Process Control System PCS 7 Getting Started - Part 1 ============================================= Purpose of the Manual PCS 7 Getting Started provides you with an initial overview of the process control system PCS 7 and helps you to create a simple project yourself. You can configure the project on an existing SIMATIC Station. Getting Started – Part 1 is intended for newcomers to PCS 7 active in the following areas: • Configuration • Commissioning and service Required Experience You should already have experience in the following areas: • Microsoft operating system Windows 2000 • Functions and configuration of SIMATIC S7 (S7-400, STEP 7) • Functions and configuration of SIMATIC NET (network components, transmission media) Scope of the Manual Getting Started applies to the PCS 7 Engineering Toolset V 6.0. Guide to the Manual ================= Getting Started explains the individual steps required to create the color_gs project. You will find the most important background information required to understand the steps in Getting and detailed instructions on how to work through the steps. You also receive the finished color_gs project as a sample project in the form of a file. This is installed along with the system documentation of PCS 7. You can open this project on an existing engineering system (ES) to view the configuration data and compare the data with your own configuration data. You can activate the project on an operator station (OS) to control and monitor the process. Note To test the sample project in the process mode, you may need to adapt the hardware configuration of the project to the hardware that is actually installed; in other words, you must replace the hardware components of the sample project with the actual existing hardware components. For more detailed information on opening the sample project, refer to Starting and Adapting the Sample. Notes on Getting Started ==================== In Getting Started, all the instructions are explained based on the full menu commands. You can also activate the majority of functions with the context-sensitive menu or by double-clicking. In PCS 7, you can use standard Windows functions in many situations: • Multiple selection with the CTRL and Shift keys • Sorting columns in tables by clicking on the column header • Using Drag & Drop instead of Copy and Paste If you open the HTML version of Getting Started, you can open video sequences. These video sequences show the exact steps that you can follow on screen before performing them yourself. Video sequences are indicated by the following icon: Click on the word Video to start a video sequence. You can freeze, stop and restart video sequences. You have buttons available similar to those of the Windows Media Player. One tutorial in Getting Started leads on to the next and you will create a complete PCS 7 project yourself step by step. This makes it essential to work through the tutorials in the correct order. Further Information =============== You will find more detailed information and wider-ranging topics in the configuration manuals Process Control System PCS 7, Engineering System and Process Control System PCS 7, Operator Station and these will be useful to you as a source of reference. These manuals are located • on the CD SIMATIC Process Control System PCS 7 V 6.0, Electronic Manuals[0]. • in the PCS 7 Software in the SIMATIC Manager[0]. You can open the documents with the menu command Start > SIMATIC > Documentation > [required language] . Here, you will also find other manuals on specific topics, for example on SFC, CFC. Further Support ============ If you have any technical questions, please get in touch with your Siemens representative or agent responsible. siemens/automation/partner Training Centers ============= Siemens offers a number of training courses to familiarize you with BATCH flexible and the Process Control System PCS 7. Please contact your regional training center or our central training center in D 90327 Nuremberg, Germany for details: Telephone: +49 (911) 895-3200. Internet: sitrain 1 Requirements for Getting Started ============================ 1.1 Requirements for Working through Getting Started --------------------------------------------------------------------- To be able to work through Getting Started the following requirements must be met for the components below: • Hardware • Software 1.1.1 Hardware Required for Getting Started -------------------------------------------------------- The list below shows the hardware components you require to work through Getting Started and that we have used in the Getting Started example. In some cases, you require a specific version of a hardware component since it is not possible to work through Getting Started with an older or different version. If you use a different hardware component, you must remember to enter the actual component you are using at certain points during the configuration, for example in HW Config. If it is at all possible, we recommend that you use exactly the same components as we used in Getting Started. If you do not have any hardware components available, you can also use the software PLC Sim that is also on the PCS 7 Toolset CD. You require a special license to use this software. If you use this software, you can use exactly the same hardware components as described in getting started. 1.1.2 Software Required for Getting Started ------------------------------------------------------- The following software must be installed: • Windows 2000 Professional • Internet Explorer 6.0 • Message queuing service • SQL Server • Software package from PCS 7: PCS 7 Engineering These packages are all available on the PCS 7 Toolset V 6.0 CD. If you have questions relating to the installation of the PCS 7 Toolset, please read the readme file on the installation CD or contact customer support 2 Overview of PCS 7 ================= 2.1 Brief Overview of PCS 7 ----------------------------------- PCS 7 is a process control system that supports you during configuration with numerous automatic functions so that you can create a project quickly and conveniently. You will get to know some of these automatic functions when you work through this Getting Started. When you have become an advanced user, you will also find that PCS 7 provides a variety of options with which you can create individual and project-specific solutions tailored to your specific requirements. These individual solutions are, of course, not part of this Getting Started – for more information in this direction, you can refer to the configuration manuals once you are familiar with the basic functionality. What is a PCS 7 Project? -------------------------------- Among other things, a PCS 7 project includes the following objects: • Hardware configuration • Blocks • CFC and SFC charts These objects always exist regardless of the number of operator stations, modules, and networking. 2.2 What Belongs to PCS 7? ------------------------------------- The project is created with the Engineering System, generally abbreviated to ES. The ES consists of various applications. All applications provide you with a graphic user interface for simple control and clear display of your configuration data. When you work through Getting Started, you will get to know the following applications: • SIMATIC Manager – the central application providing you with access to all other applications that you use to create a PCS 7 project. The SIMATIC Manager is the starting point for creating your entire project. • HW Config – configuration of the entire hardware of a system, for example CPUs, power supply, communications processors. • CFC and SFC Editor – for creating CFC charts and sequential controls • PCS 7 OS with various editors – for creating the OS configuration 2.3 Introduction to the SIMATIC Manager ----------------------------------------------------- What is the SIMATIC Manager? The SIMATIC Manager is the central application and in some ways the core of PCS 7. This is your starting point from which you can open all other applications in which you make the settings for your PCS 7 project. The SIMATIC Manager and all other applications are linked to each other. When you open the SIMATIC Manager, you can for example also see all the blocks you inserted in a CFC chart with the CFC editor. Another great advantage of this linking becomes clear when you configure the operator station. You can access all data you created in the SIMATIC Manager and the other applications, for example you can visualize a process tag from a CFC chart quickly and simply during configuration of the OS. Due to its central function within PCS 7, it is worth taking time to become familiar with the structure and functions of the SIMATIC Manager 2.4 What is the Basic Structure of the SIMATIC Manager? ------------------------------------------------------------------------ The SIMATIC Manager has a window made up of two panes – comparable with the Windows Explorer: • The left pane contains a tree structure whose contents depend on the selected view. • The right-hand window, the detailed window contains details of the object you select in the tree structure. 2.5 What Does View Mean in the SIMATIC Manager? ------------------------------------------------------------------- The SIMATIC Manager provides you with three different views. One important feature of these views is that the objects they contain exist only once in reality but can be displayed and manipulated in the various views. Each view has basically the same structure: In the left-hand pane you see the tree structure and in the right-hand pane the detailed window. Each view has its own particular advantages depending on the task in hand. • Component view – this represents the physical memory location of the individual objects, for example of the charts and blocks. In the Component view, you can see immediately which blocks and charts belong to which PLC. • Plant view – this shows the hierarchical structure of your plant. You can divide the plant into sections or units and can see which charts and which process pictures belong to which plant section. • Process object view – this shows details of the individual objects of the plant view. This is particularly suitable when you want to assign similar parameter values to a large number of objects, add comments to them or interconnect them. In the step-by-step instructions in Getting Started, you always know the view in which you should be working. All the work that you do in the SIMATIC Manager is saved automatically by PCS 7. 2.5.1 How to Open the SIMATIC Manager -------------------------------------------------------- Open the SIMATIC Manager There are two ways in which you can start the SIMATIC Manager: Option Procedure 1 Double-click on the STEP 7 icon on your desktop. 2 Start the SIMATIC Manager from the Windows taskbar with the following menu command: Start > SIMATIC > SIMATIC Manager. When you start the SIMATIC Manager, the project you last opened is opened automatically again. 3 First Steps in the Project ===================== 3.1 Introducing the Project ---------------------------------- 3.1.1 The color_gs Project ----------------------------------- After this initial theoretical introduction to PCS 7, we will now turn to more practical matters and create the color_gs project. You will, of course, be supported by detailed step-by-step instructions. To better understand the step-by-step instructions, a certain amount of theory is of course necessary – and we will provide you with the most important background information on all topics. We will only configure a small part of the entire plant for fully automatic paint production since configuring the entire plant would be beyond the scope of this Getting Started project. You should, nevertheless, know how this small part is integrated in the entire plant so that you have a more complete picture. With this in mind, the individual phases of the entire process are explained briefly below. Phase I – Raw Materials -------------------------------- The liquid raw materials required for the product are stored in two tanks and are pumped from these tanks to the reactors. The solid raw materials are stored in three silos. Three feed screws leading from the silos transport the solid raw materials to a weighing hopper where they are weighed. Once the correct mixture has been obtained, a further feed screw and a blower transport the raw materials to one of the two mixing containers. Phase II – Creating the Product ----------------------------------------- The required quantities of liquid material are fed to either reactor 1 or reactor 2 via valves. The solid materials from the mixing containers are transported to the reactors by feed screws and mixed by an agitator. The product is produced in the reactors by agitating, heating and cooling the raw materials along with the additives. The temperature in the reactors is controlled by valves and actuators. When necessary, water can be let in to the reactors flow-controlled from a filtering unit. Phase III – Holding Phase ----------------------------------- The finished product is then pumped to a holding tank. Here, it is stirred slowly and kept at a constant temperature. Phase IV – Filling ---------------------- Following the holding phase, the product is briefly stored in a filling tank from which it can then be filled into tankers or small drums. Phase V – Cleaning ------------------------- The reactors, piping, valves, actuators, holding tank, and filling tank can then be cleaned by a cleaning system (CIP). The resulting effluent is then collected in a separate effluent tank for disposal. 3.1.2 The Task for Getting Started ---------------------------------------------- Your Configuration Task… You will configure part of Phase I – Raw Materials: The storage of the liquid raw materials in two tanks and control of the pumps to pump these raw materials to the two reactors. Piping and Instrumentation Flow Diagram The piping and instrumentation flow diagram illustrates the precise sequence of the configuration tasks and shows you all the relevant measuring points (tags): Explanation of the Piping and Instrumentation Flow Diagram ------------------------------------------------------------------------------- • LI111 (Level Indicate) – measurement of the current level of the raw material tank • NK111 and NK112 (customer-specific identifier for valves) – stop valves that must always be open when dosing raw materials. • NP111 (customer-specific identifier for motors) – pump that transports the raw material to the reactors • NK113 or NK114 (customer-specific identifier for valves) – valves of which only one can ever be open at any one time used to transport the raw material to either Reactor 1 or Reactor 2 • FC111 (Flow Control) – actuator with which the amount of raw material is controlled The states of valves NK111 to NK114 will be displayed on the operator station and can be monitored. It will also be possible to influence the dosing with FC111.
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