOSTS file must be located in C:\WINNT\system32\drivers\etc\. This also contains the LMHOSTS.SAM sample file.

You can use the TRANSFER_LMHOST.bat batch file to automatically transfer the LMHOSTS file to all computers of your plant:

copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_es_01\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_es_02\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_es_03\c\winnt\system32\drivers\etc\*.*

copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_srv_1a\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_srv_1b\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_srv_2a\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_srv_2b\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_srv_3a\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_srv_3b\c\winnt\system32\drivers\etc\*.*

copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_mc_01\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_mc_02\c\winnt\system32\drivers\etc\*.* copy C:\WINNT\system32\drivers\etc\l* \\dea_cs2_mc_03\c\winnt\system32\drivers\etc\*.*



Example of the LMHOSTS file:

#Address range 142.11.80.102 to 142.11.80.128 #Network mask 255.255.0.0

#Reserved addresses: #Conware Router: 142.11.80.102, network mask 255.255.0.0 #Bridge to the location network: 142.11.80.103 and 142.11.80.104

#IP address Computer name

142.11.80.102 Router CS2 #Network mask 255.255.0.0 #142.11.80.103 Bridge1 #142.11.80.104 Bridge2 #142.11.80.105 Spare1 #142.11.80.106 Spare2 #142.11.80.107 Spare3 #142.11.80.108 Spare4 #142.11.80.109 Spare5 #142.11.80.110 Spare6 142.11.80.111 DEA_CS2_ES_01 142.11.80.112 DEA_CS2_ES_02 142.11.80.113 DEA_CS2_ES_03 142.11.80.114 DEA_CS2_SRV_1A 142.11.80.115 DEA_CS2_SRV_1B 142.11.80.116 DEA_CS2_SRV_2A 142.11.80.117 DEA_CS2_SRV_2B 142.11.80.118 DEA_CS2_SRV_3A 142.11.80.119 DEA_CS2_SRV_3B 142.11.80.120 DEA_CS2_MC_01 142.11.80.121 DEA_CS2_MC_02 142.11.80.122 DEA_CS2_MC_03 142.11.80.123 DEA_CS2_MC_04 142.11.80.124 DEA_CS2_MC_05 142.11.80.125 DEA_CS2_MC_06 #142.11.80.126 Spare7 #142.11.80.127 Spare8 #142.11.80.128 Spare9



Activate the LMHOSTS query:

Additional recommended settings: Only TCP/IP (no NETBUI) should be present under System Control Network Protocols

Enter IP addresses in accordance with the LMHOSTS file (deactivate IP address assignment using DHCP)



IP forwarding should be deactivated.



Terminal bus The TCP/IP connection in the network between OS Server and multi-clients must be dimensioned so that the network loading lies below 30%. For higher loading, message overtaking and message duplications can occur due to the characteristics of TCP/IP. This can lead to instability of the system.

Consequently, in larger plants, the terminal bus must be separated from the plant bus and from other network applications (e.g. office network, location network, etc.).

The communications software compensates for short interrupts to the network connection. Should the interrupt to the network connection lie in the range > 1 second, the network connection can be re-established after 5 minutes at the earliest.

Note: A 100 Mbit network for the communication between server and client should be used for larger plant configurations or data volumes.

System loading, response times The OS software does not perform any limitation with regard to the system loading internally. The user is responsible for ensuring the balance in the application. To ensure an adequate system response, the specified quantity details for PCS7 must not be exceeded.

The system does not hinder any violations of these limits, which may then cause longer response times.



Lifebeat monitoring via OPC In the WinCC Explorer under >Add new driver< variable housekeeping Path: SIEMENS\WinCC\BIN\OPC.CHN

Create a new connection for each OS/MC under OPC Groups. OPC Groups => New Connection.

Enter the name of the connection in the >General< register tab (e.g. MultiClient 1).

>OPCServer.WinCC< must be entered in the OPC Server Name field in the OPC Connection tab.

Enter in the >Start the server on this computer< field the server name of the MC/OS to be monitored (e.g. PCS7_DE2). You can use the >Test server< button to test the connection to the MC/OS. It is also determined here whether the computer supports OPC Server.

Configure the plant picture using the LifeBeatMonitoring editor as usual.

Start the runtime.

The following points must be observed for the configuring of the life beat monitoring in a distributed redundant system:

The life beat monitoring from a server pair monitors the lower-level ASes for this server pair and the other servers.

The monitoring of the multi-clients is either configured only from the standard server pair or the monitoring of the multi-clients is distributed to the server pairs.

Under no circumstances should all multi-clients be monitored from all server pairs.

On the multi-clients, a reference is made only to the plant configuration pictures of the server pairs.

The OPC connection variables should be configured only to those multi-clients that are actually to be monitored (i.e. delete after a multi-client is removed from the environment).

Connection termination at the client Because of the DCOM, it can take a longer time until the client registers the termination following a connection termination. Similarly, the re-establishing of the connection by the client can take some time.

Confirmation of messages The parallel confirmation requirements reduce the system performance for fast operator input of group confirmations. Any further group confirmation should be performed only when the system response action to a previous confirmation has been completed. This enables confirmations for large message volumes resulting from multiple confirmations to be performed more quickly overall.

Time synchronization A time synchronization of the OS Servers and the connected AS components is necessary for a correct annunciation processing (archiving, display, redundancy balancing).

Standard server A standard server must be configured on the multi-clients. Then, for example, OS instrumentation and control messages and operating messages that occur locally on the multi-client can be archived on this server.



General user errors The complete system can recognize and display only some of the user errors. It is the user’s responsibility to create system-conform applications. In addition to the configurations listed above, these also include the configuring of dynamic activities such as updating cycles and the use of scripts (the system can catch programming errors only to a limited extent).

The installation and parallel use of third-party programs not approved by Siemens offices can degrade the system behavior of PCS7. The user is responsible for these effects.

To ensure the stability of the complete system, systematic tests in the corresponding environment must be carried out in the case of those applications programmed by the customer.

"...EventState" variable updating When a variable connection to the ".EventState" member variable of S7 structures is used, because this structure member behaves like an internal variable, an updating of "when changed" is recommended. Because a change-controlled updating is present for the "when changed" updating type, this type is optimum for performance.

Internal variables on redundant servers: The internal variables between the redundant servers are not matched with each other. It must therefore be noted in the application that by redundancy switching the consistency of the variable contents is ensured.

Messages about the connection status: The system provides several variables for the connection status. Refer to the help for the description of these variables (Search => H-Systems). The variables must currently be created manually.

Procedure:

A new variable group must be created in the variable housekeeping -> Protocol Suite -> UNIT Named Connections -> Connection. Name: @[connectionname] The variables are now created as follows in this group:

e.g. @[connectionname]@ConnectionState of DWORD type.



SCRIPT: When is which function the correct one? GetTagMultiWait / SetTagMultiWait

When information about several variables is needed in a script – also those of different types - this can be obtained with a function call.

Advantages:

Reduced script run times.

Performance gain for picture change.

Confirmation from the AS about the execution of GetTag.. / SetTag..

Create PDL-cache on multiclient To achieve shorter picture change times on a MC, the server pictures can be copied to the MC Station (PDL-Cache).

On the MultiClient Station under C:\Siemens\WinCC\Bin\PDLCache you have to create one directory per Server; where the directory name corresponds to the Server-Prefix-Name (WinCC-Projectname_ServerPC-Name). Into this directory you have to copy all files from the GraCS directory of the specific Server.

Manual switching of the master standby server WARNING: This is permitted only for test and commissioning. Under no circumstance for plant operation!!

The following Registry entry causes a trace window to appear for the change to RT. The communication between the redundant servers is output in this window. You can also make a manual master / standby switching here.

[HKEY_CURRENT_USER]-Software-Siemens-RedundancyControl-Settings-

Set >UserDialog< to 01, default 00.



Activate Autostart The OS Stations for WinCC Server and WinCC MultiClients normally don’t have an Engineering License. Therefore it is better to activate only the Runtime on this Stations (without opening the WinCC Explorer).

To activate the Runtime automatically during the startup of the PC you have to use Start/Simatic/WinCC/Autostart to select the WinCC Project, then select „Activate Project at Startup“ and press button „Add to AutoStart“.



How to create an Icon to activate the Runtime The following procedure allows you to activate the Runtime from an Icon on the Desktop (without logoff/logon or rebooting the PC).

You first have to create an Autostart Icon and then copy the registry entry for the direct start of the Runtime into the Target field of the Shortcut folder.

The Registry entry you find under HKEY_LOCAL_MACHINE\Software\Microsoft\Windows\CurrentVersion\Run and there under AutoStartWinCCRT.

Example:

C:\SIEMENS\WINCC\bin\AutoStartRT.exe D:\PCS7_Projects\Demo\Demo_V52\wincproj\ESW1\ESW1.mcp /Activ:yes /LANG=NEU

Copy the complete string into „Target“. (/Activ:yes /LANG=NEU is not required).



User Handling of the PCS7 OS System

Initial situation The following scenarios assume that the following predefined work has been carried out and system prerequisites are present:

Installation of the complete software on all computers in the OS system (server, multi-client)

Configuration and parameterization of the computer settings and establishment of the network connections (WindowsNT operating system and PCS7 software)

Performance of all engineering work and the installation of the consistent user data on the computers (create the picture and group display hierarchy, create package).

Start the OS system Start the OS system with the following steps: switch on the computer, log in to the operating system, start WinCC, open the user project, and activate the runtime operation.

Once WinCC has loaded the user project, this is noted when WinCC is terminated and is opened automatically with the next start.

For the initial start of the OS system, we recommend that the user performs these steps in the following sequence:

Switch on and start the master server

Switch on and start the standby server (any initially entered archive data is compared automatically)

Switch on and start the multi-clients (successively).



Update user data during running operations The user wishes to add updated and extended user data during the running operations. This is possible without interruption only in an active redundant system. The following work steps must be performed:

Deactivate the master-server (the attached multi-clients switch automatically to the standby server).

Terminate WinCC on the deactivated master-server and reboot the computer (recommended).

Load the updated user data (this overwrites the current project data)

Start WinCC and activate the runtime operation of the master-server (the active standby server automatically performs an archive comparison)

Wait until the archive comparison between the two servers has been completed

Deactivate the standby server (the attached multi-clients reswitch automatically to the master server).

Terminate WinCC on the deactivated standby server and reboot the computer (recommended).

Load the updated user data (this overwrites the current project data)

Start WinCC and activate the runtime operation of the standby server (the active master server automatically makes an archive comparison)

Update the server packages on all multi-clients (this requires the deactivation of the multi-clients, the importing of package data and then the reactivation of the multi-clients).



Update the OS software during running operations The user wishes to add software updates during running operations. This is possible without interruption only in an active redundant system. The following work steps must be performed:

Deactivate the master-server (the attached multi-clients switch automatically to the standby-server).

Terminate WinCC on the deactivated master-server and reboot the computer.

Install the software updates and perform any necessary parameterization.

Reboot the computer.

Start WinCC and activate the runtime operation of the master server (the active standby server automatically performs an archive comparison).

Wait until the archive comparison between the two servers has been completed.

Deactivate the standby server (the attached multi-clients reswitch automatically to the master server).

Terminate WinCC on the deactivated standby server and reboot the computer (recommended).



Start WinCC and activate the runtime operation of the standby server (the active master server automatically performs an archive comparison).

Deactivate the attached multi-client computer.

Terminate WinCC on the multi-client and reboot the computer.



Start WinCC on the multi-client and activate the runtime operation (the multi-client connects itself automatically to the master server).

Repeat actions 12-16 for all attached multi-clients.



Online updating of process pictures Existing process pictures are created on a separate engineering computer and should be loaded onto a PCS7-OS with redundant servers operating in runtime. The following procedure is recommended:

1. Deactivate the standby server operating in runtime (the redundant partner continues to operate in runtime and supplies the attached multi-clients).

2. Load the current process pictures (PDL files) onto the deactivated server computer (primarily with data media directly to the server computer to avoid a network loading caused by the network file transfer).

3. Call the Picture Tree Manager and re-save the picture hierarchy to recreate the group display hierarchy. Export the package again.

4. Restart the server computer to the runtime.

5. Now deactivate the master-server once the archive redundancy comparison has completed (the standby server assumes the mastership).

6. Repeat steps 2 to 4 also for this server.

7. Restart the master-server to the runtime, which once again assumes the mastership.

This type of upgrade of the server project data in running operation is permitted only for process pictures. Archive configuring cannot be changed in this way. The direct online configuring on the current master computer is not permitted.

Note: When the picture cache function is used on the multi-client, any changed process pictures must also be imported there.

User-specific basic data:

The user must not change the basic data supplied with PCS7. However, there is the possibility to generate user-specific basic data from the standard basic data. The user is responsible for updating his basic data as the result of updates to the standard basic data caused by newer SW versions or updates.



Add another multi-client in the running system The addition of another ready-installed and configured operator station requires the following steps:

Switch on the multi-client and start WinCC.

Open the multi-client project.

Import the package data from all servers to be attached, including the redundant servers.

Activate the runtime operation on the multi-client.

Remove a multi-client in the running system The removal of an operator station requires the following steps:

Deactivate WinCC on the multi-client.

Terminate WinCC.

The computer can now be removed without a problem from the network environment.

Add another server pair to the running system The addition of another ready-installed and configured server pair (master server and standby server) requires the following steps:

Switch on and start the master server.

Switch on and start the standby server (any initially recorded archive data is compared automatically).

Import the server package for the new master server and the new standby server to all attached multi-clients (this requires the deactivation of the multi-clients, the importing of package data and then the reactivation of the multi-clients).

Remove a server pair in the running system The removal of a server pair requires the following steps:

Delete the server packages on all attached multi-clients (this requires the deactivation of the multi-clients, the deletion of package data and then the reactivation of the multi-clients).

Deactivate the standby server and terminate WinCC.

Deactivate the master server and terminate WinCC.

The two server computers can now be removed from the OS system.



Shutdown the complete OS system The following steps must be performed to shutdown the complete OS system:

Deactivate all multi-clients and terminate WinCC on the multi-clients.

Deactivate the standby servers and terminate WinCC.

Deactivate the master server and terminate WinCC.

(Steps 2 and 3 can be performed in parallel with all server pairs).

Restrictions The upgrade or modification of a redundant plant in running operation is not possible in the following situations and requires a shutdown of the complete OS system:

Software upgrade to a new version (major release).

Structural changes to the user data when the consistency of the data affects several server pairs (e.g. moving a PLC from one server to another).

Converting to different user data (e.g. project change).

Failure of a multi-client computer Should a multi-client computer fail, this must be removed from the OS computer environment and replaced with an equivalent computer. The equivalent software installation and user data (multi-client project) must be created. It is not necessary for the multi-client computer to have the same network address and the same computer name as the failed computer.

Refer to Section 9.5 for the addition of the new multi-client.

Failure of a server computer All server computers should be protected against power failure through the provision of an uninterruptable power supply (UPS). This is the only way to avoid the destruction of user data in the runtime database in the case of power failure.

The UPS must be parameterized so that a power failure at a server computer (either master or standby) causes the automatic deactivation of the WinCC currently in runtime and the shutdown of the operating system. Only then can the computer be removed from the power without a loss of data.

To ensure that the master server and the standby server do not fail simultaneously, these should, if possible, be connected to separate power circuits. Similarly, the attached multi-client computers should be assigned to several power circuits.

A defective server-computer or a server-computer in an undefined state must be deactivated without delay so that, if necessary, the redundancy switching to the active partner-server takes place if this has not already been done automatically.

When a failed server-computer is replaced with a new, equivalent computer, this must assume the same computer name of the failed computer. Only then can the connection to its running partner-server be re-established automatically. This also avoids the need to re-import the server packages to all multi-clients.



CEMAT Functions

CEMAT Annunciation list In the CEMAT Annunciation list as standard the annunciations of the last 24 hours are displayed. If this time is too short the value can be changed in the registry.

The name of the registry key is: HKEY_LOCAL_MACHINE/SOFTWARE/SIEMENS/ILS/CEMAT/ TimeDifferentForCurrentArchive

The value is the time in hours. The entry will be created automatically if you open first time the CEMAT Annunciation list in WinCC Runtime.



Area specific acknowledgement (from Cemat V5.02) With the acknowledge of the alarm line the acknowledge signal is sent similarly to all PLCs and all dynamic faults are acknowledged.

With an adaptation in the engineering it is possible to send the acknowledge signal only to the PLC from which the alarm was proceeding. This needs an assignment of the OS Area to the PLC.

e. g. Raw Mill = AS1 Kiln = AS2 Cement Mill1 = AS3 Cement Mill2 = AS4

Important: It is not possible to acknowledge only a part of the PLC, always all faults of a PLC are acknowledged. This implies that for an area specific acknowledgement the OS Area corresponds with the PLC. The OS Areas names must be unique.

To use the area specific acknowledgement an adaptation in file C_CONFIG.CFG is required. If you don’t want to use the filter function nothing has to be done.

How to set the area filter In file C_CONFIG.CFG a new key [PlantSection] was added. After this key the assignment of the Area to the PLC must follow. Example: [PlantSections]

Sections=Raw Mill,Kiln,Clinkertransport,Cement Mill1,Cement Mill2, Raw Mill=1 Kiln=2 Clinkertransport=3 Cement Mill1=4 Cement Mill2=5

Caution: The key „Sections“ must not be modified and there must be a Comma at the end!!!

The settings in the configuration file C_CONFIG.CFG can be done manually, but the system gives you some support. By opening the selection window from the alarm line (right mouse on “L“) all not yet available areas are entered automatically in C_CONFIG.CFG. The default PLC-No. is “-1“. The PLC-No. must then be added manually according to the PLC Assignment of the plant view.

Procedure to create the configuration file:

- Open the selection window on a MultiClient (we assume that the MultiClient has a connection to all Servers and therefore all plant sections are available).

- After that open the file C_CONFIG.CFG on this MultiClient and add the PLC-Number for each Area. Save the config file.

- At the end you have to copy file C_CONFIG.CFG to all stations.

Caution: If file C_CONFIG.CFG contains at least one area with PLC-No. “-1“, there will be no area specific acknowledgement, acknowledge will then be sent to all PLCs (“-1“ is interpreted as a faulty entry and deactivates the filter function). File C_CONFIG.CFG is read only at the first acknowledgement of an alarm, which means if the file is changed it needs a restart of WinCC to get the new information.



CEMAT Group Display The Group Display for CEMAT are derived from the Group modules. Substantial engineering time can be saved because the Group Display must not be engineered for every Motor, Damper, Measured Value, Annunciation module separately.

For representation the right small box of the group display is used.

The standard PCS 7 Group Display for each single object can be used furthermore, however they are not supported by CEMAT.

Function Every Group already has a general fault indication for all of the Group associated objects. If the Group is started and a fault appears with an object (e.g., motor), an alarm is generated and the fault indication (F) in the Group symbol flashes. After acknowledging the Group symbol displays F without flashing. If the fault has passed, the F disappears. This function is

already integrated in each Group module.

Extended Function Group Display In addition to that, you can connect all Group modules of an area to the Group Display of PCS7. Then one will get the Group Display area-wise with the picture tree.

This Group Display will be switched on only by started Groups. It disappears when this Group (respectively all Groups of the area) have no more faults.

If there is a fault in a not started Group, there is no indication of Group Display of this area. It is used to avoid indication of faults from Groups which are not involved in the production process.



Engineering of Group Display For each Group module in a picture a Group Display can be engineered. The Group Display may not be switched invisibe. So that it is not seen, the Group symbol can be pushed over it.

The Group Display has to be connected with the variables TAG.EventState of the Group module.

So that the Picture Tree Managers can transmit all faults up to the highest picture level you have to engineer Group Displays for eatch subordinate picture.

After you have selected the Group Display start the standard dynamic wizard "PCS7 group display with picture tree". You are asked to enter the name of your subordinate picture.

Finally, you must open the Picture Tree manager and save it again.

For further information about Group Display please read the PCS7 manuals, or look into the WinCC online help.



Changing of the Group Display-Symbol. For the CEMAT Group Display the internal message class "Operator prompt" is used. The standard display of PCS7 is a white O on a blue background.

We recommend white G on a red background. (Collective fault of CEMAT Group modules)

In addition @Overview1.pdl was changed. You must transfer this file into the <WinCC-Projekt>\GraCS-directory. Afterwards you can start WinCC runtime.

To get the white G on red background also for the levels below, you have to modify the display text and color of the message type “Bedienanforderung/Operator request”. In the picture @PTN0.PDL (and if already existing also in the derived @PTN_xxxx.PDL) change the properties for Object @CSIG_1 as follows:



Engeneering of CFC That is not necessary when you start with a new project. After you installed the CEMAT CD you must have the latest C_GROUP in the ILS_CEM library. Please use this library.

If you have already engineered CFC with Group modules you have to add one more message to each group to SIG_8.

Set the message class to Operator Prompt.

Engineering Manual_V5 Update-Information

Copyright Siemens AG. All Rights Reserved. 15 - 1 Edition : 07. Feb. 00 N:\AUDASCCCP\Cemat\DOKU\V500\Englisch\Engineering\15_Update-Information.doc

Update-Information

Contents Update-Information 1

Upgrade of the Complete CEMAT V5 Standard Software.......................................2 Installation of CEMAT V5............................................................................2 Update of S7 Programs ..............................................................................2 Update of the WinCC Project......................................................................3

Transfer Changed CEMAT Standard Modules........................................................4

Update-Information Engineering Manual_V5


Upgrade of the Complete CEMAT V5 Standard Software

You have received a new CEMAT CD and would now like to upgrade your PCS7 project. The following section describes the necessary steps.

Caution: A complete upgrade always requires reloading the PLC and consequently cannot be performed while the plant is running.

Installation of CEMAT V5 Start the Setup program from the CD-ROM and follow the provided instructions.

Installation path: 'D:\CEM_V5\BIN'.

Keys for project standards 000 = CEMAT 006 = Dyckerhoff 007 = Heidelberger Zement

Update of S7 Programs The CEMAT installation transfers a new version of the CEMAT Library ILS_CEM to the C:\Siemens\Step7\S7libs directory.

This library contains the current CEMAT symbol list, modules and the system plan.

Symbol list Open the CEMAT Library ILS_CEM in the Simatic Manager and export the symbols from the CEM_ALL S7 program.

Then open the symbol list of the PLCs in your project and import the current standard symbols. Analyze the error list of the import editor and correct any errors (e.g. non-unique symbols).

Modules

Attention: If at the start of the project you changed the system attributes of the modules in the module folder (e.g. by setting the parameter hidden), you must repeat these changes in the module folder after the update. The same applies to the message configuring. The existing instances are not affected, but only the new instances.

1. Delete in the module folder of your PLC all modules that have ES_MAP as author. (These are all modules that were created by the CFC.)

2. Copy all modules from the S7 program of the CEMAT ILS_CEM library into the module folder of your PLC (overwrite = yes).

3. Perform a general reset of the PLC.

4. Load the system data into the PLC and start it.

5. Open the CFC editor by opening any plan.

6. You must now use Extras -> Module Types to update all modules of the plan folder with the "New Version" key or transfer the following listed modules from the offline module folder into the plan folder.

Engineering Manual_V5 Update-Information


List of the modules in the plan folder that must be updated:

Absolute Symbolic Process-

ing in Absolute Symbolic Process-

ing in FB1001 C_DRV_1D OB1 FB503 TE_VSLCT OB1*) FB1002 C_DAMPER OB1 FB513 TE_CTRL OB35*) FB1004 C_ANNUNC OB1 FC527 OB100_SYS1 OB100 FB1006 C_MEASUR OB1 FC528 OB1_SYS2 OB1 FB1007 C_VALVE OB1 FC529 OB35_SYS1 OB35 FB1009 C_ROUTE OB1 FC530 OB35_SYS2 OB35 FB1010 C_GROUPE OB1 FC1001 C_SPEEDM OB35 FB1011 C_SILOP OB1 FC1011 C_SPCNT OB1 FB1013 C_SELECT OB1 FC1017 C_MUX OB1 FB1015 C_COUNT OB35 FC1088 C_PUSHBT OB1 FB1016 C_RUNNT OB1 FC1102 OB1_SYS1 OB1 FB1020 C_FB_PLC OB1 FC1103 C_OB1SY1 OB1 FB1052 C_PLC_SEND OB1 FB1053 C_PLC_RECEIVE OB1 FB1054 C_PLC_PLC OB1/OB35

7. Compile CFC (complete program).

8. Load the complete program into the AS.

9. Transfer the AS/OS connection data.

10. For client/server projects, the "package" on the server must be regenerated and reloaded on the multi-client.

Update of the WinCC Project After the CEMAT installation, the D:\Cem_V5\WinCC directory contains the current version of the global scripts and the system pictures. These must be transferred to the WinCC project.

1. Close WinCC Explorer.

2. Copy global scripts from 'D:\CEM_V5\WinCC\Library' into the PCS7 project '<OS>\Library'.

3. Copy all pictures (*.pdl) from ''D:\CEM_V5\WinCC\GraCS' into the PCS7 project '<OS>\GraCS'.

4. Directly open the WinCC project (*.mcp) using the Start button, Simatic -> WinCC -> Windows Control Center but not using the SIMATIC Manager.

5. Open 'Global Script' and regenerate the header. (Menu/Options/Regenerate Header)

Update-Information Engineering Manual_V5


Transfer Changed CEMAT Standard Modules One or more S7 modules have been changed for extension / error correction reasons and must now be copied into the PCS 7 project. You have received a library that contains the modified modules.

Note: This procedure is possible only when no changes have been made to the modules. If at the start of the project you changed in the module folder the system attributes of the affected modules (e.g. by setting the parameter hidden), you must repeat these changes in the module folder after the update. The same applies to the message configuring. The existing instances are not affected, but only the new instances.

Proceed as follows to update the S7 modules:

1. Copy all modules from the S7 program of the CEMAT "Update" library into the module folder of your PLC.

2. Open the CFC editor by opening any plan.

3. You must now replace the changed modules in the plan folder of the CFC with the new version from the offline module folder (Option Extras -> Module Types).

4. Compile CFC.

5. Load changes in the program into the PLC.

deckblatt mmi v3 - siemens · guide the current manual ... planning the process control interface...

Documents