Configuration Instruction

Transcription

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

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: mailto:online-support.automation@siemens.com V /134

3 Table of Content Table of Content Table of Content Introduction Goal Test environment Equipment for the Windows active directory domain Installed software SIMATIC IT Historian in combination with SIMATIC PCS7 / SIMATIC BATCH10 2 Installation Engineering Data Real-time tags engineering from PCS7 ES using the SIMATIC Tag Browser Engineering in SIMATIC PCS Engineering in SIMATIC IT Real-time tags engineering from SIMATIC PCS7 OS (SPOSA) using the SIMATIC Tag Browser Engineering in SIMATIC PCS Engineering in SIMATIC IT Real-time tags engineering using the OPC Tag Browser Engineering in SIMATIC PCS Engineering in SIMATIC IT Remarks and restrictions Historical tags engineering using the SIMATIC data channel Engineering in SIMATIC PCS Engineering in SIMATIC IT Remarks and restrictions Historical tags engineering using the OPC-HDA data channel Engineering in SIMATIC PCS Engineering in SIMATIC IT Remarks and restrictions Message engineering using the SIMATIC data channel Engineering in SIMATIC PCS Engineering in SIMATIC IT Remarks and restrictions Batch stepping protocol and alarm/events engineering Engineering in SIMATIC PCS 7 / BATCH Engineering in SIMATIC IT Remarks and restrictions Realtime Data Process Values via SIMATIC Data Access Channel (ivar2) Configuration in SIMATIC PCS V /134

4 Table of Content Configuration in SIMATIC IT Visualizing and testing of the data exchange Process Values via OPC DA Channel Configuration in SIMATIC PCS Configuration in SIMATIC IT Online messages via SIMATIC Message Channel Engineering in SIMATIC PCS Engineering in SIMATIC IT Visualizing and testing of data exchange Data Transfer from SIMATIC BATCH to SIMATIC IT PPA Configuration in SIMATIC PCS 7 / BATCH Configuration in SIMATIC IT Visualizing of the data exchange Historical Data Process Values via the Historical Data Access Channel Engineering in SIMATIC PCS Engineering in SIMATIC IT Without engineering in SIMATIC IT Visualization and testing of historical data exchange Process Values via OPC HDA Channel Engineering in SIMATIC PCS Engineering in SIMATIC IT Historical Messages via SIMATIC Message Channel (WinCC Tag Logging) Engineering in SIMATIC PCS Engineering in SIMATIC IT Visualization and testing of the historical data exchange Appendix Appendix A: installing a PPA database Installation of the SIMATIC IT PPA database Reporting and Archiving Appendix B: configuring a SPOSA station in SIMATIC Manager References Abbreviations V /134

5 Introduction 1 Introduction In this paper the basic engineering, which has to be done in SIMATIC PCS 7 / BATCH and SIMATIC IT Historian in order to exchange data, is described. The focus is on the configuration of the interfaces. The paper should allow the SIMATIC PCS 7 user to understand what has to be done on the IT side to make the communication happen and it should allow the IT user to understand what has to be done in SIMATIC PCS 7 in order to exchange data. Additionally the paper gives information on which engineering can be done online, which kind of engineering requires a downtime. This paper will be used as a reference in other use cases. Starting point is a finished SIMATIC PCS 7 / SIMATIC BATCH project. All additional engineering which has to be done on the SIMATIC PCS 7 / BATCH side will be described in detail. The necessary engineering on the IT side will be described. The starting point will be an empty SIMATIC IT Historian project. V /134

6 Introduction 1.1 Goal After setting up the basic communication between SIMATIC PCS 7 / BATCH and 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 /134

7 Introduction 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. This allows us to describe which engineering has to be done in the following cases: SIMATIC IT Historian is used in combination with SIMATIC PCS 7 / BATCH (part of this paper). SIMATIC IT Historian and Production Modeler are used together in combination with SIMATIC PCS 7 / BATCH (not part of this paper). 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. On the SIMATIC PCS 7 side we have a pair of redundant SIMATIC BATCH Servers and a separate pair of redundant OS Servers. Additional we have an engineering station and two PCS 7 OS Multiclients which are also used as SIMATIC BATCH Clients. Figure 1-2 Schema of the Windows active directory domain computers A private IP address band is used with fixed IP addresses. V /134

8 Introduction NOTE In this configuration it is necessary that BPM (Business Process Modeler) is installed and running on the SIMATIC IT Historian machine in order to be able to import the equipment model of SIMATIC BATCH into SIMATIC IT Plant Performance Analyzer (PPA). Data exchange between SIMATIC PCS 7 / SIMATIC BATCH and SIMATIC IT Historian can be divided in three different categories: exchange of engineering data exchange of realtime data exchange of historical data 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 /134

9 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 V7.0 SP1 Version 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 A detailed list of the installed SIMATIC software can be found in the attachment A of the document SIMATIC software in a domain. V /134

10 Introduction 1.3 SIMATIC IT Historian in combination with SIMATIC PCS7 / SIMATIC BATCH In this case SIMATIC IT Historian is used to collect data coming from SIMATIC BATCH and SIMATIC PCS 7. In the following picture the layout of such a configuration is displayed. The SIMATIC IT Report Manager is used to create an EBR (electronic batch record). Figure 1-3 Integration between SIMATIC PCS 7 / SIMATIC BATCH and Historian, single server The WinCC process values archives and alarm archives are used to provide the operator with the necessary alarms and process values information. SIMATIC IT Historian is used to aggregate data, calculate KPI's, statistics, reporting... and to archive on the long term important process information. V /134

11 Introduction In the case of redundant SIMATIC PCS 7 OS server, the configuration looks like shown in the following picture: Figure 1-4 Integration between SIMATIC PCS 7 / SIMATIC BATCH and Historian, redundant servers V /134

12 Installation 2 Installation Before engineering the integrated project and exchanging data the integration pack 2007 has to be installed on the SIMATIC PCS 7 and the SIMATIC IT computers. The integration pack 2007 consists of two CD s (CD1= SIMATIC PCS 7 and CD2 = SIMATIC IT). Independent of the type of data which will be exchanged (realtime variables, historical variables, batch data exchange ) the following steps as described in the following table need to be performed. Table 2-1 Installation and configuration steps Step Action 1 Take CD1 of the integration pack 2007 and install the provided SIMATIC PCS 7 hotfixes. In the release notes of the integration pack 2007 is mentioned which hotfix has to be installed on which type of machine. 2 Take CD2 of the integration pack 2007 and install the provided SIMATIC IT hotfixes (SIMATIC_IT_V6.3.1+HF2) on every SIMATIC IT machine in the system. 3 Install additionally the PCS7_COMMUNICATION_IF_V7.0+SP1 software from CD2 on the SIMATIC IT Historian server. 4 Using the SIMATIC manager, configure the SIMATIC IT Historian machine as a SPOSA station inside the SIMATIC PCS 7 project/multiproject (see Appendix B: configuring a SPOSA station in SIMATIC Manager for a detailed description). 5 Using SIMATIC manager, download the SPOSA station (see Appendix B: configuring a SPOSA station in SIMATIC Manager for a detailed description). V /134

13 Installation Applied to the test system, used in this whitepaper, our test system looks like shown in the next picture. Figure 2-1 Integration pack 2007 applied to our system V /134

14 Engineering Data 3 Engineering Data Since SIMATIC IT tags and SIMATIC PCS 7 ES and WinCC variables are managed by different databases, a relationship must be set among them in order to create an integrated SIMATIC IT / SIMATIC PCS 7 system. Figure 3-1 Overview of engineering data exchange 1 and 2: SIMATIC PCS 7 ES and SIMATIC PCS 7 OS realtime variables are browsed and selected with SIMATIC Tag Browser and imported in SIMATIC IT RTDS and PDA. 3: SIMATIC PCS 7 ES historical variables, which will be transferred from the PCS 7 ES project to SIMATIC IT Plant Performance Analyzer, can be imported directly into PPA. 4: The batch plant hierarchy and the batch relevant historical tags can be directly imported in PPA. 5: SIMATIC PCS 7 OS realtime variables are browsed and selected with OPC Browser and imported in SIMATIC IT RTDS. 6: SIMATIC PCS 7 OS historical variables, which will be transferred from the SIMATIC PCS 7 OS project to SIMATIC IT Plant Performance Analyzer, can be imported directly into PPA. The variables in the SIMATIC IT RTDS can be easily accessed by SIMATIC IT Historian and SIMATIC IT Production Modeler. In the following paragraphs the six different types of exchanging engineering data will be described. V /134

15 Engineering Data 3.1 Real-time tags engineering from PCS7 ES using the SIMATIC Tag Browser The next paragraphs describe the importing of tags using the path 1 shown on 1Figure Engineering in SIMATIC PCS 7 In order to import tags in SIMATIC IT using the SIMATIC Tag Browser no additional configuration needs to be done. However if you want also to import the following data: UOM (Unit of measurement) and low/high limit, additional configuration has to be done in the SIMATIC PCS7 project. If you want to use the MES-relevant filter capacity inside SIMATIC Tag Browser, additional configuration has to be done. NOTE The amount of engineering can be strongly reduced if these configurations are applied on the Process Tags in the SIMATIC PCS7 project library at the beginning of the project. In the next two paragraphs the additional engineering which is needed to import the additional data (low/high limit, UOM) and the use of the MESrelevant filter will be described. MES-relevant filter The use of the "MES-relevant" attribute decreases the effort of browsing the engineering data. NOTE The importing of SIMATIC PCS 7 tag engineering data in SIMATIC Tag Browser can be made easier by using the attribute "MES-relevant" for inputs/outputs of the function blocks used inside the CFC charts. In the SIMATIC IT environment it is then possible to filter directly the tags that have this attribute set. The attribute has to be set both at the function block levels and the parameter(s) of interest. V /134

16 Engineering Data Figure 3-2 Engineering of the MES-relevant attribute in CFC Example: For the PID controller above the attribute "MES-relevant" can be set for the inputs PV_IN, LMNR_IN and SP. V /134

17 Engineering Data After opening the properties of this PID controller block, the MES-relevant attribute can be set on the block level. Figure 3-3 Set the MES-relevant attribute Afterwards for each individual tag the MES-relevant attribute can be set as shown in the following picture. Figure 3-4 Setting the MES-relevant flag on parameter level V /134

18 Engineering Data Importing of the UOM and the low/high limit In order to import the UOM and low/high limit of a process variable the following parameter attributes need to be used on the SIMATIC PCS 7 function blocks: S7_unit: allows to specify the UOM of a tag S7_trend: allows to specify two limits, syntax: low limit, high limit In the following paragraphs you will adapt a custom function block such that the UOM and the low/high limits become available for SIMATIC IT. Our block is called MY_MEAS_MON as shown in the next picture. Figure 3-5 Custom function block MY_MEAS_MON V /134

19 Engineering Data We open this block using right mouse button "open object" and go to the input attributes for the input called "U Figure 3-6 Adapt input parameter attributes We added the following attributes: "S7_trend" with as value "U_AL,U_AH "S7_unit" with a default value "C_UOM The attribute "S7_trend" specifies that the input parameter called "U_AL will be used as the lower limit and the parameter "U_AH as the high limit. After this configuration, the function block "MY_MEAS_MON is instantiated in a CFC chart. V /134

20 Engineering Data Figure 3-7 Instantiation of the function block in CFC Engineering in SIMATIC IT NOTE To import tags defined in SIMATIC PCS 7 into the SIMATIC IT system there exist currently two tools. For real time data exchange between SIMATIC PCS 7 and SIMATIC IT the SIMATIC Data Access Channel (therefore the SIMATIC Tag Browser) should be used. Before using the SIMATIC Tag Browser you have to configure a SIMATIC Data Access Channel (ivar2). The next pictures show the configuration necessary to set up a SIMATIC Data Access Channel. V /134

21 Engineering Data Figure 3-8 Communication channel configuration of RTDS In the picture below the configuration of a SIMATIC Data Access Channel driver is shown. Multiple SIMATIC Data Access Channel drivers can be connected using one RTDS. For each channel the configuration has to be done, using a different name for each channel. Figure 3-9 Configuration of the SIMATIC Data Access Channel V /134

22 Engineering Data Once the SIMATIC Data Access Channel driver is configured, tags can be added to the data dictionary (this is the configuration tool where the properties of RTDS, PDA... tags are set). Figure 3-10 starting the SIMATIC PCS 7 Tag Browser In this browser it is possible to browse the tags of the SIMATIC PCS 7 project/multiproject. Different naming strategies can be chosen to abbreviate the SIMATIC PCS 7 tag names. NOTE The abbreviation of the SIMATIC PCS 7 tag name is necessary since the tag names in the RTDS are limited to 32 characters. The SIMATIC Tag Browser has different configurable naming strategies in order to create meaningful shorter RTDS tag names. V /134

23 Engineering Data You can either use the wizard or manually open the project. In the following picture the ES multiproject is opened manually. Figure 3-11 Open the project on the PCS 7 ES Station V /134

24 Engineering Data Now you can browse for the ES multiproject on the SIMATIC PCS 7 ES station. Figure 3-12 Browse for the multiproject on the SIMATIC PCS 7 ES station V /134

25 Engineering Data And you can select one or more tags to import. Figure 3-13 Select the tag(s) V /134

26 Engineering Data And as a last step, you can now import the tags. Figure 3-14 Adapt and import the tag(s) In this version of the Tag Browser a new window pops up where you can apply online naming strategies. Once all selected tags have the status ready for import. You can finalize the import operation by selecting the button Import. The result of the import can be seen in the following picture. Figure 3-15 Importing tags with the SIMATIC Tag Browser V /134

27 Engineering Data MES-relevant filter If the MES-relevant flag was configured inside the SIMATIC PCS 7 project you can use the option MES relevant tags only as shown in the next picture. Figure 3-16 aactivation of the MES-relevant flag After this only the tags which were configured as MES-relevant in SIMATIC PCS 7 will be shown. Importing of the UOM and the low/high limit If in the SIMATIC PCS 7 project/multiproject the parameter attributes "s7_unit and "s7_trend are configured, the SIMATIC Tag Browser can import this data in the data dictionary (RTDS + PDA) during the import operation of the tags. In order to import this information, you have to make some settings in the SIMATIC Tag Browser BEFORE starting the import operation. V /134

28 Engineering Data Figure 3-17 Configuration of the Default tag properties 1/2 In the dialog box which pops up, the user can choose if imported tags are imported in RTDS only or in RTDS and PDA. If you want that the UOM and the low/high limit are deducted from the engineering done in SIMATIC PCS 7, you have to leave the corresponding fields blank. Figure 3-18 Configuration of the Default tag properties 2/2 V /134

29 Engineering Data As an example you set the following default values for the tag import operation. Figure 3-19 Setting the default parameters example V /134

30 Engineering Data Now, in the browser window, you browse for our MY_MEAS instance as described in the SIMATIC PCS 7 engineering part Figure 3-20 Browsing for the MY_MEAS instance V /134

31 Engineering Data and you import this tag called "U Figure 3-21 Import of the U variable In this window you can already see the result of our Default tag properties configuration. The default values in this window are corresponding with the values as shown in Figure 3-21 Import of the U variable. Values can still be changed at this time. The result in the data dictionary can be seen in the following three pictures. V /134

32 Engineering Data Figure 3-22 Result in data dictionary 1/3 Figure 3-23 Result in data dictionary 2/3 V /134

33 Engineering Data Figure 3-24 Result in data dictionary 3/3 V /134

34 Engineering Data 3.2 Real-time tags engineering from SIMATIC PCS7 OS (SPOSA) using the SIMATIC Tag Browser The next paragraphs describe the importing of tags using the path 2 shown on 1Figure Engineering in SIMATIC PCS 7 In SIMATIC PCS 7 no specific engineering has to be done. The filter MES-relevant is not applicable for this kind of tags. The import of low/high limits is not applicable for this kind of tags. The only prerequisite to start the engineering of the tags on SIMATIC IT side is that the computer, on which the SIMATIC Tag Browser is started, is configured as a SPOSA (Single Point Of System Access) station inside the SIMATIC PCS 7 project/multiproject (see Appendix B: configuring a SPOSA station in SIMATIC Manager) and that the WinCC project is opened on the SIMATIC OS sever Engineering in SIMATIC IT In order to import tags from the SIMATIC OS project, the Tag Browser has to be started and a connection to the SPOSA station has to be made. This is shown in the following picture. Figure 3-25 Open the SPOSA station V /134

35 Engineering Data After opening the SPOSA station, a browser similar to the Tag Browser in WinCC opens where the user can select the tags he wants to import. Figure 3-26 Browsing the SPOSA station Here the user can select internal as well as external tags. The external tags are not displayed in a flat list but in a hierarchical list containing the CFC chart name and the function block name. Figure 3-27 Selection of external tags V /134

36 Engineering Data The result of the import can be seen in the following pictures. Figure 3-28 Result of the import operation 1/2 Figure 3-29 Result of the import operation 2/2 As you can see from the last picture, the result after import is exactly the same as you would have added the tag using the SIMATIC PCS 7 ES project. Also in this case, in runtime the SIMATIC Data Access Channel (ivar2) will be used. NOTE Using this method, also internal tags from the WinCC servers can be browsed and configured. V /134

37 Engineering Data 3.3 Real-time tags engineering using the OPC Tag Browser The next paragraphs describe the importing of tags using the path 5 shown on 1Figure Engineering in SIMATIC PCS 7 In SIMATIC PCS7 no specific engineering has to be done. The only prerequisite to start the engineering of the tags on SIMATIC IT side is that the computer, on which the OPC Tag Browser is started, is configured as a SPOSA (Single Point Of System Access) station inside the SIMATIC PCS 7 project/multiproject (see Appendix B: configuring a SPOSA station in SIMATIC Manager) and that the WinCC project is opened on the SIMATIC OS server Engineering in SIMATIC IT Tags imported in this way require the setup of an OPC channel driver. The next pictures show the configuration necessary to set up an OPC channel. V /134

38 Engineering Data In the picture below the setup of the OPC channel driver is shown. Multiple OPC channels can be connected with one RTDS. For each channel the setup has to be done, using a different name for each channel. The computer to which the OPC channel driver is referring will be defined during the configuration of the tags (see lower). Figure 3-30 Configuration of RTDS Figure 3-31 Configuration of the OPC channel V /134

39 Engineering Data Once an OPC channel is configured the OPC browser can be used to add tags to the data dictionary. Figure 3-32 Starting the OPC browser Figure 3-33 Working with the OPC browser V /134

40 Engineering Data In the menu Tools > DB Configuration the OPC channel driver (source) and the RTDS unit (destination) can be defined. All selected tags will be added into the data dictionary using this information. The tags are browsed on the local installed OPC server provider by the Open PCS7 installation. Figure 3-34 Working with the OPC browser NOTE Notice that in this example the OPC browser to be browsed is called PCS7.OPCDAServer. This is the OPC server which is installed during the installation of the Open PCS 7 software. V /134

41 Engineering Data The result of the import is shown in the following picture. For each tag the user fields 1 to 3 are filled in during the automatic import of the tags. As default value the class 0 is used. Alternatively tags can be created and linked manually inside the SIMATIC IT system but this increases the risk of making mistakes. Figure 3-35 Importing tags with the OPC browser V /134

42 Engineering Data Remarks and restrictions CAUTION In order to use the communication as described in this paragraph an Open PCS 7 license is required on the SIMATIC IT Historian machine. If the OPC channel driver is used to connect the RTDS with a redundant SIMATIC PCS 7 OS Server it is necessary to install the SPOSA station software and to create an SPOSA project on the machine on which the RTDS is installed. The installation of a multiclient + Open PCS 7 station on the SIMATIC IT machine is not allowed. Only the Open PCS 7 software can be installed. Tags configured as described here will use OPC communication during runtime and not the SIMATIC Data Access Channel during runtime. Both the OPC channel driver and the SIMATIC Data Access Channel driver allow adding tags online. Therefore the tags need to be imported by using the OPC Tag Browser or the PCS 7 Tag Browser and afterwards the RTDS engine needs to be updated. The following picture shows how to update the RTDS online: V /134

43 Engineering Data Figure 3-36 Updating RTDS After pushing the update button the tags will be available without stopping the RTDS engine. V /134

44 Engineering Data Figure 3-37 Updating RTDS V /134

45 Engineering Data 3.4 Historical tags engineering using the SIMATIC data channel The next paragraphs describe the importing of tags using the path 3 shown on 1Figure Engineering in SIMATIC PCS 7 In order to exchange historical data between SIMATIC PCS 7 and SIMATIC IT, historical tags have to be defined inside the SIMATIC PCS 7 ES project. This configuration can be done in CFC. Figure 3-38 Setting the archive attribute in CFC After compiling the OS project, these tags will be available in the system archive of the SIMATIC PCS 7 OS Server. V /134

46 Engineering Data Engineering in SIMATIC IT From PPA you can directly browse the WinCC tag logging archives and select the tags which you want to archive in PPA. The configuration of a new point in SIMATIC IT PPA is shown in the following pictures. Figure 3-39 Creating source points based upon WinCC Taglogging tags (1/4) In the WinCC Taglogging class you can add a new point by browsing the WinCC Taglogging workspace. V /134

47 Engineering Data Figure 3-40 Creating source points based upon WinCC Taglogging tags (2/4) V /134

48 Engineering Data Figure 3-41 Creating source points based upon WinCC Taglogging tags (3/4) V /134

49 Engineering Data Figure 3-42 Creating source points based upon WinCC Taglogging tags (4/4) After this configuration the WinCC Taglogging point can be further used for calculations, archivation in SIMATIC IT PPA Remarks and restrictions In the case of a disconnection between SIMATIC IT Historian (PPA) and the SIMATIC PCS 7 OS Servers (for example network connection broken) data recovery will be done as soon as the connection is available again. The prerequisite is that the option Enable recovery after failure is set during the creation of the PPA project (see Appendix A: installing a PPA database). Historical tags can be added online inside the SIMATIC PCS 7 system. On the SIMATIC IT side the PPA has to be stopped but after starting the PPA again the data can be recovered. The prerequisite is that the option Enable recovery from stop to start is set during the creation of the PPA project (see Appendix A: installing a PPA database). V /134

50 Engineering Data 3.5 Historical tags engineering using the OPC-HDA data channel The next paragraphs describe the importing of tags using the path 6 shown on 1Figure 3-1, but instead of using the SIMATIC historical data channel the OPC HDA server of the SPOSA station is used Engineering in SIMATIC PCS 7 In order to exchange historical data between SIMATIC PCS 7 and SIMATIC IT, the historical tags have to be defined inside the Tag Logging system of the SIMATIC PCS 7 OS Server(s) Engineering in SIMATIC IT From PPA you can directly browse the OPC HDA server provided by the SPOSA station and select the tags which you want to archive in PPA. The configuration of a new point in SIMATIC IT PPA is shown in the following pictures. Figure 3-43 Create OPC HDA class V /134

51 Engineering Data Figure 3-44 Create OPC HDA class Figure 3-45 Server definition NOTE Notice that in this example the OPC browser to be browsed, is called PCS7.OPCHDAServer and runs locally. This is the OPC server which is installed during the installation of the Open PCS 7 software (see CD2 integration pack 2007). In the OPC-HDA class you can add a new point by browsing the OPC-HDA workspace. V /134

52 Engineering Data Figure 3-46 Tag definition Figure 3-47 Tag definition V /134

53 Engineering Data Remarks and restrictions CAUTION In order to use the communication as described in this paragraph an Open PCS 7 license is required on the SIMATIC IT Historian machine. If the OPC HDA channel driver is used to connect with a redundant SIMATIC PCS 7 OS Server it is necessary to install the SPOSA station software and to create an SPOSA project on the machine on which PPA is installed. The installation of a multiclient + Open PCS 7 station on the SIMATIC IT machine is not allowed. Only the Open PCS 7 software can be installed. Tags configured as described here will use OPC communication during runtime and not the SIMATIC historical Data Access Channel during runtime. V /134

54 Engineering Data 3.6 Message engineering using the SIMATIC data channel Engineering in SIMATIC PCS 7 No specific additional engineering has to be done in SIMATIC PCS 7 in order to exchange engineering data to the SIMATIC IT environment Engineering in SIMATIC IT No specific engineering such as importing of message texts, etc. has to be done. Data exchange configuration is based upon the runtime interface. The necessary configuration which has to be done is described in the chapter 4 "Realtime Data" Remarks and restrictions When alarms are added inside the SIMATIC PCS 7 system they will be automatically available for the SIMATIC IT environment. Therefore messages can be added online. V /134

55 Engineering Data 3.7 Batch stepping protocol and alarm/events engineering The next paragraphs describe the importing of tags using the path 4 shown on 1Figure Engineering in SIMATIC PCS 7 / BATCH Basic engineering In order to be able to exchange runtime data between SIMATIC BATCH and SIMATIC IT Historian, some configuration has to be done first. CAUTION In contradiction to the previous integration pack V6.1 SP1 TIA hf4, you do not need to install/configure the SIMATIC IT HISTORIAN computer as a SIMATIC BATCH client anymore. It is necessary to configure the PPA machine as a SPOSA station inside the SIMATIC PCS7 project/multiproject. For the detailed configuration you refer to Appendix B. Do not forget to verify that the following project setting has to be made: This following picture shows the situation after a creation of a project. The checkbox "Deactivate SIMATIC BATCH Server (SBS) has to be Unchecked in order to make the SIMATIC BATCH Server running. V /134

56 Engineering Data Figure 3-48 Activation of the SIMATIC BATCH server To check if the SIMATIC BATCH Server (SBS) is activated and running, you can verify on the SIMATIC BATCH Server(s) the following new icon: Figure 3-49 Activated SBS server In this version of SIMATIC BATCH it is also possible to deactivate the SIMATIC BATCH CDV component. This SIMATIC BATCH component collects all the batch relevant tag values and the messages and writes them temporarily into XML files. The data in these XML files is used later for the creation of batch reports inside SIMATIC BATCH. Since these XML files can become very big when many tag collect blocks are used (you refer to the performance data in the Appendix B: configuring a SPOSA station in SIMATIC Managerabout the restrictions regarding this size) you can switch off the SIMATIC BATCH CDV component as shown in the following picture: V /134

57 Engineering Data Figure 3-50 Deactivating the SIMATIC CDV component NOTE The deactivation of the CDV component has as a result that in the standard SIMATIC BATCH XML reports the messages and the curves are not displayed anymore. After making the configuration as shown before, the SIMATIC BATCH configuration needs to be downloaded to the SIMATIC BATCH Server(s). After starting the SIMATIC BATCH launch coordinator the following icons will be shown: Figure 3-51 Deactivated Batch CDV component If the CDV is activated the following icons are visible: Figure 3-52 Activated Batch CDV component V /134

58 Engineering Data Additional engineering for Tag collect blocks Additionally, in order to simplify later the calculations of KPI's, "Tag collect" blocks can be added to the SIMATIC PCS 7 application. After configuration of these "Tag collect" blocks will be available inside the SIMATIC BATCH recipes. This will make it possible for example to archive the temperature of a reactor during the execution of the heat operation. The configuration of the "Tag collect" block will automatically start the archiving of this tag when in batch the heat operation is started and stop the archiving of this tag when the heat operation is stopped. Therefore the engineering effort will be decreased substantially (no configuration of triggers...). To add "Tag collect" blocks to the Automation system, the following actions have to be performed. Figure 3-53 Add a tag collect function block in CFC A tag collect block (CFC Batch library) needs to be added to the CFC (the tag collect block can be placed on unit level, phase level...). All the information which needs to be collected needs to be connected with the tag collect block. Information can be of the type REAL, BOOL... In our example the temperature (REAL parameter) of the reactor is connected. V /134

59 Engineering Data On the parameter block the QACT_VAL can already be configured to be archived (see below) such that during the compilation of the OS a tag is already created in the Tag Logging archive of WinCC. This tag will be needed during the configuration of SIMATIC BATCH. After the compilation of the OS, the configuration of SIMATIC BATCH can be completed. Figure 3-54 Configuration of the process tag type After the generation of the batch types, the tag collect blocks become available under the folder "Process tag types". The batch types can then be propagated to the different projects. NOTE The goal is to archive this temperature tag only for the duration of the heat operation. Since SIMATIC BATCH related tags are based upon the tags in WinCC Tag Logging, it is required to check the flag "Archive measured variable". V /134

60 Engineering Data Figure 3-55 Configuration of the process tag instance For each instance where a tag collect block is configured, a tag (from WinCC Tag Logging) has to be assigned. In our case you took the already created tag QVAL_ACT tag inside the Tag Logging (see action before). Due to this configuration the PPA will be able to automatically create tags inside the PPA database. Do not forget to update the process cell in SIMATIC BATCH! NOTE An update of the process cell has to be done before the "import from BPM" action will be performed (see engineering SIMATIC IT) in order to see the changes done in SIMATIC PCS Engineering in SIMATIC IT Basic engineering Before the batch stepping protocol information can be collected and stored into the PPA database a new database with the right options has to be created. In the SIMATIC IT Historian help, a complete set-up is described. V /134

61 Engineering Data During the configuration of the PPA database you have to select which kind of integration you want to perform. In our case you want only to integrate SIMATIC IT Historian with SIMATIC BATCH. For a detailed description of the creation of a new database you refer to Appendix A: installing a PPA database. After the creation of the database a new configuration can be created. The first configuration which has to be done is to import the SIMATIC BATCH process cell into the PPA. This is shown in the next pictures: Figure 3-56 Importing the SIMATIC BATCH equipment model into PPA Figure 3-57 Importing the SIMATIC BATCH equipment model into PPA After this operation the complete SIMATIC BATCH equipment model and the batch relevant process tags are available in PPA as shown in the following picture: V /134

62 Engineering Data Figure 3-58 Importing the SIMATIC BATCH equipment model into PPA For the SIMATIC BATCH alarms no specific additional engineering such as importing of message texts, etc. has to be done. Data exchange configuration is based upon the runtime interface. The necessary configuration which has to be done is discussed in the 4"Realtime Data" Additional engineering data for Tag collect blocks In case "Tag collect" blocks are used inside SIMATIC PCS 7 / SIMATIC BATCH you will find automatically the configured tags from the tag collect blocks in the class "SIMATIC BATCH". The default trigger for this class is 1 min. NOTE The prerequisite for the automatic importing of batch related KPI s is that the option Batch related tag is set during the creation of the PPA project (see Appendix A: installing a PPA database) Figure 3-59 Automatic configuration of the Tag collect block related tags V /134

63 Engineering Data Remarks and restrictions "Tag collect" blocks can be added online (delta download AS, restrictions can be found in the online help) to the automation system, WinCC tags can be created online. The process cell in SIMATIC BATCH can be updated online. The PPA configuration needs to be stopped and started, but the data can be recovered. Therefore it is possible to add measurement points online. V /134

64 Realtime Data 4 Realtime Data Runtime data are created during the runtime process. Typical runtime data are process values, messages, events and methods. The runtime data are transferred via several channels. Depending on the Tag Browser used during engineering phase, the online access on process values by SIMATIC IT is automatically defined: SIMATIC PCS 7 ES variables and WinCC variables (SPOSA), browsed via SIMATIC Tag Browser, are transferred via SIMATIC Data Access Channel. SIMATIC PCS 7 OS variables, browsed via OPC Browser, are transferred via OPC Data Access Channel. Further runtime data (online) are transferred as follows: WinCC messages are transferred via SIMATIC Message Channel. SIMATIC BATCH events are transferred via the SIMATIC BATCH Data Channel. 4.1 Process Values via SIMATIC Data Access Channel (ivar2) The SIMATIC Data Access Channel is important for the direct transfer of process values at runtime. SIMATIC IT Historian asks periodically for process values. The required process values are transferred from SIMATIC PCS 7 to SIMATIC IT RTDS via the SIMATIC Data Access Channel. Once data are in SIMATIC IT RTDS, they become SIMATIC IT data and can be used by components such as: PDA: Plant Data Archive: Allows to compress data and to store it in a cyclical buffer. PPA: Plant Performance Analyser: Allows to store data and to perform calculations on this data and store the results in a SQL database. V /134

65 Realtime Data Figure 4-1 SIMATIC Data Access Channel data exchange in runtime Configuration in SIMATIC PCS 7 In SIMATIC PCS 7 no additional engineering has to be done in order to exchange data over the SIMATIC Data Access Channel with SIMATIC IT Configuration in SIMATIC IT The application which will receive the real-time data in the SIMATIC IT environment is RTDS (Real Time Data Server). After importing tags into RTDS, some additional information can be set in order to specify the runtime behaviour. The following properties can be changed: Acquisition class: the default acquisition class = 0. You can choose also fixed cyclic classes as shown below. Safe value: a safe value can be provided. In case of a network problem between SIMATIC IT and the SIMATIC PCS 7 OS Server(s) this value will be used. V /134

66 Realtime Data Figure 4-2 Acquisition classes in RTDS Figure 4-3 Safe value in RTDS Figure 4-4 Display of the safe value in ODS In the example the safe value was set = 22. Afterwards the network connection between the SIMATIC IT Historian Server and the PCS 7 OS Serv- V /134

67 Realtime Data ers was disconnected. The application requesting the value from the RTDS will receive the safe value. The quality status for this tag is BAD, the sub quality is OUT OF USE (this information can be seen after right clicking on an item and selecting "Quality information"). Additional engineering for compression If a huge amount of real-time data has to be collected in a fast cycle it becomes necessary to compress the data before storing it into the database. The tags which are already available in RTDS can be compressed before they are stored in a database by using a PDA (Plant Data Archive) Server inside SIMATIC IT. NOTE The PPA can also store real-time data (using an RTDS class). However, the goal of the PPA is to analyze data. For huge amount of data it is better to compress the data first using the PDA and then later analyze and store the compressed data with the PPA. The PDA stores the compressed data into a cyclical buffer. The configuration of the PDA is done as follows: Figure 4-5 Starting the PDA Server Before starting the configuration of the PDA, the PDA Server application has to be started. V /134

68 Realtime Data Figure 4-6 Configure the PDA Server Once the PDA is running, it can be configured. The PDA stores his data in a propriety database based upon files. During the configuration you have to select how big and how many files you want to create. Figure 4-7 Configuration of the PDA archive V /134

69 Realtime Data Figure 4-8 Configuration of the PDA archive Figure 4-9 Configuration of the PDA archive Once the PDA archives are created, you can go to the database dictionary and configure our points for which you want to use compression. In the tab PDA, you can define the horizontal and slope compression which is defined as a percentage of the maximum-minimum range (0 means no compression). This configuration can be done for each point in the database. V /134

70 Realtime Data Figure 4-10 Configuration of the PDA archive NOTE The low/high limit and the engineering unit will be automatically filled in when the SIMATIC Tag Browser is used and the engineering in SIMATIC PCS 7 is done as described in chapter 3.1 Real-time tags engineering from PCS7 ES using the SIMATIC Tag Browser. Once the configuration of the compression is done, the PDA archive has to be updated. V /134

71 Realtime Data Figure 4-11 Update of the PDA archive Figure 4-12 Update of the PDA archive After clicking on the button "Points", you can select the unit for which the PDA has to compress data. V /134

72 Realtime Data Figure 4-13 Update of the PDA archive After pushing the button "Apply you will receive a message which tells you how many points are updated... Figure 4-14 Update of the PDA archive The first time you activated the PDA, the archiving has to be started. V /134

73 Realtime Data Figure 4-15 Update of the PDA archive After acknowledging this message the PDA archiving is started and the compressed data will be available for the other applications (PPA...) Visualizing and testing of the data exchange RTDS data can only be visualized using the ODS as described in Figure 4-4. PDA data can be visualized using a trend in HDD (Historian Data Display). Figure 4-16 Starting of the Historian Data Display V /134

74 Realtime Data Once opened, a new trend can be added and configured. Figure 4-17 New trend of the Historian Data Display V /134

75 Realtime Data A trend based upon the PDA can be configured and the temperature tag is selected from the online archive... Figure 4-18 Configuration of the Historian Data Display V /134

76 Realtime Data and below you see the result of the configuration: Figure Process Values via OPC DA Channel The OPC Data Access Channel is important for the direct transfer of process values at runtime from an OS Server configured as an OPC Server. SIMATIC IT Historian asks periodically for process values. The required process values are transferred from SIMATIC PCS 7 to SIMATIC IT RTDS via the OPC Data Access Channel. Once data are in SIMATIC IT RTDS they become SIMATIC IT data and can be used by every component of SIMATIC IT. NOTE For real time data exchange between SIMATIC PCS 7 and SIMATIC IT the SIMATIC Data Access Channel (therefore the SIMATIC Tag Browser) is recommended. V /134

77 Realtime Data Figure 4-20 Data exchange in runtime Configuration in SIMATIC PCS 7 In SIMATIC PCS 7 no additional engineering has to be done in order to exchange data using the OPC Data Access Channel Configuration in SIMATIC IT The description of the configuration is identical as the description for the SIMATIC Data Access Channel. Additional engineering for compression The description of the configuration is identical as the description for the SIMATIC Data Access Channel. Visualizing and testing of the data exchange The description of the configuration is identical as the description for the SIMATIC Data Access Channel. V /134

78 Realtime Data 4.3 Online messages via SIMATIC Message Channel The integration of SIMATIC IT Historian with SIMATIC PCS 7 allows the archiving of WinCC messages in SIMATIC IT Plant Performance Analyzer. The messages can be transferred directly via the SIMATIC Message Channel to SIMATIC IT PPA. Figure 4-21 Message data exchange in runtime Engineering in SIMATIC PCS 7 No specific additional engineering has to be done in SIMATIC PCS 7 in order to exchange runtime data to the SIMATIC IT environment Engineering in SIMATIC IT The application which will receive the messages inside the SIMATIC IT environment is the PPA. Message filters can be defined inside the PPA project. Upon installation there is already one message class installed which is capturing all the SIMATIC BATCH related messages. After selecting the button "Messages" on the left side, you see the predefined "Batch related messages" filter. This standard defined filter is based upon the online message archive. V /134

79 Realtime Data Figure 4-22 The standard batch message filter The filter condition for this filter is based upon the PValue3. In case a message is related to a batch this PValue3 field will contain the batch ID, therefore with this filter all batch messages will be filtered. NOTE This standard "batch related messages" filter cannot be modified, however it is possible to switch it off (see below). Using the Toggle Status it is possible to switch this filter completely off, meaning that no messages at all will be captured. V /134

80 Realtime Data Figure 4-23 Switch off the batch related messages Next to the standard available message filter, you can also create your own message filters. Figure 4-24 Creating a new message filter In the first step of the wizard you select the name of the filter and the types of archive. In case of a filter based upon an historical alarm archive you have to specify how frequent you want to collect the data. V /134

81 Realtime Data Figure 4-25 Creating a new message filter In this example you called our filter All_messages without specifying a specific filter. This message filter will store all messages coming from WinCC. Figure 4-26 Creating a new message filter V /134

82 Realtime Data Afterwards you have to specify the condition which has to be applied. Here some knowledge is needed in order to configure the filter. In order to simplify this operation the following table can be used for specifying a class and type filter: Table 4-1 Overview of message classes and types TYPE Name of type CLASS Name of class 1 Alarm High 1 Alarm 2 Alarm Low 1 Alarm 19 Warning High 2 Warning 20 Warning Low 2 Warning 37 Tolerance High 3 Tolerance 38 Tolerance Low 3 Tolerance 55 System 4 PLC process control messages 56 Error 4 PLC process control messages 71 System 5 OS process control system messages 72 Error 5 OS process control system messages 80 Type 80 5 OS process control system messages 89 Maintenance. 6 Preventive maintenance 106 Process message. 7 Process message 122 Process message. 8 Operating message 139 Request for Operator Input. 9 Request for Operator Input 156 Operator Input Message. 10 Operator Input Message 253 Status PLC 16 Status Message 254 Status OS 16 Status Message 257 Process control system 17 System, must be acknowledged 258 System messages 17 System, must be acknowledged 273 Process control system 18 System, need not be acknowledged 274 Operator input messages 18 System, need not be acknowledged Additional to the specified condition it is also possible to store only certain states of the alarms and events, for example only COME and GONE states. V /134

83 Realtime Data Figure 4-27 Creating a new message filter With the option expanded, each change of a message (Come, Go, Ack) creates a new line in the SQL DB. With the option compressed an existing line will be updated (for the selected states). V /134

84 Realtime Data Figure 4-28 Creating a new message filter NOTE As a last step the attributes which have to be stored for the messages which pass the filter have to be specified. As a result, a custom object is created inside the PPA to store the alarms which fulfil the filter. Message filters which have to be stored with the same attributes can use the same custom object. In case you have already a message class defined with the same attributes as the newly created filter you can select the second option in the previous dialog box. V /134

85 Realtime Data Figure 4-29 Creating a new message filter NOTE If you create multiple filters and an incoming alarm is fulfilling multiple filters, the alarm will be stored multiple times into the PPA database (one time for each filter which is fulfilled). Therefore you should be careful not to specify too many overlapping filters. In the case overlapping filters are used, the estimation of the size of the database has to be reviewed too. Only the results of the standard defined filter "batch related messages" are standard available in the report manager. The custom build message filters require also some customization of the report manager universe which is explained in the Report Manager manual. V /134

86 Realtime Data Visualizing and testing of data exchange In HDD you can verify if the different defined filters are working correctly. HDD can be started from the management console. Once opened, a new message viewer can be added and configured. Figure 4-30 Displaying messages in Historian Data Display Figure 4-31 Displaying messages in Historian Data Display In the configuration wizard you can choose between ONLINE ARCHIVE and CUSTOM of the PPA database. Since you want to look at the online messages you choose the ONLINE ARCHIVE. V /134

87 Realtime Data Then you choose our message filter "DaEngineMsg/All_messages" which you configured before. Figure 4-32 Displaying messages in Historian Data Display V /134

88 Realtime Data Figure 4-33 Displaying messages in Historian Data Display And finally you select the time frame for which you want to see the messages. V /134

89 Realtime Data Figure 4-34 Displaying messages in Historian Data Display As a result you see the requested messages in our viewer: Figure 4-35 Displaying messages in Historian Data Display V /134

90 Realtime Data 4.4 Data Transfer from SIMATIC BATCH to SIMATIC IT PPA To ensure that a data transfer from SIMATIC BATCH to SIMATIC IT Plant Performance Analyzer is possible during runtime, the PCells and their related properties must be imported to SIMATIC IT PPA. During runtime, events are created in SIMATIC BATCH and sent with the required data to SIMATIC IT PPA using the SIMATIC BATCH data channel. In the PPA the data are stored for further elaborations, for example to make reporting and to calculate KPI values Configuration in SIMATIC PCS 7 / BATCH In SIMATIC PCS 7 no specific configuration is needed. In SIMATIC BATCH recipes need to be created and batches based upon these recipes need to be created and started. During the runtime of a batch, SIMATIC IT Historian will receive events and store them in the PPA database. In the case tag collecting blocks are used, they need to be configured in the SIMATIC BATCH recipes at the level (RP, RUP, ROP, RPH) at which they are needed. In the following picture for example the parameter temperature was configured at the operation level (HEAT operation). Therefore automatically, without any configuration in SIMATIC IT Historian, the tag associated with this temperature parameter will be recorded from the start until the stop of the HEAT operation. In the batch recipe you can activate a batch KPI on different levels (RUP, ROP, RPH). In the example below you activated the batch KPI on the HEAT ROP level. V /134

91 Realtime Data Figure 4-36 Configuration of a batch relevant KPI in SIMATIC BATCH Configuration in SIMATIC IT In SIMATIC IT the equipment model and the batch relevant tags need to be imported Visualizing of the data exchange With the SIMATIC IT Historian Data Display you can visualize the SIMATIC BATCH stepping protocol. V /134

92 Realtime Data Figure 4-37 Displaying the batch stepping protocol in Historian Data Display Once the HDD is started a new production viewer can be defined: Figure 4-38 Displaying the batch stepping protocol in Historian Data Display With the configuration wizard you can decide to see information stored in the online database or the offline databases. V /134

93 Realtime Data Figure 4-39 Displaying the batch stepping protocol in Historian Data Display Figure 4-40 Displaying the batch stepping protocol in Historian Data Display V /134

94 Realtime Data In this case you choose the online database. Figure 4-41 Displaying the batch stepping protocol in Historian Data Display V /134

95 Realtime Data Different templates allow the user to select a timeframe. For displaying the batch information you choose the "Batch_ID" key. Figure 4-42 Displaying the batch stepping protocol in Historian Data Display V /134

96 Realtime Data More specific filters can be built using the different lines. Each line allows the definition of one condition which are combined with an AND function. The result of the filter can be seen in the following picture: Figure 4-43 Displaying the batch stepping protocol in Historian Data Display In the case "tag collect" blocks are used in the project you can directly visualize in the process parameter starting from the stepping protocol. V /134

97 Realtime Data In our example you configured that the temperature of the reactor should be recorded during the duration of the HEAT operation. Figure 4-44 Display the process data during the heat operation V /134

98 Realtime Data If you go to the operation level you will see in the lower window the temperature appearing as one of the measures (you have to be on the level on which you have defined the parameter). Right click on the parameter and choose "Add to New > Standard trend". This will bring up the trend window and give you the temperature profile for the duration of the HEAT operation. Figure 4-45 Display the process data during the heat operation V /134

99 Historical Data 5 Historical Data SIMATIC PCS 7 maintains two kinds of data archives on the OS Servers. SIMATIC IT accesses these archives through dedicated data channels: Process values are stored in WinCC Tag Logging and they are transferred via the SIMATIC Historical Data Access Channel or via the OPC Historical Data Access (OPC HDA) channel to SIMATIC IT PPA. Archive data can be simply stored in SIMATIC IT PPA database or used as input for predefined aggregation or script calculation functions in SIMATIC IT PPA. Messages and alarms are stored in the Alarm Logging and they are transferred via SIMATIC Message Channel to SIMATIC IT PPA. 5.1 Process Values via the Historical Data Access Channel The integration of SIMATIC IT Historian with SIMATIC PCS 7 enables the archiving of process values in SIMATIC IT Historian. First the process values created during runtime are stored in the archives of the Tag Logging on the SIMATIC PCS 7 OS Server. Then, SIMATIC IT PPA collects the required data from the Tag Logging via the SIMATIC Historical Data Access Channel. V /134

100 Historical Data Figure 5-1 Historical data exchange using the historical Data Access Channel Engineering in SIMATIC PCS 7 As mentioned in the the historical tags can already be defined at CFC level or at Tag Logging level Engineering in SIMATIC IT In the SIMATIC IT environment tags which are related to SIMATIC BATCH are entered automatically into the PPA database after the import operation. Additionally not SIMATIC BATCH related tags can be configured as described in These tags can be used as source points for custom calculations in PPA. NOTE Make sure that the SIMATIC IT Historian Server and the OS Server(s) are time synchronized Without engineering in SIMATIC IT In the current version of SIMATIC IT Historian some new features have been added to directly access and display data coming from WinCC tag- V /134

101 Historical Data logging archives. In contradiction to the engineering described in the features described below do not require any engineering in the PPA project. Trend based upon WinCC Taglogging The trend window wizard allows selecting WinCC Tag Logging as a source point as shown in the following pictures: Figure 5-2 Trend based upon WinCC Tag Logging V /134

102 Historical Data Figure 5-3 Trend based upon WinCC Tag Logging Figure 5-4 Trend based upon WinCC Tag Logging As you can see, no engineering was necessary to show SIMATIC PCS 7 related data inside SIMATIC IT. V /134

103 Historical Data Trend formulas The trend window wizard allows defining a formula. The parameters of these formulas can have different sources as shown in the following pictures: Figure 5-5 Trend based upon a formula V /134

104 Historical Data Figure 5-6 Trend based upon a formula As an example, you want to display the sum of the two levels of tank SL01 and SL02. Figure 5-7 Trend based upon a formula V /134

105 Historical Data Each parameter of the formula is specified.. Figure 5-8 Trend based upon a formula V /134

106 Historical Data In the same way you configure the second parameter of the formula. Figure 5-9 Trend based upon a formula V /134

107 Historical Data And the result is a trend which shows us directly the sum of both levels. Figure 5-10 Trend based upon a formula As you can see, no engineering was required in PPA to make a calculation based upon data coming from SIMATIC PCS 7. V /134

108 Historical Data Visualization and testing of historical data exchange In the PPA administration tool there is an option to switch on an online monitoring of the tags: Figure 5-11 Online monitoring of the status of a tag Here you can see the status of each tag. For cyclically called tags you can see that the status is: Running enabled. For event driven tags you can see that the status is: Idle enabled and that this status is changed upon event: for example once a batch is running a HEAT operation (remember that you configured SIMATIC BATCH in a way that the Process tags will only be recorded during the HEAT operation) they will change status to: Running enabled. After the running of the HEAT operation the status will be again Idle enabled. V /134

109 Historical Data Figure 5-12 Online monitoring of the status of a tag 5.2 Process Values via OPC HDA Channel The integration of SIMATIC IT Historian with SIMATIC PCS 7 enables the archiving of process values in SIMATIC IT Historian. First the process values created during runtime are stored in the archives of the Tag Logging on the SIMATIC PCS 7 OS Server. Then, SIMATIC IT PPA collects the required data using the OPC Historical Data Access Channel (OPC HDA). Figure 5-13 OPC HDA data exchange in runtime V /134

110 Historical Data Engineering in SIMATIC PCS 7 As mentioned in the the historical tags can already be defined at CFC level or at Tag Logging level. In the Tag Logging of WinCC already some data compression can be done Engineering in SIMATIC IT In the SIMATIC IT environment tags which are related to SIMATIC BATCH are entered automatically into the PPA database after the import operation. Additionally not-simatic BATCH related tags can be configured as described in Historical Messages via SIMATIC Message Channel (WinCC Tag Logging) The integration of SIMATIC IT Historian with SIMATIC PCS 7 allows the archiving of WinCC messages. First the messages created during runtime are stored in archives of the Alarm logging on the OS Server. From there the messages are transferred via SIMATIC Message Channel to SIMATIC IT PPA. It is possible to create dedicated data structures in the SIMATIC IT PPA database to store WinCC messages from a logical point of view. Stored data can then be retrieved from the database by configuring a specific filter. Figure 5-14 Historical messages data exchange in runtime V /134

111 Historical Data Engineering in SIMATIC PCS 7 No specific additional engineering has to be done in SIMATIC PCS 7 in order to exchange runtime data to the SIMATIC IT environment Engineering in SIMATIC IT In 4.3 "Online messages via SIMATIC Message Channel" it was explained how to exchange online alarm data from SIMATIC PCS 7 to SIMATIC IT. Another possibility to exchange alarms is based upon the historical alarm archive of SIMATIC PCS 7. In the PPA you can specify with which frequency the PPA has to scan the historical alarm archive of SIMATIC PCS 7 and to update the PPA with the fetched data. This is done by inserting a new message filter as shown below (only the most important steps are shown): Figure 5-15 Configuration of a new message filter The archive type is in this case "Archive". The frequency with which the update of the PPA message archive has to happen is specified in seconds. In our example you assign a value of "60" to the frequency, meaning that the SIMATIC PCS 7 historical message archive will be scanned every minute and accordingly the PPA message archive will be updated. V /134

112 Historical Data Figure 5-16 Configuration of the filter conditions A filter condition has to be provided (in this case you specify again to display all batch relevant messages). V /134

113 Historical Data Figure 5-17 Configuration of the filter conditions It is also possible to rename the header of the columns which will be displayed in the HDD message viewer. Click on the display name which you want to change and rename the field. Figure 5-18 Configuration of the filter conditions V /134

114 Historical Data Visualization and testing of the historical data exchange In HDD you can use the message viewer to see the result of our filter. Using the refresh button you will see only every minute a change in the display since you configured this filter to scan only every minute. Figure 5-19 Display of the configured message filter V /134

115 Appendix 6 Appendix 6.1 Appendix A: installing a PPA database Installation of the SIMATIC IT PPA database In this chapter the complete procedure for the installation of a new PPA database is given. More details can be found in the SIMATIC IT Historian PPA online help. NOTE The directory structure must be created before a new project is created. Under "File > New Project" you can create a new project. In the first step you have to specify in which SQL instance the databases (configuration, online, offline) have to be created. Figure 6-1 Creation of the PPA database, selection of the SQL instance V /134

116 Appendix Figure 6-2 Creation of the PPA database, definition of username and password Figure 6-3 Creation of a new PPA database V /134

117 Appendix We choose to name our database "COLOR". Figure 6-4 Definition of the PPA database name The PPA is consisting of one configuration database, multiple online databases and additionally some offline databases. For each of them a storage location has to be specified. V /134

118 Appendix Figure 6-5 Definition of the storage directory for the configuration database Figure 6-6 Selection of the number of online databases V /134

119 Appendix Figure 6-7 Definition of the storage directory of the online databases Figure 6-8 Definition of the size of the database For the estimation of the required database size, a tool under "Tools > Online DB size estimation can be used. V /134

120 Appendix Figure 6-9 Definition of the computer where the PPA engine runs Figure 6-10 Project type definition SIMATIC BATCH integration and recovery options V /134

121 Appendix Figure 6-11 Creation of a new configuration Figure 6-12 Creation of a new configuration V /134

122 Appendix Figure 6-13 Name of the new configuration Reporting and Archiving In the text below the performance data concerning the batch reports (XML files) created by SIMATIC BATCH are shown. The SIMATIC BATCH Report can process up to 200 MB of data (archive XML). The data amount consists of the following: Size of the Batch process cell Number of running recipe functions/ recipe operations Keep in mind multiple: Sequences in loops Number of recipe parameters Number of trends and the number of measured values per trend Keep in mind the time period of the recordings and the cycle time. V /134

123 Appendix The following optional average amounts of data can be used for an estimate: ca 1.1 MB for 100 recipe functions ca 0.5 MB for 100 recipe parameters ca 0.05 MB for 1 trend with 300 measured values ca 0.1 MB for 1 trend with 600 measured values The following recipe constellations may be critical: When recipe functions run in numerous loops When incorrect cycle times for trend archives are configured in WinCC NOTE You should limit the number of measured values for trends to approx. 1,000 which is enough to maintain a clear overview. The maximum number of measured values per trend is 50, sec. cycle time and 24 hour run time -> 86,400 measured value A recipe with 1500 recipe functions results in archive data amounting to around 30 MB with a run time of about 6 hours. If the recommendations given here are not heeded, in some circumstances the reporting and archiving of the batches may no longer be possible. V /134

124 Appendix 6.2 Appendix B: configuring a SPOSA station in SIMATIC Manager In this appendix you will describe how to create a SPOSA station inside a SIMATIC PCS 7 project/multiproject. Figure 6-14 Insert a SIMATIC PC station at the project level Figure 6-15 Rename the PC station name V /134

125 Appendix Figure 6-16 Open the object properties and check the option Computername identical to PC station name Figure 6-17 Open the configuration of the PC Station V /134

126 Appendix Figure 6-18 Insert by drag and drop a SPOSA Application Figure 6-19 Save the configuration V /134

127 Appendix Figure 6-20 Expand the PC station object Figure 6-21 Open the object properties V /134

128 Appendix Figure 6-22 Object properties -> second TAB Target system Figure 6-23 Map a network drive to the Automation project folder on the Historian machine V /134

129 Appendix Figure 6-24 Result after configuring the target system Figure 6-25 Assign OS server to the SPOSA project V /134

130 Appendix Figure 6-26 Assignment of the OS and Batch project to the SPOSA station Figure 6-27 Download the SPOSA station to the Historian server V /134

131 Appendix Figure 6-28 Result of the download operation V /134

132 Appendix Figure 6-29 Result after downloading on the Historian server V /134