Configuration Instruction

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1 Configuration Instruction SIMATIC PCS 7 SIMATIC IT Integration SIMATIC PCS 7 / SIMATIC IT Integration Pack 2007 Data exchange between SIMATIC IT Production Modeler/ SIMATIC IT Historian and SIMATIC PCS 7 / SIMATIC BATCH

2 Warranty, liability and support NOTE The application examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The application examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used. These application examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these application examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these application examples at any time without prior notice. If there are any deviations between the recommendations provided in these application examples and other Siemens publications - e.g. Catalogs - then the contents of the other documents have priority. Warranty, liability and support We do not accept any liability for the information contained in this document. Any claims against us - based on whatever legal reason - resulting from the use of the examples, information, programs, engineering and performance data etc., described in this application example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health The above provisions does not imply a change in the burden of proof to your detriment. Copyright 2008 Siemens A&D. It is not permissible to transfer or copy these application examples or excerpts of them without first having prior authorization from Siemens A&D in writing. For questions about this document please use the following address: V /33

3 Table of Contents Table of Contents Table of Contents Introduction Goal Test environment Equipment for the Windows active directory domain Installed software... 8 Operating systems... 8 SIMATIC software SIMATIC IT PMr and SIMATIC IT Historian in combination with SIMATIC PCS 7/SIMATIC BATCH Introduction Merging of the plant equipment model Prerequisites in SIMATIC PCS 7 / SIMATIC BATCH Prerequisites in SIMATIC IT Production Modeler Prerequisites in SIMATIC IT Historian Merging the equipment models Defining and scheduling KPI s Defining KPI s in SIMATIC BATCH Importing batch KPI s in SIMATIC IT Historian Scheduling batch KPI s in SIMATIC BATCH Defining KPI s in SIMATIC IT Production Modeler Importing PM KPI s in SIMATIC IT Historian Scheduling of PM KPI s in Production Modeler References Abbreviations... 49H33 V /33

4 Introduction 1 Introduction In this paper the basic engineering, which has to be done in SIMATIC PCS 7 and SIMATIC IT Production Modeler / SIMATIC IT Historian in order to exchange data, is described. The emphasis lies on the configuration of these interfaces. The starting point is a finished SIMATIC PCS 7 / SIMATIC BATCH project. All additional engineering which has to be done on the SIMATIC PCS 7 / SIMATIC BATCH side will be described in detail. Also the necessary engineering on the SIMATIC IT side will be described. 1.1 Goal After setting up the basic communication between SIMATIC PCS 7 / SIMATIC BATCH and SIMATIC IT Production Modeler/ SIMATIC IT Historian it will be possible to exchange data between these two layers of automation. For the data exchange between the two automation systems the terminal bus of the SIMATIC PCS 7 system is used. The possible communication paths can be seen in the following drawing: Figure 1-1 Overview communication paths V /33

5 Introduction In order to avoid recurrences of some configurations already explained in other documents, this paper will refer to the following papers: Data exchange between SIMATIC PCS 7 / BATCH and SIMATIC IT Historian Data exchange between SIMATIC PCS 7 / BATCH and SIMATIC IT Production Modeler 1.2 Test environment Many different architectures can be build. In our case (the COLOR project) we installed SIMATIC IT Historian on one machine and the SIMATIC IT Production Modeler on another computer. The SIMATIC IT components (Material Manager, Production Order Manager ) are installed on a third machine and the Client Application Builder Server (CAB) and Report Manager are installed on a fourth computer. On the SIMATIC PCS 7 side we have a pair of redundant SIMATIC BATCH-Servers and a separate pair of redundant SIMATIC PCS 7 OS- Servers. Additional we have an engineering station and two SIMATIC PCS 7 OS-Clients which are also used as SIMATIC BATCH-Clients. Figure 1-2 Overview complete system A private IP address band is used with fixed IP addresses. V /33

6 Introduction NOTE BPM must be installed on the Historian and on the PM computer, but it is started only on one of these machines. V /33

7 Introduction Equipment for the Windows active directory domain 2 Windows active directory domain controllers (DNS, WINS) 2 SIMATIC PCS 7 OS-Servers (redundant) 2 SIMATIC BATCH-Servers (redundant) 1 SIMATIC PCS 7 Engineering System (ES) 2 SIMATIC PCS 7 OS Multiclient + SIMATIC BATCH-Client 1 SIMATIC IT Production Modeler 1 SIMATIC IT Historian + PPA DB 1 SIMATIC IT Report Manager/CAB engineering 1 SIMATIC IT components software + SITMesDB 1 SIMATIC AS CPU 417 with a CP V /33

8 Introduction Installed software Operating systems The used operating systems for the domain computers can be found in the following table. Table 1-1 Server Client Station Domain Controller Installation Windows 2003 MUI (Multilanguage User Interface) with SP2 Internet Explorer V6.0 SP2 ( ) Image software Windows XP SP2 Image software Windows 2003 MUI (Multilanguage User Interface) with SP2 Internet Explorer V6.0 SP2 ( ) SIMATIC software SIMATIC software and its required software packages (e.g. message queuing, SQL Server 2005 with SPx,..) are installed as needed. The installed software for SIMATIC PCS 7 and SIMATIC IT is the released Integration Pack 2007 on top of the released SIMATIC Versions. Table 1-2 Product SIMATIC PCS 7 SIMATIC IT Version Delivery version from September 2007 (V7.0 SP1) Microsoft SQL 2005 SP1 HF PCS 7 / SIMATIC IT Integration Pack 2007 Part1 Updates SIMATIC PCS 7 ( _ ) V6.3 SP1 Microsoft SQL 2005 SP2 PCS 7 / SIMATIC IT Integration Pack 2007 Part2 Updates SIMATIC IT ( _ ) SIMATIC_IT_V6.3.1+HF2 (K _ ) PCS 7_COMMUNICATION_IF_V7.0+SP1 A detailed list of the installed SIMATIC software can be found in the attachment A of the document SIMATIC software in a domain. V /33

9 2 SIMATIC IT PMr and SIMATIC IT Historian in combination with SIMATIC PCS 7/SIMATIC BATCH 2.1 Introduction SIMATIC IT Production Modeler / SIMATIC IT Historian can exchange data with SIMATIC PCS 7 and SIMATIC BATCH. In this chapter we will discuss the merging of the equipment model and the definition of KPI s. Figure 2-1 Integration between SIMATIC PCS 7 / SIMATIC BATCH and SIMATIC IT Production Modeler / SIMATIC IT Historian V /33

10 2.2 Merging of the plant equipment model Both in SIMATIC BATCH and in SIMATIC IT Production Modeler an equipment model can be defined. In SIMATIC BATCH the equipment model is build following the S88 standard and includes the following levels: Process cell Unit Equipment module Control module level In SIMATIC IT Production Modeler the equipment model is build following the S95 standard and includes: Enterprise Site Area Cell Unit level In SIMATIC IT Historian it is possible to merge the equipment models from SIMATIC BATCH and SIMATIC IT Production Modeler into one general equipment model. This allows the user to retrieve the data collected by SIMATIC IT Historian by browsing one equipment model. Additionally, both in SIMATIC BATCH and SIMATIC IT Production Modeler it is possible to define KPI's (Key Performance Indicators) and to link them to the unique equipment model. V /33

11 2.2.1 Prerequisites in SIMATIC PCS 7 / SIMATIC BATCH The process cell level and the unit level are available after the standard engineering of a SIMATIC BATCH project. Figure 2-2 Plant model in SIMATIC Manager In SIMATIC PCS 7 it is possible to define Standard folder (for example FILLING TANK on the picture above) in between the PCell level and the unit level. These folders will not be taken into account during the merge of the equipment models. V /33

12 2.2.2 Prerequisites in SIMATIC IT Production Modeler Linking of SIMATIC IT Production Modeler units and SIMATIC BATCH units In SIMATIC IT Production Modeler the levels Enterprise, site, area, cell and unit are the standard available levels. It is allowed to skip certain levels as shown in the next picture. Figure 2-3 Plant model in Production Modeler In the example above the "area" level of the S95 equipment model was skipped. Since both S88 and S95 equipment models overlap each other, the process cell(s) and unit(s) which are defined both in the SIMATIC IT Production Modeler and SIMATIC BATCH need to be linked to each other. The configuration of the links is done in Production Modeler. On the unit level the link can be seen in the following picture. The attribute Sb-Unit- V /33

13 Name contains the unit name of the unit as programmed in SIMATIC BATCH. Figure 2-4 Linking the Production Modeler units with the SIMATIC BATCH units NOTE The unit names used in the SIMATIC IT Production Modeler does not necessarily need to be the same as the ones used in SIMATIC BATCH. However, to increase the readability of the whole project, it is advantageous to use the same unit names in both environments. NOTE Unit names inside the SIMATIC IT Production Modeler cannot be a number, they must contain as a minimum one character. NOTE For the process cell and unit level, the names as defined in SIMATIC BATCH will be used in the merged equipment model. In the same way, the cell level can be linked to the process cell in SIMATIC BATCH. V /33

14 Figure 2-5 Linking the Production Modeler Cell with the SIMATIC BATCH PCell NOTICE The cell object used in SIMATIC IT Production Modeler which is used to represent a SIMATIC BATCH PCell has to be a subclass of the PCell object which can be found in the library SIMATIC BATCH library V3.00. The attribute Project-Name of the PCell object contains the SIMATIC PCS 7 (multi)project name. The attribute PCell-Name of the PCell object contains the name of the SIMATIC BATCH PCell name. Units and PCells which are linked are shown in the BPM client as shown in the following picture. V /33

15 Figure 2-6 BPM client view of linked units and PCell In this view, the names in brackets are the names as used by SIMATIC BATCH. Here it can be easily verified which units/cell are linked. Other prerequisites in Production Modeler NOTE Before continuing make sure the plant is set as "current" and do not forget to save the plant in the working area. V /33

16 Figure 2-7 Set the plant as the current plant Figure 2-8 Set the plant as the "current plant" After this operation the plant needs to be saved, also in the BPM. V /33

17 2.2.3 Prerequisites in SIMATIC IT Historian During the creation of the PPA database some options have to be checked in order to obtain a merged plant model. In the following picture the different options are shown. Figure 2-9 Configuration options of the PPA project In the configuration shown in the picture above, the equipment model of SIMATIC BATCH and SIMATIC IT Production will be merged together during the execution of the command "import from BPM". If the option "Disable automatic plant management" is unchecked, it is possible to change the plant model in the SIMATIC IT Production Modeler. The plant model in the SIMATIC IT Historian will be automatically adapted Merging the equipment models When all prerequisites described in the previous paragraphs are fulfilled, we can merge the two equipment models by executing the following steps: V /33

18 In the configuration editor of the PPA, go to: Tools > Import from BPM. PPA will first read the equipment model of SIMATIC BATCH. Then also the equipment model of the Production Modeler, which is stored in the BPM, will be read and merged with the SIMATIC BATCH equipment model. Figure 2-10 Importing the plant model in the PPA project After the import of the equipment model the PPA configuration looks as follows: V /33

19 Figure 2-11 Merged equipment model V /33

20 NOTE In case of problems during the plant model import, the logfile "Plantmodel.log" can be checked. This file can be found under: <PLANTNAME>.PLT\PPA.LOG\ <PLANTNAME> is the name of the project as defined in the SIMATIC IT Management Console. 2.3 Defining and scheduling KPI s In the previous paragraphs the equipment models were merged. Additionally, the user can define KPI s in SIMATIC BATCH and in SIMATIC IT Production Modeler and relate them to the appropriate equipment model level. Figure 2-12 Overview KPI definition Different KPI types can be used. The following table gives an overview. Table 2-1 Supported KPI types KPI type Description BATCH KPI cyclic on-event on-eventover-time Cyclic data processing within a certain period of execution, as the duration of a rule/ps/batch step (RP/RUP/ROP) or the duration of a series of consecutive steps. 'One-shot' data processing on event occurrence, as the start/end of a rule/ps/step. 'One-shot' data processing on event occurrence, as the end of a rule/ps/step execution, but based on samples taken within a certain time- X PM KPI X X X V /33

21 KPI type Description BATCH KPI span. PM KPI dummy Used for modeling purposes only. X During runtime, the KPI s can be triggered by SIMATIC IT Production Modeler rules or process segments (for KPI s defined in Production Modeler) or by the SIMATIC BATCH control recipe (for SIMATIC BATCH KPI s). Figure 2-13 Overview KPI scheduling In the following paragraphs a detailed description on how to define/schedule KPI s will be provided Defining KPI s in SIMATIC BATCH The following steps need to be done in order to add a batch KPI to SIMATIC BATCH: Insert a TAG_COLL block (Tag collection block) in a CFC at the desired level (Unit, Equipment module). Configure one or more process values to be collected and connect them to the TAG_COLL block. Compile and download the application to the AS. Compile and download the OS. Open the SIMATIC BATCH dialog box on the Multiproject level and generate/propagate the batch types. V /33

22 In the SIMATIC BATCH dialog box configure all TAG_COLL blocks => provide for each collected process value a corresponding tag in the WinCC archive. Merge/compile all batch instances. Download the batch configuration. Update the PCell in SIMATIC BATCH. In our example we have added two KPI s on the unit level (inside and kettle temperature on RC01) and one KPI on the equipment module level (Temp_RC on the equipment module TEMP on RC01) as shown in the next pictures. Figure 2-14 Configuration of a TAGCOLLECT on unit level V /33

23 And the result in the SIMATIC BATCH dialog box. Figure 2-15 Result of the configuration in the SIMATIC BATCH dialog box On the equipment module level we have defined one temperature KPI. Figure 2-16 Configuration of a TAGCOLLECT on equipment module level V /33

24 In the SIMATIC BATCH dialog box this looks like: Figure 2-17 Result of the configuration in the SIMATIC BATCH dialog box V /33

25 2.3.2 Importing batch KPI s in SIMATIC IT Historian Before executing the import, modify the PPA project settings as shown in the next picture. Figure 2-18 Adapting the PPA project in order to import batch KPI The option Enable batch-related tags will import the batch KPI s which were configured as described in the previous paragraphs. After executing the command Tools > Import from BPM in the PPA Admin tool, we will find the configured batch KPI on the corresponding equipment levels. V /33

26 Figure 2-19 Result on the unit level after import Figure 2-20 Result on the equipment module level after import V /33

27 2.3.3 Scheduling batch KPI s in SIMATIC BATCH In the previous paragraph we described how to configure and import the batch KPI s in SIMATIC IT Historian. Now we will configure in the batch recipe when the KPI s will be scheduled. Figure 2-21 Recipe for batch KPI scheduling On this very simple recipe we have added our two batch KPI s which are scheduled on the RUP level: Inside_temp : temperature of the product in the reactor Kettle_temp : wall temperature of the reactor V /33

28 Figure 2-22 Configuration of batch KPI at unit level For every batch based upon this recipe, the two batch KPI s will be archived during the runtime of the RUP REACTOR. We also configured one batch KPI which is scheduled on the ROP level: Temp_RC: temperature of the product in the reactor Figure 2-23 Configuration of batch KPI at phase level For every batch based upon this recipe, the batch KPI will be archived during the runtime of the ROP HEAT. V /33

29 2.3.4 Defining KPI s in SIMATIC IT Production Modeler In SIMATIC IT Production Modeler it is possible to define KPI's related to an equipment. The following steps need to be executed to add a KPI: In the library area (on the object class level) add one or more KPI s. Configure the type of the KPI (on event, on event over time, cyclic). Synchronise the plant instances. Save the plant. The following picture shows the definition of a KPI at the unitclass level. Figure 2-24 Adding a KPI to the unitclass Color_Reac (1/4) V /33

30 Figure 2-25 Adding a KPI to the unitclass Color_Reac (2/4) In the tab KPI we can define one or more KPI related to this unit class. Figure 2-26 Adding a KPI to the unitclass Color_Reac (3/4) For the KPI types we refer to Table 2-1 Supported KPI types. Figure 2-27 Adding a KPI to the unitclass Color_Reac (4/4 After the definition of the KPI on the unit class we have to synchronise the plant model such that each instance of the unitclass Color_Reac contains the defined KPI Importing PM KPI s in SIMATIC IT Historian For the batch KPI s we saw that the user can choose, if he wants/does not want, to import the batch KPI s together with the batch equipment model. V /33

31 KPI s defined in the Production Modeler are always imported together with the import of the Production Modeler equipment model. The result of the import, in our case, is shown in the next picture. Figure 2-28 Result after import the Production Modeler KPI Next to the two already imported batch KPI s we now also see an additional Production Modeler KPI. This KPI needs to be configured, meaning that it has to be linked to a PPA tag Scheduling of PM KPI s in Production Modeler For a complete and detailed description of the KPI scheduling options in Production Modeler and for the configuration of the communication channels between Production Modeler and SIMATIC IT Historian we refer to [1]. V /33

32 References 3 References [1] SIMATIC IT 6.3 SP1, KPI management, Configuration management, see standard installed SIMATIC IT documentation V /33

33 Abbreviations 4 Abbreviations In this manual are used several abbreviations. Please find here the corresponding complete name. Table 4-1 API AS BPM CFC CIB CIL GUI KPI MES MUI ODS OS PDA PI PM PO PP PPA ROP RTDS RUP SCI SFC SP XML Abbreviation Complete name Application Programming Interface Automation System Business Process Modeler Continuous Function Chart COM Interface for SIMATIC BATCH Cross Industry Library Graphical User Interface Key Performance Indicator Manufacturing Execution System Multilanguage User Interface Operating Debugging Support Operator System Plant Data Archiver Parameter Input Production Modeler Parameter Output Parameter Parameter Plant Performance Analyzer Recipe Operation Procedure Real Time Data Server Recipe Unit Procedure Siemens Communication Interface Sequential Function Chart Service Pack extended Markup Language V /33

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