BRAUMAT Operator Manual V3 en

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BRAUMAT Operator Manual
BRAUMAT Operator Manual

Copyright Siemens AG 2013 All rights reserved
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Table of Content
Table of Content
1 Introduction ....................................................................................... 6
1.1 Intended Audience............................................................................. 6
1.2 BRAUMATClassic Software Structure ................................................ 6
1.3 Abbreviations used ............................................................................ 6
1.4 Further Reading................................................................................. 6
2 Compact Manual for Operators .......................................................... 7
2.1 Common functions............................................................................. 7
2.2 Process picture, visualization ............................................................. 8
2.2.1 Navigation between the process images ............................................ 8
2.2.2 Printing of process pictures .............................................................. 10
2.3 General operation ............................................................................ 10
2.3.1 Searching for variables and objects in project pictures ..................... 10
2.3.2 Variable and object information ........................................................ 13
2.3.3 Setting bit variables (for switches and selections)............................. 14
2.3.4 Setting text variables ....................................................................... 15
2.3.5 Faceplates....................................................................................... 15
2.3.6 Individual Control Elements (ICM) faceplate (for valves and
motors) ............................................................................................ 15
2.3.7 Digital faceplate (for sensors, swing-bend etc) ................................. 19

2.3.8 Analogue Faceplate (for measurements, analog outputs etc) ........... 21
2.3.9 Controller Faceplate ........................................................................ 23
2.3.10 Entity Faceplate............................................................................... 25
2.3.11 Unit Control Faceplate (for sequences) ............................................ 26
2.3.12 RCS Faceplate (for route control) .................................................... 35
2.3.13 RCS troubleshooting........................................................................ 38
2.4 Batch handling (unit recipes)............................................................ 40
2.4.1 Basic structure of the programs for plant units and for basis
operations ....................................................................................... 40
2.5 Curve visualization: Trends ........................................................... 45
2.5.1 Types of Trends............................................................................... 45
2.5.2 Selection of Trends.......................................................................... 45
2.6 Step Protocols ................................................................................. 47
2.7 Alarm System .................................................................................. 48
2.7.1 Overview ......................................................................................... 48
2.7.2 Message types ................................................................................ 49
2.7.3 Message archive ............................................................................. 51
2.7.4 Change Protocol .............................................................................. 51
2.8 Special values ................................................................................. 52
3 Compact Manual for Maintenance Personnell .................................. 54
3.1 Maintenance Information in the Process Pictures ............................. 54
3.1.1 Tab "General". ................................................................................. 54
3.1.2 Tab "Extended"................................................................................ 55
3.1.3 Tab "Maintenance" .......................................................................... 57
3.1.4 Additional information ...................................................................... 58
3.2 Recipe system ................................................................................. 59
3.2.1 General information ......................................................................... 59
3.2.2 Using the Recipe application............................................................ 59
3.3 Tools ............................................................................................... 60
3.3.1 Status S7 block................................................................................ 60
3.3.2 Forcing ............................................................................................ 61
3.3.3 DB editor ......................................................................................... 61
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Table of Content
3.3.4 Graphical source view ..................................................................... 61

4 Compact Manual for System Administrators..................................... 62
4.1 Process Visualization....................................................................... 62
4.2 Recipe-System ................................................................................ 64
4.3 RCS system .................................................................................... 65
4.3.1 General information ......................................................................... 65
4.3.2 Switch RCS servers......................................................................... 65
4.4 Data handling and backup ............................................................... 66
4.4.1 Automatic delete function................................................................. 66
4.4.2 Storage locations ............................................................................. 67
4.4.3 PCU data backup and restore .......................................................... 68
4.5 User administration and password ................................................... 69
4.6 STEP7 programs ............................................................................. 70
5 Troubleshooting ............................................................................... 73
5.1 Problems starting a unit ................................................................... 73
5.2 Problems when the step chain doesnt proceed properly .................. 73
5.3 Sequence control issues .................................................................. 74
5.4 Changing more Parameters ............................................................. 75
6 History ............................................................................................. 75
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Introduction
1 Introduction
1.1 Intended Audience
This document is structured in three parts, intended for different audiences:
Chapter 2, Compact Manual for Operators is intended for plant operators who
need a basic understanding of the brewerys operation,
Chapter 3, Compact Manual for Maintenance Personnell addresses
maintenance staff who is supposed to service and repair the plant,
Chapter 4, Compact Manual for System Administrators is intended for
administrators who supervise the proper plant operation and adjust it
accordingly.
1.2 BRAUMATClassic Software Structure

The BRAUMATClassic Software consists of the following modules:
The configuration system:
Visualization System
SIMATICSoftware
BATCH System
Route control
The Runtime:
In the SIMATIC environment the Runtime is employed for
visualization,
messages,
curves and
step protocols
1.3 Abbreviations used

Throughout this document, the following abbreviations are frequently used:
Table 1
Abbreviation Complete name Description
ICM Individual control module Valves, pumps and motors
OP-REQ Operator requests Requests which must be confirmed
by the operator with the OP-REQ
button (see )
GOP Unit operation One recipe step
RCS Route Control system Route control
1.4 Further Reading

This document is complemented by the BRAUMAT HMI Design Guide, which
contains additional information for the interested reader.
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Compact Manual for Operators
2 Compact Manual for Operators

This chapter gives you an overview over the basic handling of BRAUMAT and
introduces you to the most important functionalities.
2.1 Common functions

BRAUMATClassic consists of several applications. In this section, functions which
are common to all of them are described.
Table 1
Functionality Commands
Terminating the To exit the current
program program,
Click the
corresponding icon
(see image), or
Press Alt + F4, or
Select the entry

End from the

Program menu
ICM (Valve, Motor) - To acknowledge all
acknowledge fault pending ICM alarms,
Click the
corresponding icon
(see image), or
Press F11, or
Select the entry
menu item ICM
Acknowledging
faults
Acknowledge horn To reset the alarm
device (lamp, horn),
Click the
corresponding icon
(see image), or
Press F12, or
Select the menu
item Acknowledge
horn
Password Reset To reset the password,
Click the
corresponding icon
(see image), or
Select the menu
item Reset
Password
The current user will be
logged out, and logged
files are not registered
under this user anymore.
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2.2 Process picture, visualization

The application "process diagrams" provides a system overview. The operator can
manipulate the ongoing process by various controls.
2.2.1 Navigation between the process images
General navigation
There are various means to navigate between the pictures of a project:
Table 2
Use the application Process

diagrams
Click on the navigation

buttons in the pictures,
provided they have been
configured, or
Click on the menu item

Open image, which allows
the loading of external
pictures.
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Going backwards
Table 3
To move back to the last

previously visited screen,
click on the icon highlighted
to the right, or use the keys
"Ctrl + F12".
Navigation panel
The system also provides a panel faceplate which allows you to navigate through
the images and image areas.
Features:
Direct jump to the starting page
Direct selection of process images (brewing house, fermenting area, ...)

Direct selection of images

Jump to the next or previous image in an image block
Execution of BRAUMAT applications
Right-click on the navigation field to receive additional information.
Table 4
Table 5
Click on the
highlighted icon to
move to the plant
overview.
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Click on one of the

highlighted icons to
move to the
corresponding
pictures
2.2.2 Printing of process pictures
To print the view of the currently openend process picture, do one of the following:
Table 6
Click on the highlighted printer

symbol icon,
Press CTRL + P on the

keyboard, or
Select the menu item Print
2.3 General operation

Tags
Tags are names given to various project components, like valves, motors and
controllers. A tag uniquely identifies the corresponding component.
2.3.1 Searching for variables and objects in project pictures
BRAUMAT lets you search for components used in the project by means of their
tags. Searches can be confined to the current picture, or be exteded to cover in all
pictures.
Searching within a picture

To start a search for a tag within the current picture only, do one of the following:
Table 7
Click the highlighted icon, or

Click the menu item Variable search
Within picture
A dialog box opens which lists all tags in the current picture, sorted by their name.
You can use the dropdown list Filter to limit the displayed tags to specific types.
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Selecting one of entries in the main list will highlight the corresponding component
in the process picture.
Table 8
Project-wide search
To start a search for a tag within the whole project, do one of the following:
Table 9
Click the menu item Variable search

Global
A dialogue with two tabs Seek and Browser will open.
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Table 10
Select the Seek tab to start a

free-text search across the
project. By entering the tag
name in the Seek field and
clicking on the Start button, the
list Hit will show matches to
the search term.
Select one of them.
Alternatively, select the

Browser tab to comb through
your project. The dropdown list
PCU and the Modules list
allow you to filter the tags in the
project.
The Instances list is updated
with the tags which match the
filter criteria.
Select one of them.
Click Goto process image, and the image of the corresponding tag will open.
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2.3.2 Variable and object information
The system offers two ways to show the information associated with tags in the
current picture:
Table 11
Click the menu item Variable

information
As a result, the tags of all components are superimposed on the current picture:
Table 12
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Symbolic representation in the process picture

Next to the individual devices, one or more additional icons may be displayed in the
process picture, indicating the device status.
Table 13
Priority Icon Meaning
1 Affected by Maintenance (ABM)
2 In maintenance
3 Manual operation active
4 Force release active
5 Simulation feedback active

6 Missing operation interlock
Table 14
Example for a device status: Manual operation active, Force release

active
2.3.3 Setting bit variables (for switches and selections)
Double-clicking on a binary variable brings up a dialog box.

Table 15
You can either set or clear the

corresponding binary flag. Confirm your
selection by clicking the OK button.
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2.3.4 Setting text variables
Double-clicking on a text variable brings up a dialog box

Table 16
The dialog box shows a list of

predefined texts for the corresponding
variable.
Chose the desired value with a single
mouse click, and confirm your
selection by clicking the OK button.
2.3.5 Faceplates
Faceplates are pop-up windows that appear when the user left-clicks on an object
on the image such as a valve or pump. Faceplates can also be opened by using
the Tag Browser button on the button bar. The resulting pop-up window can be
used to issue commands to the device and to switch between automatic and
manual mode.
2.3.6 Individual Control Elements (ICM) faceplate (for valves and motors)
For the monitoring, control and simulation of Individual Control Elements (ICM), a
particular faceplate is designed.
You bring it up by double-clicking the corresponding element symbol.
The faceplate dialog consists of five tabs:
General
Extended
Maintenance
Parameter
About
Only General and About are required for operator tasks. Information about the
other tabs can be found in chapter 4.
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Tab "General"
The General tab gives an overview over the current state of the ICM and allows
for basic control of it.
Table 17
Status Display
In the left part of the dialogue, the status of the ICM is displayed by means of six
status bits.
Table 18
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Their respective meanings are:

Table 19
Abbr. Meaning Value = 1 Value = 0
CA Command automatic, Control Active Disabled
of the user program or
procedure
IL Operating Interlock Enabled, ICM Locked, ICM is
can be switched automatically turned off and
locked
ON Feedback ON of ICM On
OF Feedback OFF of ICM Off
MA Manual mode Active Disabled (Mode is
Automatic)
LO Load output Active Disabled
Interlock Diagnostics
The interlock status of the ICM can be displayed by clicking the "Status" button.
This is important if a valve or motor can not be switched on. A separate window
with the corresponding S7Code opens.
Table 20
Table 21
End signal ICM status
1 Active
0 Disabled
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Table 22
Query Release status required
A (And) 1
AN (And Not) 0
Fault Acknowledgement
Faults of the ICM (for example no feedback or expired timeouts) are acknowledged
by clicking the button "Q".
Table 23
Tab "About"
In the tab "About" configured information is displayed (Description, address,
location).
Table 24
Other Tabs
Not relevant for operators.
For details, see chapter 4.
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2.3.7 Digital faceplate (for sensors, swing-bend etc)
This faceplate is used for the monitoring and simulation of digital inputs. It is
realized through the timer which is connected with the inputs.
The faceplate features three tabs:
General
Parameter
About
Tab General
The tab General renders an overview of the state of the digital inputs and outputs
both as trend curves and through symbol indicators.
Table 25
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Simulated input values

Setting the checkbox Simulation allows simulated input values to be used.
Table 26
NOTE While the simulation is running, a red exclamation mark ! is displayed to the
right of output status symbol in the General tab (see above).
Tab "Parameters"
The tab Parameters allows the setting of several parameters in connection with
the inputs.
Table 27
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Tab "About"
In the tab "About", general configuration information is displayed (description,
address, location).

Table 28
While the simulation is running, a red

exclamation mark ! is displayed to the
right of the device symbol in the process
picture.
2.3.8 Analogue Faceplate (for measurements, analog outputs etc)
The faceplate is used to monitor and simulate analog input and output values.
Tab "General"
In the tab "General", the analog values are displayed numerically and as a vertical
bar graph.
Table 29
In the left window segment, the current analog value is shown with its limiting value
and physical unit.
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Table 30
Selecting the checkbox "Simulation" will use simulated analog values. They can be
manually modified through the buttons to the right of the bar graph:
Table 31
Button Effect
Large increase
Small increase
Small decrease
Large decrease
Tab "Trend"
Here, the trend curve of the analog value is displayed.
Table 32
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Tab "About"
address, location).

Table 33
While the simulation is running, a red

exclamation mark ! is displayed to the
right of the device symbol in the process
picture.
2.3.9 Controller Faceplate
This faceplate is used to monitor and simulate PID- and three-step controllers.
In the faceplate, the following variable names are used:
Table 34
Name Meaning
KP Proportional gain
TV Rate time
TN Reset time
X Actual value
Y Process value (output)
W Setpoint
XD Deviation actual value/setpoint
Tab "General
In the tab "General" all the relevant control values and parameters can be
displayed and set.
Table 35
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The Control area in the right part of the faceplate is divided into four sections.
1. In the top left section, the buttons Auto and Manual toggles between
automatic and manual operation.
2. In the top right section, the source of the PID setpoint is chosen. External will
use the parametrized value Source. Internal enables manual control of the
setpoint W (see 4).
3. In the middle section labelled Parameters, the PID parameters KP, TV,
and TN can be set.
4. In the bottom section, the setpoint W, actual value X and process output
value Y are displayed. If the Intern/extern selector switch at the top (see 1) is
set to Internal, then the setpoint W can also be changed here.
Tab "Parameter"
This tab allows control over several more process variables.
Table 36
Tab "Trend"
This tab displays trend curves of the analog values for
Process output value Y,
Setpoint W, and.
Actual value X
Furthermore, the controller parameters KP, TV, TN, and the sampling time are
displayed.
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Table 37
Tab "About"
address, location).

To display the current status of the device in the process pictures, the following
icons are used:
Table 38
Icon Controller status
Manual
Internal
2.3.10 Entity Faceplate
Features
Collection of important values via templates
Read-only or read-write
Display of value, text, or bit-related text
Customized status display
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Table 39
Status-View to show bit-related text

Table 40
2.3.11 Unit Control Faceplate (for sequences)
For the operation and monitoring of the state of a sequence, a special faceplate
can be activated in the process picture.
Symbolic representation in the process-picture

The " Unit Control" can be represented symbolically in several ways.
Line representation
Window display by clicking the corresponding icon
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Line representation
The line representation of a unit control appears as below:
Table 41
In the line representation of a sequence, the following information is displayed and

the following operations are possible:
Table 42
Individual control components

From left to right, the individual control components have the following functions:
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Table 43
Icon/Display Function Note
1. Step forward Off The currently executed step is stopped. The component does not
proceed to the next step. Pumps and valves remain active.
2. Manual Step-Selection A dialog opens which allows the selection of the next step:
3. Operator request acknowledge A dialog opens which allows the acknowledgment of an operator
request by clicking the corresponding button:
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4. Additional device activation Flag 101.5 is toggled
5. Sequence number and name of plants
6. Sequence status (idle, running, hold ...)
7. Sequence displays "A / M": Auto / manual - mode

"+ / -": Step change on / off
"#": No permanent condition available
"0/1": State of the flag additional device
"O": Operator request is active
"S": Fault "time control"
"E": Warning fault flag active
"W": Flag warning message is active
"M": General alarm flag is active
"=": Sync is active
"_": An alternative is active
8. Step-related actual values/Setpoints are Change of the setvalues is possible here
shown
9. Step-related information Current number of step recipe

Absolute GOP number in the PLC
Current Step Name (GOP name)
Current Step running time
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10. Batch-related information Current job number
Current batch number
Actual recipe category
Current recipe
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Window display
Table 44
To open the window display, click on

the sequence icon in one of the
process pictures.
The dialog which subsequently opens displays most of the process relevant
information and allows the basic control of the unit:
Table 45
Individual control components

From top to bottom, the individual control components have the following functions:
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Table 46
1. Open plant overview A corresponding dialog opens:
2. Open online recipe A corresponding dialog opens:
3. Open order parameter list (not relevant here)
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4. Open feedstock list (not relevant here)
5. Sequence-related Set / actual values are displayed
6. Skip synchronizationn
7. S88.1 commands for basic operations
8. Step related setpoints
9. Display of Next-Step-condition logic See below.
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Display of the Next-Step-condition logic

Table 47
Table 48
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Changing step set points (current batch only)

In the unit control open the list of step-related values. There you can adjust the
recipe set points for the current batch.
For the next batch, the values from the recipe will be used again.
Table 49
2.3.12 RCS Faceplate (for route control)

The faceplate is used to display the status and operation of a configured route.
Table 50
For additional information,

click on the control with the
left mouse button.
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Detailed view
This window consists of three sections, from top to bottom:
Way view
Element view
Message view.
Figure 1
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Table 51
Way view In this view the active ways are displayed.

The full name of the element, name of
source and destination are displayed as
tool tips.
Element The element view is similar to the RCS-

view online view, but the columns Feature and
Function number are grouped.
To set a filter that will display only faulty

items, click the funnel icon on the window.
This includes all faults that affect operation
and malfunction.
Message In the message window alarms are shown

view that originated in the plant section of the
selected route.
Filtering by clicking on the funnel icon
reduces the displayed error messages
again.
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Symbolic representation of the process picture

The current status of the route is indicated by a symbol in the detailed view:
Table 52
Icon Route state
Route is in state "idle" (inactive)
Route is requested (the route is checked)
Route is ok and active (control elements are

checked and activated)
Route is in stop (route is still active, outputs

are not active)
Route is active, but an error has occurred
Route is in manual mode
NOTE Hover with the mouse pointer over the RCS icon to receive a tool tip with
detailed information about the current element.
2.3.13 RCS troubleshooting
This section deals with problems which can occur in connection with step
processing.
No stepping forward because of errors
NOTE If a plant unit does not step to the next step although the error is acknowledged,
then probably the activated way is not working properly.
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Table 53
Open the element view.

In the element view you
see the element(s) that
caused the RCSerror.
Using the tag name and

the search function of
the process picture,
search for the element
in the process picture in
which the element is
used.
Acknowledge Alarms of RCS
NOTE An Alarm must be acknowledged after correction of the faulty element.
Table 54
In the RCS-faceplate or
in the RCS-online-tool,
set the route mode to
Manual.
Reset the fault with the
acknowledgment button
(see picture), and the
way is started again.
Switch the route again

to "Automatic".
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More RCS fault localization

If there is an RCS request error, then proceed as follows:
From the "process image" or from the menu, start the application "RCS".
In this application, all routes are listed line by line. Their highlight colour indicates
their current status:
Table 55
Highlight Way is is has Note
colour Loaded? Active? errors?
No way loaded for this way,
White No No No
way is inactive
Way is loaded into the PCU,
Yellow Yes No No
but inactive
Way is active and running
Green Yes Yes No
faultlessly
Errors are already pending
Red Yes Yes Yes
to be checked
White ? ? ? No information available
Perform a horn acknowledgment to request the way again

The program will now try to load the route again. If this still does not work, error
messages are displayed.
NOTE If many elements simultaneously show alarms, the reason may be that the RCS
server is disconnected from one of the PCU's.
2.4 Batch handling (unit recipes)

2.4.1 Basic structure of the programs for plant units and for basis
operations
The individual processes are controlled by the programming of plant units or

sequencers. One sequence is responsible for one particular part of the process.
Each sequence is divided into a number of steps. The individual steps are stored in
a list of recipes with a maximum of 13 set points (flow, pressure, temperature etc.)
for each step.
The so-defined steps of a process are executed by the sequence one after
another. It is possible to interrupt the sequential execution of the recipe list and to
jump to another step (forward, backward) if required.
How to start a recipe of a unit

A process is started by starting its corresponding sequence. This is done by setting
the step number from 0 to 1. This can be done in three different ways:
From the system overview,
From a control unit - faceplate in the process picture, or
From the batch list (order system).
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NOTE If order parameters are used, only the batch list/order system can start the
recipe.
Starting the sequence from the system overview

This method uses the application Sequence-control from the menu Process-
Monitoring.
Table 56
Select the
appropriate
group from the
pull-down menu
Process-cell. A
dialog box opens
(see below)
If more than one
recipe is
available, select
the required one.

Press the Start
button to activate
first step of the
sequence.
The process is
now active.
Starting from the "unit control faceplate in the process picture

In the unit control faceplate press the "Start Sequence" button.(See section
2.3.11) A dialog box opens, allowing the sequence to be started.
Table 57
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Starting from the application "batch list" (order system)

Table 58
10. Start the application

Batch scheduler in the
menu "Process
monitoring".
11. In the window which
opens, select the orders
to appear.
12. In the menu "Edit", select

"New Order".
A dialog box opens.
Select the desired recipe
here.
13. If this function is used,

you have to select one or
several order parameters
with the Parameter
button, otherwise the
recipe cant be started.
Parameters can be for
example Tank-Nr or
quantities or pipes to be
cleaned.
Confirm this window with
OK.
The new order is
displayed in the list as
locked.
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14. Double-click on the new

order.
A dialog box appears.
Change the order status
to "able to start".
The order will be started
with the previously
parametrized set of
conditions (start time as
soon as possible, etc.)
Stopping a recipe from a unit

To Stop the recipe select Step = 0 or

Use the button "Unit Stop".
This causes the program to be stopped, and all elements used by this unit are
switched off.
A sequence can be stopped by the application Sequence control in the main
menu, or by the unit control faceplate in the process image.
Changing a recipe temporarily

(See also 2.3.11)
Table 59
From the process image

or sequence overview,
enter the desired values.
The change is valid only for this batch. For the next batch, the original recipe
settings are used again.
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Watching the graphical recipe online

To watch the graphical recipe online, there are two options:
Table 60
Press F9 in the sequence

overview, or
In the unit faceplate, press

the highlighted button.
Job and Batch-numbers

Job and batch numbers are needed to
plan a process (for example filtration)
get a report as a step protocol.
It is therefore important to increase the batch and / or order number before starting
a unit.
When a process is started by the batch list, the system will automatically increase
the batch number or order-number (depending on the selected algorithm).
The order number can be seen here as superior. By one order number, one or
more processes with different batch-numbers can be started.
In the Brewhouse, the batch-number can count up for one year and then restart.
Thus, a process with the same batch and order-number will generate the same
protocol-file, which makes it difficult to identify the batch.
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2.5 Curve visualization: Trends

The system can log measurements of specific values over a certain period,
creating so-called Trends. These curves can be displayed with the application
"Trending".
The values to be archived and displayed with the trend are defined thorough the
application "Trending definition" from the tab Engineering-Tools.
2.5.1 Types of Trends
BRAUMAT supports three types of trend curves:

Short term trends: User-selected collections of trend curves which are not
stored on the hard disk
Weekly archives (stored on hard disk)
Batch archives (stored on hard disk)
NOTE Short-Time Curves, are defined in the "Trending definition" application.

2.5.2 Selection of Trends
To select the curve to be displayed, there are two options:

Table 61
Select "Open"
from the "File"
menu, or
Press the
button "Open
image".
A dialog box opens which allows the selection of the relevant curves, sorted by
batch or week.
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Features
Each picture may contain up to eight analog and 16 digital curves in one
picture. Each curve can be individually turned on and off.
The operator can print snapshots of the curves.
A zoom function serves to examine picture details.
A ruler shows the exact process values and time.
The scaling of the curve, physical units etc. are configured in the application
"Trending definition".
There are different options to display the cuves:

Table 62
1. The measured values are related to a batch id; in a second step the user selects the
batch id.
2. The curve of the current batch is compared to the curve of a previously saved batch.
Again, the user select the batch id in a second step.
3. Through Free Selection it is possible to superimpose up to eight batch curves in a
single display. The selection is specific to the measured value, and will be used as
reference for the selection reference curves.
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Table 63
2.6 Step Protocols

Table 64
To display a list of
current step protocols
select from the Tab
Process archives,
Step protocols
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From the
File Open menu or
by clicking the
corresponding button
(right), the available
Step protocols can be
selected, sorted by
batch and order number.
2.7 Alarm System

2.7.1 Overview
Messages and Alarms in the processes are displayed in a message window and
archived on the hard disk.
For each message, separate texts for incoming and outgoing messages are
available.
Table 65
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Features
Display of messages
Size and position freely configurable
Filter tracing
Messages are archived for 24 hours
Jump from the messages directly to the corresponding process image
Process unit related messages list
Table 66
2.7.2 Message types
There are seven different types of messages in the BRAUMAT system:

1. User Alarms
2. System Alarms
3. Warnings
4. User Messages
5. Operator Mmessages
6. Operator Requests
7. IOS-Messages
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Table 67
Name Colour Code Purpose Example
code letter
1. User Pink F Critical alarm 01:56:59 F fountain pen-lines 000107 000001 026 035 fountain pen-routes 4 026
Alarm REPORTS 0648 intrusions river-supervision MIN comes under-stride
02:35:50 F CIP HWA49 000015 000001 020 016 CIP FK HWA49 020 REPORTS 0031
intrusions FASHION is caused BY AUTOMATIKPROGRAMM LOVELY
2. System Red S Critical alarm 00:15:03 S CIP UF LB32 000036 000001 020 002 CIP UF LB32 020 ICM3 0091
Alarm LB32ESV9304 ICM3-berwachungszeit disturbance beginning
18:04:20 S Dosage Dosimat14 000034 000010 021 009 Dosimat 14 021 MEASURES
beginning 0020 DS14LE1414 intrusions: Measurement Messw.unterschr.
3. Warning Yellow W Step time, monitoring time 00:02:01 W filter-traces 3 000001 000001 023 001 KGF FL3 023 TeilAnl 0001 KGF FL3
supervision-time disturbance beginning
4. User Green M Raise operator awareness 02:59:29 m of filter-route 1 000117 000001 022 001 KGF FL1 022 REPORTS 0037
Message notifications maximum finish-pressure I comes particle-filters FL1
16:33:43 m of CIP KGF LB42 000072 000001 020 009 CIP FK LB42 020 ICM1 0036
HWS46ESV3449 ICM activates in the hand-mode
5. Operator Blue B Sequence-related or route- 00:27:17 B filter-traces 3 000001 000001 023 004 PT1 FL3 023 TeilAnl 0004 PT1 FL3 part-
Message control-related alarms installation-news: Schrittanwahl
01:20:13 B ways filter-line 000031 000001 026 028 filter-traces 3 026 RCS_Svr2 0104 filter-
line 3_1 ANF openings: Pressure-tank 1 > pressure-tank 46
6. Operator Green O Operator advice 00:55:10 O CIP KGF LA41 000183 000001 020 008 CIP FK LA41 020 TeilAnl 0001
Request Bedienanf. Start
7. IOS - Brown P Actions of the IOS
Message
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2.7.3 Message archive
Newly generated messages are displayed in the window of the PCU-Server.

Simultaneously, each new message is logged in the "Message archive", which can
be found in the section "Process archives".
Table 68
The command Select from the

Functions menu configures a filter to
select the displayed alarms.
The section Field name lists the

avaiable data record fields.

To employ a filter, select the required

field (eg Batch) and enter the
corresponding value (eg the batch
number) in the field Enter.
NOTE The batch number must be padded with leading zeroes, ie to filter for the batch
number 3, enter 000003.
2.7.4 Change Protocol
All user activity is logged alone with the user id in the Change protocol.
Table 69
The Change
protocol displayed
through the Tab
Process archives,
Change Protocol
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Filtering for the

activity date
Filtering for the

data record fields
to be displayed
2.8 Special values

This application is used to display up to 511 special values. In most cases these
will be timer values.
The values can be displayed in one of the formats:
Table 70
Abbreviation Type
KF Fixed point
KH Hexadecimal
KT Time value
KZ Counter value
The special values represented correspond to the data block DB 709.

The selected area corresponds to one PCU.
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Table 71
The operator can change the respective values in this application by highlighting
the corresponding line and pressing the key F4 or selecting the menu entry
Function, Value entry.
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Compact Manual for Maintenance Personnell
3 Compact Manual for Maintenance

Personnell
BRAUMAT is shipped with several functions for the maintenance purposes.
3.1 Maintenance Information in the Process Pictures

The ICM-faceplate contains maintenance information.
It is displayed through ICM-Faceplate (for valves and motors), Detailed View.
3.1.1 Tab "General".
Table 1
Each fault increases the internal error

counter of the ICM.
To reset the error counter to 0, press

the Reset button.
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3.1.2 Tab "Extended"
Simulated feedback
Table 2
In the Tab Extended, feedback can be

set to be generated from the
simulation. In this case, no Feedback
alarms are generated anymore, and the
process continues.
In the process image, the simulated

feedback for a component is indicated

by a special icon.
NOTE In any case, the offending fault must be fixed!
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Interlock disabling
Table 3
Interlocks can be temporarily disabled

here.
Disabled interlocks are highlighted by a

special icon.
Maintenance mode
To use this feature, ICM groups must have been defined previously in another application.
NOTE
See the Braumat manual for more information.
The ICM can be set to maintenance mode here. In maintenance mode, the PLC
can not switch the ICM on anymore, and work on the ICM can be done without
interruption.
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Table 4
From
Engineering
tools select
Entity definition
to define the
maintenance
groups.
3.1.3 Tab "Maintenance"

The Maintenance tab allows the definition of an hour counter and a switch
counter for each element.
Table 5
Click the
Parameter
button to define
up to 5
parameter sets
which will
generate alarms
when reached.
Clicking the
Reset button
resets the
corresponding
counter or timer
to 0.
Alarms are
displayed in red.
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3.1.4 Additional information
Process archives
Table 6
Select the Application Process

archives, Maintenance from the basic
menu to open the dialog to show all
elements.
Elements which require maintenance are highlighted in red.
Maintenance information as alarm triggers

Maintenance information from the hour and switch counters can be used to trigger
alarms.
Table 7
Activate the checkbox

Enable maintenance
supervising in the
Configuration dialog to
trigger alarms from the
hour and switch counters.
Alarm messages will be created, and additional files will automatically be generated
which contain only maintenance-related alarms.
NOTE The name of the maintenance archive has the following format:
.../Windcs/pcu.xxx/MAINT/maint_YYYY_MM/maint_YYYY_MM_DD.TXT
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3.2 Recipe system

3.2.1 General information
Recipes provide a scheme for the control of complex processes. A recipe

combines three components:
A procedure, which describes how the process is supposed to be run,
Process parameters, which are used in the procedure, and
A list of consumables, which are fed to the process.
The use of recipes ist configured with the Recipe application.
See also 4.2
3.2.2 Using the Recipe application
Open the Recipe editor in Process supervising.

Table 8
To open and configure a recipe, right-

click on its entry in the recipe list and

select Open master recipe from the
context menu.
Table 9
With the button "Open

in the recipe
procedure, you open
the corresponding
graphical view of the
recipe with the table of
the DFM-set values.
Batch Recipe Recipe Recipe Master Process parameters

size procedure status category recipe
name
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The parameter table

allows you to edit the
parameters used in
the actual recipes. The
parameters here may
belong to several
different brands.
3.3 Tools
3.3.1 Status S7 block
Table 10
To get an overview over

the status of all S7

blocks, you can access
the Status S7
application from the
main menu through
Program, Service,
Tools.
All blocks which are
online in any machine
will be displayed along
with the status of their
result flag.
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3.3.2 Forcing
Table 11
To get an overview over

the status of your
program variables,
access the
corresponding tool from
the main menu through
Program, Service,
Tools, Forcing.
All flags, data blocks,
inputs and outputs form
all online machines are
displayed, and can be
forced to particular
values.
3.3.3 DB editor
Table 12
Data blocks from the

program can be viewed
and edites with the
corresponding tool from
the main menu,
Program, Service,
Tools.
All DBs from all
connected machines are
displayed.
3.3.4 Graphical source view
Table 13
A graphical overview
showing the connections
of the various blocks is
available from the main
menu through
Process, Service,
Tools.
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Compact Manual for System Administrators
4 Compact Manual for System

Administrators
This section is dedicated to particulars functions which are reserved for system
administrators.
4.1 Process Visualization

Various faceplates for process visiualization are available.
ICM faceplate (for valves and motors), Detailed View, Tab "Parameters"
Here, the parameters of the ICM, such as Delay on, Delay off and Monitoring
time can be changed. In the "Extended" section, plant unit, manual group and ICM
type can be assigned.
Table 1
NOTE To temporarily exempt an ICM from its group, assign it to the Manual group 0.
This allows you to individually switch this ICM.
Reset it to its previous manual group afterwards.
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Digital Faceplate (for sensors, hand-tabs, swing-bows), Detailed View, Tab "parameters"
Allows the setting of the Delay on and Delay off values.
Table 2
Analog Faceplate (for analogue values, analog outputs, DFMs), Detailed View, Tab
General
In the Parameters field, the relevant parameters, such as range, limits and switch-
flags can be changed. The Change checkbox must be selected for changes to be
possible.
Table 3
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Controller Faceplate, Detailed View, Tab "Parameters"

Controller parameters like limits, sampling, dead band, etc. can be changed here.
The controller can be set to reverse and X-tracking.
The YN flag is displayed, but read-only here.
Table 4
If the YN flag is raised, the controller switches off, and a fixed value defined in
the parameter YNF is transferred to the output.
In operation mode X-Tracking (XTR = "1") the internal target value is adjusted
to the actual value of XIST. This renders possible a smooth transfer from
external to internal tracking.
If the Reversing duty flag is raised, then an increased of the actual value will
result in a decrease of the output, and vice versa.
4.2 Recipe-System
General information
For each Sequence there is a recipe with the according steps and parameters.
(See also 3.2)
There is an active and a passive recipe server. The recipes are stored on both
servers, but at any time only one server will load the recipes at the start of a unit to
the PCU. The active server can be determined from the toolbar of the PCU server.
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Switching recipe-servers
By default, an automatic switch-over of the recipe servers occurs, when the active
server drops out.
Table 5
The status of the active and passive recipe server is displayed by an icon in
the toolbar.
If a recipe-load error occurs, this may be ther consequence of both servers

being set to passive. You manually activate an Recipe server with the
corresponding button in the toolbar of the PCU server
Troubleshooting
The recipe server can only operate properly when all of the following conditions are
met:
All connections must be established for each PCU in the PCU-Server. (To
verify this, switch the PCU-server with the pull-down menu to "View", coupling-
status".)
The connection state for the PCUs is green.
The network cables must be connected properly.
The PCU must not be in state "STOP".
4.3 RCS system

4.3.1 General information
The route control system (RCS) is primarily a tool by which the planning,
processing and the diagnosis of routes can be performed in environments with
many different routes, like in the tank farm.
It allows controlling and monitoring in an easy and transparent manner.
4.3.2 Switch RCS servers
Like the recipe server, at any time only one RCS server is active on one IOS, but
the active server can be switched to a different IOS, similar to the recipe server.
Like with the recipe server, the active RCS server can be switched through the
corresponding buttons in the toolbar of the PCU server, and the RCS server status
(active/passive) is displayed with an icon there.
In order for the RCS server to start up properly, all connections must be
established for each PCU.
To check this, switch the PCU-Server to " Options", route-control".
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Table 6
Table 7
By selecting the tab

"PCU" the dialog box to
the right appears,
showing all configured
connections.
All PCUs must be in the state "server" to be able to receive telegrams.

If this is not the case, select the command Restart from the menu "Functions".
NOTE If the PCU was in "stop" mode, or the power supply was off, a restart of the PCU-
Server is always required.
4.4 Data handling and backup

4.4.1 Automatic delete function
In the background, new data in the form of protocols, reports, graphs, etc. are
constantly stored by the system, thereby decreasing the free hard disk space.
Therefore, the remaining space on the hard disk must be checked in regular
intervals, and old data deleted.
NOTE We recommend for this a maintenance interval of approximately one year.
To keep administration to a minimum, the process data is stored only on the two
servers. The clients take their data from the servers and need not be checked.
Table 8
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4.4.2 Storage locations
Data archives are stored in various default paths of the system:

Table 9
Data Location Example
archive
Step "C:\Windcs\Srprot"
protocols
Curves C:\Windcs\Trend\
Logging C:\Windcs\Logging\
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4.4.3 PCU data backup and restore
Backups of all PCU blocks (DB, FBs, FCs) should be performed at regular
intervals. This can be made by the Simatic Manager, or more easily with Braumats
application File transfer.
Backing up data from the PCU

Table 10
Open one of the CPU-files

"S7PCU00X.TRS" according to
your PCU.
Click the Button "PCU> IOS" to
backup the files to the IOS.
This ensures that in the event of a PCU failure or an empty buffer battery on the
CPU, you restore current data to the new PCU.
Restoring data to the PCU

To restore data to the PCU after a failure, use Braumats File transfer application in
the other direction:
Table 11
The corresponding files are stored in

C:\WINDCS\PCU.003\DB,
C:\WINDCS\PCU.003\FB, and
C:\WINDCS\PCU.003\FC, respectively.
NOTE If the buffer battery of the PCU is empty, your program will be lost in case of a
power failure, and you will have to resort to your backup.
To avoid this, we recommend checking the buffer battery in regular intervals.
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4.5 User administration and password

User administration
The system offers the possibility to password-protect all operations and inputs. The
protection is provided by assigning various access levels (2 to 255) to the different
users. Password administration is performed is in the application User
management.
Table 12
From the System setting

dialog, click the button
Define in the Password
field to open the password
dialog (see below).
To define a new program
level, click the button
Define in the Program
level field, which opens to
Program level dialog (see
far below).
Password dialog: To create

new accounts and edit
existing ones
Program level dialog
Password factory settings

These are the factory settings for an initial user account:
Table 13
User name su
Pasword su
NOTE su is short for super user.
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Assigning new passwords

Table 14
To create a new account, go to the

Password dialog and create a new name by
clicking the button New.
Then go to any application where a password

is needed (for example Image design) and
enter the new Name. Then press New
password and enter the password twice.
NOTE You need an existing password to perform this operation.
NOTE Passwords may have a length of up to 8 characters
4.6 STEP7 programs

Required additional programs
As long as no hardware changes are made, the project can be edited using any
standard STEP 7 software.
Curves, Trending definition

All recorded measured values must be configured with the Application Trending-
definition. There are two lists, one for analog and one for digital measurement
values.
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Measurement-description-list
Table 15
An analog measurement value is characterized by the following attributes:

Table 16
Name Definition Notes
ID System-wide unique This number also define the filename used in the archive
(Identification) identifier. Directly on the hard disk drive.
dependent on this are the Permitted number of entries: 1 to 1200.
derived digital values and
trends
Measured Name of the measured The name is limited to 16 characters, with no special
value name value and the characters allowed.
corresponding trend
caption
Addressing Addressing mode Analog measured values can be addresses in two ways:
1. By direct definition of an absolute address (in the
Editor: "Absolute")
2. By an attribute of a system or user object (in the Editor:
"System")
PCU PCU number where the
value originated
Class Braumat class Only relevant for the "System" source version.
Instance Braumat instance number
Attribute Braumat attribute
Absolute Relevant for addressing type Absolute only: a Simatic
address address in STEP 7 syntax (e.g. DB712.DBW8). For an S5
machine an equivalent syntax is expected (e.g.
DB712.DL8). For absolute addressing the Input- Output or
Flags/Memory ranges in AWL-Syntax may be defined as
well (e.g.. I35.7, M99.1, MW 132, QB22).
Archive type Every analog measured value has to be assigned one of
these archive types:
Short-time archive (see 2.5.1)
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Name Definition Notes

Batch archive
Long-time archive
Manual archive
Curve group Number of the curve
group to which this value
belongs
Refresh Recording cycle, ie the Value is given in seconds, valid range is 2 to 32767
time interval between two seconds.
scannings The real cycle depends on the hysteresis and the slope of
the curve.
Lower limit Minimum value of the
scaling in the picture
Upper limit Maximum value of the
scaling in the picture
Hysteresis Tolerance band where a Hysteresis is not used for short-time archives (see 2.5.1).
value is stored if it is
outside this range.
Dimension Physical unit e.g. C, sec,
Decimal point Number of digits for the

axis marking
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Troubleshooting
5 Troubleshooting
This section gives you a few hints to solve simple troubles which may occur when
working with BRAUMAT.
5.1 Problems starting a unit

If the sequence of a plant unit doesnt start up properly, check the following points:
The Sequence-status must be "A" (automatic) and "+" (step forwarding active).
(see the black circle in the figure below)
The permanent condition must be ok. If the condition "#" is displayed, the
system is locked and cant start. (see the black circle in the figure below)
If an order parameter is used in the recipe, then a sequence can only be
started from the order system.
Table 1
5.2 Problems when the step chain doesnt proceed

properly
If the program doesnt proceed to the next step although apparently all next step
conditions are cleared, the following should be checked:
Are all transition conditions fulfilled?

To test this, proceed as follows:
Activate the S7-Code viewer of the relevant basic operation with the "Detail"
button in the Unit faceplate.
Use the "+" button to go to the last network.
The display shows the relevant commands for the transition condition.
Common errors are quantities which are not ok, or tanks which are not yet empty,
etc.
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Troubleshooting
Table 2
5.3 Sequence control issues

Several error conditions can be checked from the Sequence control application.
Is any next step condition (Temperature, Time) not ok?

Chose the sequence and select Program, Step-on-condition or press F4, to see
the next-step conditions.
Is there an operator request pending?
Is the program waiting for another sequence (synchronization)?

Select the correct sequence and press F9. The graphical recipe will come up, and
synchronizations are displayed.
Are there relevant entries in the Alarm list?
Is the Sequence in "Automatic"?

The automatic mode of the sequence must be set to A in the column "Status.
Is the Step set to A ?

The Status column must be set to "+".
Is the program on "hold" mode?

In the "Status" column the S88-buttons must be set to "hold" mode.
Are there any error messages from one of ICM's used in this area?
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History
5.4 Changing more Parameters

The Parameterization menu allows you to adjust many more parameters
NOTICE Since this can severely mess up your configuration, any changes you make here
are performed at your own risk!
Table 3
6 History
Tabelle 6 History
Version Date Changes
V3.0 01.08.2013 First issue of manual rewrite.
This version is based on V2.1 of the BRAUMAT Operator
Manual
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described in this Application Example shall be excluded. Such an exclusion shall

Any form of duplication or distribution of these Application Examples or excerpts

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"BRAUMAT" Operator Manual

2.3.7 Digital faceplate (for sensors, swing-bend etc) ................................. 19

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3.3.4 Graphical source view ..................................................................... 61

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"BRAUMAT" Operator Manual

1.2 BRAUMATClassic Software Structure

1.3 Abbreviations used

1.4 Further Reading

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"BRAUMAT" Operator Manual

2 Compact Manual for Operators

2.1 Common functions

Select the entry

End from the

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"BRAUMAT" Operator Manual

2.2 Process picture, visualization

2.2.1 Navigation between the process images

Use the application Process

Click on the navigation

Click on the menu item

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"BRAUMAT" Operator Manual

To move back to the last

Direct selection of process images (brewing house, fermenting area, ...)

Direct selection of images

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"BRAUMAT" Operator Manual

Click on one of the

2.2.2 Printing of process pictures

Click on the highlighted printer

Press CTRL + P on the

2.3 General operation

2.3.1 Searching for variables and objects in project pictures

Searching within a picture

Click the highlighted icon, or

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"BRAUMAT" Operator Manual

Click the highlighted icon, or

Click the menu item Variable search

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"BRAUMAT" Operator Manual

Select the Seek tab to start a

Alternatively, select the

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"BRAUMAT" Operator Manual

2.3.2 Variable and object information

Click the highlighted icon, or

Click the menu item Variable

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"BRAUMAT" Operator Manual

Symbolic representation in the process picture

1 Affected by Maintenance (ABM)