Efficient engineering of interlocking with PCS 7 Logic Matrix

Transcription

1 Application Example 06/2018 Efficient engineering of interlocking with SIMATIC PCS 7 V8.2, V8.2

2 Siemens AG 2018 All rights reserved Warranty and liability Warranty and liability 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 for ensuring that the described products are used correctly. These Application Examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we 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 the contents of the other documents have priority. 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 ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of the Siemens AG. Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a productspecific newsletter. For more information, visit Entry ID: , V1.1, 06/2018 2

3 Siemens AG 2018 All rights reserved Table of contents Table of contents Warranty and liability Task and solution Task Solution Learning objectives Logic Matrix Description of the example project Hardware and software components Basics Logical operations Configuring the Logic Matrix Creating the Logic Matrix Editing the properties of Logic Matrix Configuring the connection of cause/effect to a process tag Direct connection Input and Output tag selection Generating the Matrix CFCs Final configuring work Starting the application Preparation Commissioning Controlling the application Overview Scenario A Response to a closed valve Scenario B Response at reaching the maximum fill level Scenario C Response at reaching the upper alarm limit for the fill level Scenario D - Response at reaching the minimum fill level Scenario E Response at reaching the temperature upper alarm limit in the heating circuit Scenario F Response at reaching the temperature upper alarm limit in the reactor References History Entry ID: , V1.1, 06/2018 3

4 Siemens AG 2018 All rights reserved 1 Task and solution 1.1 Task 1 Task and solution 1.1 Task The basic automation tasks in process automation involve the creation of logic operations. The main tasks of the logic operations are: Permission Protection Interlock Typical interlocking functions include stopping a pump with a closed valve or preventing a mixer from starting if the minimum fill level is not reached. Other reasons for interlocking can be, for example, high temperature or pressure. The typical interlocking functions for a stirred tank reactor should be created. A fundamental requirement is to create the interlocking function in such a way that in case of interlocking, the operator can find and resolve the cause quickly. 1.2 Solution This application example describes the creation and visualization of interlocking using the. It provides step-by-step instructions and an example project of a stirred tank reactor to demonstrate the visualization. Benefits The creation of the interlocking with offers the following benefits: Clear display of interlocking using the Logic Matrix Editor according to the causes and effects principle. Simple modification and optimization of interlocking More efficiency compared to the "standard" interlock at CFC level Integrated alarm messages for status changes of cause and effect Clear representation of interlocking in the OS Runtime Filter options for rapid location of the interlocking cause within the OS Runtime Time and cost savings in engineering and operation Delimitation The following topics are not described in this application example: How to create the PCS 7 project How to install the software components Physical relationships between, for example, temperature and fill level are not taken into account in the simulation Entry ID: , V1.1, 06/2018 4

5 Siemens AG 2018 All rights reserved 1 Task and solution 1.2 Solution Required knowledge Fundamental knowledge of the following specialist fields is a prerequisite: Configuring with SIMATIC PCS 7 Basic knowledge of process technology CFC Good understanding of the type/instance concept of PCS 7 in the form of process tag types / control module types (CMT) Learning objectives This application example includes the following learning objectives: General presentation of the (ch. 2) Configuring the Logic Matrix (ch. 3) Testing the Logic Matrix and knowing its functions (from ch. 4) Logic Matrix PCS 7 Interlock blocks are available for configuring the interlocking. As of PCS 7 V8.2, interlocking can be defined in the form of cause/effect matrices using logic operations, as customary in the process engineering planning. In PCS 7, the Logic Matrix Editor is the tool used for creating and optimizing the interlocking. In this application example, the Logic Matrix is used for the creation of the interlocking functions. It is based on the PCS 7 project of a stirred tank reactor. Entry ID: , V1.1, 06/2018 5

6 Siemens AG 2018 All rights reserved 1 Task and solution 1.3 Description of the example project 1.3 Description of the example project Process picture of the general overview The figure below shows the process picture of the application example: Project structure The following logical operations are realized for the stirred tank reactor: 1. Valves in the inflow close if: alarm limit of fill level is reached temperature in the reactor is too high 2. Reactor agitator is locked if fill level is too low 3. Pumps in the inflow stop if: valves are closed alarm limit of fill level is reached temperature in the reactor is too high 4. Pumps in heating circuit stop if temperature is too high 5. Valve in heating circuit closes if temperature is too high 6. Pumps in the inflow stop if valve is closed The PCS 7 example project contains a stirred tank reactor with the following functions: Agitator Inflow Discharge Temperature control Level measurement Entry ID: , V1.1, 06/2018 6

7 Siemens AG 2018 All rights reserved 1 Task and solution 1.4 Hardware and software components The example project is designed as a multiproject with a separate AS and OS project. In the AS project, the functions are built using control module types (CMTs) from the master data library. The OS project contains the process picture for the operator control and monitoring of the stirred tank reactor. A PH folder (PH: Plant Hierarchy) "R100" has been created for the stirred tank reactor. This contains a further subfolder for each function. These include the instances of the CMTs and a further subfolder with the CFCs for the simulation. 1.4 Hardware and software components Hardware components The application example has been created with the following components: Component SIMATIC PCS 7 ES/OS IPC847D W7 Note For the PCS 7 V8.2 example project Note In case of different hardware, please take heed of the minimum requirements for installing the software components. The minimum requirements can be found in the Readme file of the SIMATIC PCS 7. Software components Component Note SIMATIC PCS 7 V8.2 S7 PLCSIM Part of SIMATIC PCS 7 ES/OS IPC847D W7 The license does not form part of SIMATIC PCS 7 ES/OS IPC847D W7 APL library Part of SIMATIC PCS 7 V8.2 SIMATIC Logic Matrix ES pack SIMATIC Logic Matrix Editor SIMATIC Logic Library SIMATIC Logic Matrix OS pack SIMATIC Logic Viewer Not part of SIMATIC PCS 7 V8.2 Not part of SIMATIC PCS 7 V8.2 Note SIMATIC Logic Matrix Editor: Creating and configuring the Logic Matrix Generation of CFCs in a PCS 7 project SIMATIC Logic Library: Function Blocks for matrix, cause and effect The SIMATIC Logic Matrix Viewer: Visualization Entry ID: , V1.1, 06/2018 7

8 Siemens AG 2018 All rights reserved 1 Task and solution 1.4 Hardware and software components Licensing The following licenses are required: per matrix = 1 PO per cause = 1 PO per effect = 1 PO 1 license per operating station (e.g., OS client) for the Logic Matrix Viewer The currently used POs can be determined in the Matrix settings. Entry ID: , V1.1, 06/2018 8

9 Siemens AG 2018 All rights reserved 2 Basics Basics 2.1 The is a tool for creating and visualizing interlocking with up to 125 causes and up to 125 effects. A cause represents a logical function with up to six inputs (three analog and three digital), whose result is good or bad, and whose effect can be transmitted via so-called nodes (intersections) to effects with one or more outputs. This allows each cause to act on each effect or even on just a part of the effects. Note A detailed description of the concepts and components of the Logic Matrix can be found in chapter 1.3 "Term definitions" of the Equipment Manual "Process Control System ". 2.2 Logical operations This application example contains the process tag instances of the CMTs of the master data library. The connections between the available interlock blocks and the technological blocks or a primary logic have already been applied in the CMTs. The interconnection to the interlock blocks is realized by means of Logic Matrix. The causes for interlocking are displayed in causes and the effects are interconnected, for example, to the interlock blocks. Entry ID: , V1.1, 06/2018 9

10 Siemens AG 2018 All rights reserved Stop Stearing 2 Basics 2.2 Logical operations The figure below describes the mode of operation by means of the interlock of the agitator. Effect Cause Level Low N Intersection Causes Matrix Effects LS103 CM Cause001 In Result Cause002 Result In In In Matrix Effect001 In Result Effect002 In Result NS107 CM CM Cause125 In Result In Effect125 In Result CM An instance of the function block (FB) "LM Cause" is created for each cause. The causes are connected to its inputs. In the example above, it is the process value of the level sensor "LS103". The FB "LM_Cause" processes these values according to the set parameters and passes on the processing result to the FB "LM_Matrix" of the matrix (an instance of the FB "LM_Matrix" is applied to each matrix). The instance of the "LM_Matrix" FB creates the logic operation between cause and effect depending on the configured nodes. The described logic operation example is a non-latching logic operation "N". An instance of the FB "LM_Effect" is created for each effect. This is where the post processing of the nodes (such as Bypass, Delay,etc.) is carried out. The result is interconnected to the process tags. In the above example, it causes the motor of the agitator (NS107) to lock at low level (LS103). Entry ID: , V1.1, 06/

11 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 2.2 Logical operations 3 Configuring the Logic Matrix The following section describes the work steps for the Logic Matrix Editor by means of a stirred tank reactor example. It discusses different terms and options, and refers to the corresponding manual entries with detailed descriptions. Note The matrix described in the demo project has already been created and fully configured. The following section describes the configuration procedure. In order to carry out the described configuration steps, first you have to retrieve the example project on your Engineering System. To do this, follow the instructions in chapter. 4.1 "Preparation". Then remove the existing Logic Matrix as described below: 1. Right click on "Reactor_MP > Reactor_AS > AS410 > CPU 410-5H > S7 Program > Logic Matrix" and select the menu command "Delete". 2. In the dialog that opens, click the "Yes" button. The Logic Matrix Editor opens. 3. Click the "Yes" button in the Dialog "Matrix LM_R100 delete". The Logic Matrix and all associated data is deleted. 4. Confirm "Matrix LM_R100 deleted" by clicking on "OK". 5. Close the Logic Matrix Editor. 6. Open any CFC and compile the AS program (in the CFC editor) 7. Then compile the OS. Requirement Recommendation For configuring with Logic Matrix, it is required to have first created the project structure in SIMATIC Manager. For efficient engineering with the Logic Matrix Editor, you should use a type instance concept with the master data library. The Logic Matrix works with the CFC types (process tag type and CMTs) of the master data library. These should be already created before the Logic Matrix is configured. Entry ID: , V1.1, 06/

12 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.1 Creating the Logic Matrix 3.1 Creating the Logic Matrix Creation The Logic Matrix is created in the program folder of the AS. Then, the Logic Matrix can be renamed. In this example project: in "LM_R100". Procedure 1. Open the multiproject in the "Component view". 2. Right-click the S7 program in the AS project. 3. Select the menu item "Insert New Object > Logic Matrix". A new folder "Logic Matrices" is created with the Logic Matrix inside the S7 program folder. 4. Rename it (in the example project: LM_R100). 3.2 Editing the properties of Logic Matrix General procedure After the Logic Matrix has been created, the general properties are saved. 1. Double-click on the LM to open it. 2. Select the menu command "Edit > Read project data". The command "Read project data" reads the current information from the PCS 7 project that contains the Logic Matrix (e.g. process tag types and control module types from the master data library). 3. Select the menu command "Edit > Properties". 4. Go to the "Plant hierarchy" field in the "General" tab and select the hierarchy folder where you want to generate the Matrix CFC. 5. In the "Matrix cycle time" field, select the cyclic interrupt OB in which the Matrix CFC is to be integrated. Entry ID: , V1.1, 06/

13 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.2 Editing the properties of Logic Matrix 6. In the "Intersection DB" field, select the DB where Logix Matrix stores the information. 7. Adjust the other properties according to your project requirements. Note A detailed description of the properties and settings can be found in chapter 5.3 "Editing the properties of Logic Matrix" of the Equipment Manual "Process Control System PCS 7 Logic Matrix". Settings in the example project The following adjustments/settings were done in this example project: General tab: Plant hierarchy: "Plant\R100" Matrix cycle time: "OB32: 1s" Intersection DB: "DB1" Title: "Logic Matrix R100" Alarms tab: Cause field: Message if "Tag simulated" has been deactivated (since all tags in this example project are simulated) Note Messages for causes, effects and the matrix can be configured globally in the Matrix properties and for individual causes and effects, if needed. General tab: Entry ID: , V1.1, 06/

14 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag Alarms tab: 3.3 Configuring the connection of cause/effect to a process tag There are two options for the connection between cause/effect and a process tag in the AS program: Direct connection for cause or effect Input tag selection (cause), Output tag selection (effect) Type/instance concept Both options are described in the following section by means of interlocks for the example project Direct connection Requirement Process tags must be created in advance if they are to be directly connected to a cause or an effect. Causes and effects as an example The level sensor "LS 102" stops and closes the following pumps and valves in the inflow when the maximum fill level is reached: Pumps: NS101, NS102 and NS103 Valves: YS101, YS102 and YS103 Cause Effect LS102 active YS101, YS102 and YS103 close, NS101, NS102, NS103 stop Entry ID: , V1.1, 06/

15 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag Procedure as an example 1. Open the Logic Matrix in the Logic Matrix Editor. 2. Go to the "Input-Tag" column, right click in the first row and select "Direct connection...". The window "Select direct link" is displayed. 3. Select the Input Tag "LS102\S.Out" and then click on "Select". The cause is created as a direct connection. The "Cause details" (1) button allows you to adjust Cause-specific settings Go to the "Output-Tag" column, right click in the first row and select "Direct connection...". The window "Select direct link" is displayed. 5. Select the Output-Tag "NS101\Intlock.In01" and then click on "Select". 6. Right click on the effect you have just edited and select "Add Output-Tag". A further Output-Tag is added for the effect. 7. Right click on this Output-Tag and select "Direct connection". 8. Select the Output-Tag "YS101\Intlock.In1" and then click on "Select". Entry ID: , V1.1, 06/

16 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 9. Repeat steps 4 to 8 for the Output-Tags: NS102\Intlock.In01 NS103\Intlock.In01 YS102\Intlock.In1 YS103\Intlock.In1 You have now created the direct connections for the effect. 10. Click the "effect details" symbol. This opens the "Effect details" window. 11. In the mode field, enter "Deenergized to trip" and then click on "OK". Entry ID: , V1.1, 06/

17 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 12. At the intersection of the created cause and effect, enter "N" for a non-latching logical operation. Note N non-latching means that the logical operation is a simple transition function. If the cause is active, the effect is tripped. You can find detailed information about the intersections in chapter 5.7 "Configuring the intersections" of the the Equipment Manual "Process Control System PCS 7 Logic Matrix". You have now created the first cause and effect by means of direct connections Input and Output tag selection Requirements Process tags must be created in advance if they are to be directly connected to an Input or Output tag. Process tags are instances of CFC types (process tag types and control module types) Cause and effect links are created Entry ID: , V1.1, 06/

18 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag Causes and effects for Example 1 The valves "YS101", "YS102", "YS103" and "YS104" stop, and the pumps "NS101", "NS102", "NS103" and "NS106" lock if they are closed. Cause Effect YS101 closed YS102 closed YS103 closed YS104 closed NS101 is stopped and locked NS102 is stopped and locked NS103 is stopped and locked NS106 is stopped and locked Procedure for Example 1 Before you can start configuring the Input and Output tags, you have to create the cause and effect links. The following section shows you how to create the digital Input link and output link that are both required. Note A detailed description of the links and the Link Editor can be found in chapter 5.6 "Configuring the links" of the Equipment Manual "Process Control System PCS 7 - Logic Matrix". 1. Open the Logic Matrix "R100" with the Logic Matrix Editor. 2. Select the menu command "Edit > Links ". The "Cause links" tab opens in the Link Editor. Note Remove any links that may be present. To do this, select link after link and click on the "Delete link" button. 3. Select "Link1". 4. Enter "VALFbkClosed" in the "Name" field (1). 5. Enter "Valve closed" in the "OS displayed Name" field (1). 6. Select the "Tag type" option (2) in the "Scope" area. 7. Select the following process tag types in the dropdown menu (2): VAL Std VAL_An_AfbSplitSlave 8. In the "Connection" area, select the "V" block and the "FbkCloseOut" connection for the "Dig*" connection (3). Entry ID: , V1.1, 06/

19 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 9. Click on "Commit" Switch to the Effect Links tab. 11. Select "link2". 12. Enter "MOTORIntlok" in the "Name" field (1). 13. Enter "interlock Motor" in the "OS displayed Name" field (1). 14. Select the "Tag type" option (2) in the "Scope" area. 15. Select "MOT_1sp_1fb_1cm Std" as the process tag type (2). 16. In the "Connections" area for the "Out*" connection, select the block "Intlock" and the connector "In01" (3). 17. Click on the "Alternative link" button. A further connection is added. 18. For this connection, select the block "Intlock" and connector "In02". Entry ID: , V1.1, 06/

20 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 19. Click the "Commit" button and then on "Close" After creating the links, you can configure the Input and Output tags. 1. Right click on the second cause in the "Input-Tag" column and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 2. Select the tag "YS101" and then click on "Select" 3. Right click on the second effect in the "Output-Tag" row and select "Select Output-Tag...". The "Output-Tag Selection" window is displayed. Entry ID: , V1.1, 06/

21 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 4. Select the tag "NS101" and then click on "Select". 5. At the intersection of the created cause and effect, enter "N" for a non-latching logical operation. 6. Repeat steps 1 to 5 for the tags "YS102" and "NS102", "YS103" and "NS103" as well as "YS104" and "NS106". The causes, effects and logic operations for Example 1 have now been created. Causes and effects for Example 2 The level sensor "LS103" stops and the drive of the agitator "NS107" locks. Cause Effect LS103 active NS107 is stopped and locked Procedure, Example 2 Besides the Output tag for the drive, which you have already created in Example 1, to stop and lock the agitator you also require an Input tag for the digital monitoring of process tag "LS103". 1. Open the Logic Matrix "R100" with the Logic Matrix Editor. 2. Select the menu command "Edit > Links ". The "Cause links" tab opens in the Link Editor. 3. Click the "New link" button. A new link called "Link1" is added. 4. Select this link. 5. Enter "DOMON" in the "Name" field. 6. Enter "Digital Monitoring" in the "Displayed name" field. 7. Select the "Tag type" option in the "Scope" area. 8. Select "DMON Std" as the process tag type. 9. In the Connection area, enter the values shown in the following figure. Entry ID: , V1.1, 06/

22 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 10. Click on "Commit" and then on "Close". After creating the digital link "DMON", you can then configure the cause and effect for Example Right click on the sixth cause in the "Input-Tag" column and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 2. Select the tag "LS103" in the "Input-Tag selection" window and then click on "Select". 3. Right click on the sixth effect in the "Output-Tag" row and select "Select Output-Tag...". The "Output-Tag Selection" window is displayed. 4. In the "Output-Tag selection" window, select the tag "NS107". 5. At the intersection of the created cause and effect, enter "V" for an overridable logical operation. Note V - overridable means that the tripping of the effect can be overridden. If the cause is active, the effect is tripped and can be overridden as long as the cause is active. Either by means of a manual intervention or by setting a configured tag. If the cause becomes active again, even the effect is reactivated. You can find detailed information about the intersections in chapter 5.7 "Configuring the intersections" of the the Equipment Manual "Process Control System PCS 7 Logic Matrix". Cause, effect and logical operation for Example 2 have now been created. Causes and effects for Example 3 The level sensor "LS 101" (analog) stops, closes and locks the pumps and valves in the inflow, and locks them as soon as the set upper alarm limit is exceeded. If the lower alarm limit is underranged, the drive of agitator "NS107" is stopped and locked. Cause LS101 Alarm High active (extension of the cause from ch ) LS101 Alarm Low active (expansion of the cause from Example 2) Effect YS101, YS102 and YS103 close and lock, NS101, NS102, NS103 stop and lock NS107 is stopped and locked Entry ID: , V1.1, 06/

23 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag Procedure, Example 3 An analog cause link must be created for Example Open the Logic Matrix "R100" with the Logic Matrix Editor. 2. Select the menu command "Edit > Links ". The "Cause links" tab opens in the Link Editor. 3. Click the "New link" button. A new link called "Link 1" is shown. 4. Select this link. 5. In the "General" area, select the "Analog link" option. 6. Enter "AMONhigh" in the "Name" field. 7. Enter "Analog Monitoring" in the "Displayed name" field. 8. Select the "Tag type" option in the "Scope" area. 9. Select "AMON Std" as the process tag type. 10. In the Connection area, enter the values shown in the following figure. 11. Click on "Commit" and then on "Close". After creating the analog link, you can configure the cause. The Example 2 is an expansion of cause Right click on the first cause in the "Input-Tag" column and select "Add Cause Input". A new cause Input is added for the first cause. 13. Right click on this cause Input and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 14. Select the tag "LI101" in the "Input-Tag selection" window and then click on "Select". Entry ID: , V1.1, 06/

24 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 15. Click the "Cause Details" symbol of cause 1. The "Cause 1 Details" window is displayed. 16. Switch to the "Analog parameter" tab and apply the settings shown in the following figure. Then click "OK". The cause 1 for Example 3 has now been extended. Causes and effects for Example 4 The temperature sensors "TI111", "TI112" and "TI113" stop, close and lock pump "NS104" and valve "YC131" as soon as the upper alarm limit has been exceeded at two or three sensors. Cause 2oo3 TI111, TI12 or TI113 Alarm High active Effect YC131 close and lock, NS104 stop and close Procedure, Example 4 All the links required for the logical operation of Example 4 have already been created in the previous examples. Only the corresponding cause and the corresponding effect together with the logical operation must be configured. 1. Right click on the seventh cause in the "Input-Tag" column and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 2. Select the tag "TI111" and then click on "Select". 3. Right click on the seventh cause in the "Input-Tag" column and select "Add Cause Input". A new cause Input is added for the seventh cause. 4. Right click on this cause Input and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 5. Select the tag "TI112" and then click on "Select". Entry ID: , V1.1, 06/

25 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag 6. Repeat steps 3 to 5 for the tag "TI113". 7. Click the "Cause Details" symbol of cause 7. The "Cause 7 Details" window is displayed. 8. Enter the following settings in the "Configuration" tab" Function type: "2oo3" Deviation limit: "Deviation limit monitoring enabled", Limit = 2.0 Features: "Cause becomes active if deviation is violated" Note The cause is activated by means of two evaluations: At least two of the three input tags exceed the upper alarm limits (2oo3). Two of the three input tags deviate above the deviation limit from the mean value (2oo3). 9. Right click on the seventh effect in the "Output-Tag" row and select "Select Output-Tag...". The "Output-Tag Selection" window is displayed. 10. Select the tag "NS104" and then click on "Select". 11. Right click on the seventh effect in the "Output-Tag" row and select "Add Effect Output". A new effect Output is added for the seventh effect. 12. Right click on this effect output and select "Select Output-Tag...". The "Output-Tag Selection" window is displayed. 13. Select the tag "YC131" and then click on "Select". 14. At the intersection of the created cause and effect, enter "S" for latching logical operation. Entry ID: , V1.1, 06/

26 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag Note S latching means that if the cause is active, the effect is tripped. The effect remains active even if the cause is no longer active and has to be reset by the operator or by configuring a Reset tag. You can find detailed information about the intersections in chapter 5.7 "Configuring the intersections" of the the Equipment Manual "Process Control System PCS 7 Logic Matrix". Cause, effect and logical operation for Example 4 have now been created. Causes and effects for Example 5 The temperature sensors "TI121", "TI122" and "TI123" stop, close and lock the pumps and valves in the inflow as soon as the upper alarm limits have been exceeded. A separate cause is created for each sensor. The cause for "TI121" acts directly on the effect. The causes of "TI122" and "TI123" work according to the majority principle. Cause TI121 Alarm High active TI122 Alarm High active (acc. to the majority principle) TI123 Alarm High active (acc. to the majority principle) Effect YS101, YS102 and YS103 close and lock, NS101, NS102, NS103 stop and lock Procedure, Example 5 A cause is created for each of the temperature sensors "TI121", "TI122" and "TI123". "TI121" acts directly on the effect 1 (already created). "TI122" and "TI123" act on the effect according to the majority principle. All necessary links have already been created in the previous examples. 1. Right click on the eight cause in the "Input-Tag" column and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 2. Select the tag "TI121" and then click on "Select". 3. In the intersection between cause 8 and effect 1 enter "N" for a non-latching logical operation. 4. Right click on the ninth cause in the "Input-Tag" column and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 5. Select the tag "TI122" and then click on "Select". 6. In the intersection between cause 9 and effect 1 enter "2 N" for a non-latching logical operation according to the majority principle. 7. Right click on the tenth cause in the "Input-Tag" column and select "Select Input-Tag...". This opens the "Input-Tag Selection" window. 8. Select the tag "TI123" and then click on "Select". 9. In the intersection between cause 10 and effect 1 enter "2 N" for a non-latching logical operation according to the majority principle. Entry ID: , V1.1, 06/

27 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.3 Configuring the connection of cause/effect to a process tag Note XooN (e.g. 2 N) causes are allocated according to the majority principle. X is entered by the User. N is the number of intersections with X as coefficient (X N). The effect is active if N of X causes are active. You can find detailed information about the intersections in chapter 5.7 "Configuring the intersections" of the the Equipment Manual "Process Control System PCS 7 Logic Matrix". Causes and logical operation for Example 5 have now been created. The figure below shows the ready configured Logic Matrix for the "R100" reactor. Entry ID: , V1.1, 06/

28 Siemens AG 2018 All rights reserved 3 Configuring the Logic Matrix 3.4 Generating the Matrix CFCs 3.4 Generating the Matrix CFCs Once you have configured the links, causes, effects and intersections, you can generate the Matrix CFC. Note A detailed description for the generation of Matrix CFCs can be found in chapter 6 "Transferring the Logic Matrix" of the the Equipment Manual "Process Control System PCS 7 Logic Matrix". Procedure 1. Select the menu command "Generation > Generate CFC". The "Matrix generation" window is displayed. 2. Check the settings. 3. Click the "OK" button. The Matrix CFC is generated. 4. Check if the generation was error-free from the "Generation Log" window. 5. Click the "Close" button. 6. Close the Logic Matrix. 3.5 Final configuring work After creating the Logic Matrix and generating the Matrix CFC chart was, you have to compile the AS program and the OS. Entry ID: , V1.1, 06/

29 Siemens AG 2018 All rights reserved 4 Starting the application 4.1 Preparation 4 Starting the application 4.1 Preparation 1. Copy the file " _LMReac_PROJECT_PCS7_V82.zip" into any folder on the configuration PC. 2. Open the SIMATIC Manager. 3. Click on "File > Retrieve" in the menu bar and select the file " _LMReac_PROJECT_PCS7_V82.zip". Then confirm with "Open". 4. Select the folder in which the project should be saved and confirm by pressing "OK". The project is retrieved. Once this is done, click "Yes" in the dialog to open the project. 5. Right click on "Reactor_MP > Reactor_OS > PCSESOS8201 > WinCC Appl. > OS" and select the menu command "Open object". WinCC Explorer opens. 6. Confirm the "Configured server not available" dialog with "OK". 7. In the WinCC Explorer, open the properties of your PC and, in the opened Properties dialog, click on the "Use local computer name" button. 8. Confirm the "Change computer name" message with "OK". 9. In the WinCC Explorer, click on "File > Exit" and in the subsequent dialog select "Terminate WinCC Explorer and close project". 10. Then confirm with "OK". 11. Open the WinCC Explorer. 12. Double-click on "Tag management" to open it. 13. In the "WinCC Configuration Studio", right-click on "Tag management > SIMATIC S7 Protocol Suite > TCP/IP" and select the menu command "System parameters". 14. In the "Unit" tab, check the "Logical device names" setting. If the "S7 PLCSIM" program is used, the device name "PLCSIM.TCPIP.1" is selected. If the device name is changed, the program must be restarted. 15. Restart the WinCC Explorer. Note If the OS cannot establish a connection with the AS (grayed out faceplates), select the logical device name "CP_H1_1:" and restart the OS. Entry ID: , V1.1, 06/

30 Siemens AG 2018 All rights reserved 4 Starting the application 4.2 Commissioning 4.2 Commissioning The following instructions describe how the application is initialized. For commissioning, SIMATIC Manager must be already open and the project must be selected in the component view. Starting the simulation (S7 PLCSIM) To start the simulation, proceed according to the following instructions: 1. Open S7 PLCSIM. 2. Click on "Simulation > Open target system" in the menu bar. 3. Select the file "AS410.plc" from the path "<Project path>\reactor_\reac_prj\as410.plc". 4. In the menu, select "Execute > key switch position > RUN-P". Activate OS (WinCC runtime) To activate the OS, proceed according to the following instructions: 1. Right click on "Reactor_MP > Reactor_OS > PCSESOS8201 > WinCC Appl. > OS" and select the menu command "Open object". WinCC Explorer opens. 2. To activate the OS (WinCC Runtime), select "File > Activate" in the WinCC Explorer menu. 3. In the "System Login" dialog, enter the user "Unit" and "Template" as the password; confirm with "OK". 4. In the area of the Unit Template, select "R100". Note The plant is already in the production state because the AS program execution (SIMATIC PLCSIM) has already started. Entry ID: , V1.1, 06/

31 Siemens AG 2018 All rights reserved 5 Controlling the application 5.1 Overview 5 Controlling the application 5.1 Overview Some of the reactor's components can be operated and monitored by means of the process picture "R100". The following scenarios relate to the examples in ch. 3. The focus is on the functions and the operation of the Logic Matrix: Response to closed valve behind a pump Response at reaching the maximum fill level (LS102) Response at reaching the upper alarm limit for the fill level (LI101) Response at reaching the minimum fill level (LS103) Response at reaching the temperature upper alarm limit in the heating circuit (TI111, TI112 and TI113) Response at reaching the temperature upper alarm limit in the reactor (TI121, TI122 and TI123) Note A detailed description of the block icons and faceplates of the Logic Matrix can be found in chapter 7 "Operator control and monitoring" of the Equipment Manual "Process Control System ". 5.2 Scenario A Response to a closed valve This application example provides a variety motor interlocks. After putting the OS and the AS in runtime, the 4 effects are already active due to the closed valves. Entry ID: , V1.1, 06/

32 Siemens AG 2018 All rights reserved 5 Controlling the application 5.2 Scenario A Response to a closed valve The following procedure describes how to comfortably remedy to the pumps interlocking by means of the Logic Matrix Viewer. 1. Open the process picture "R100". 2. Click on the block icon of Logic Matrix. The Logic Matrix Viewer opens. 3. Click on the filter symbol. 4. Set "Link = Valve Closed" as a filter and click then click on "Set". You will only be shown the causes with the "Valve Closed" link. 5. Click on the "magnifying glass" in the Input tag row "YS101". The faceplate for cause 2 (C002) is displayed. Entry ID: , V1.1, 06/

33 Siemens AG 2018 All rights reserved 5 Controlling the application 5.3 Scenario B Response at reaching the maximum fill level 6. Click on the symbol to call up the faceplate of valve "YS101". The faceplate is displayed. 7. Open valve "YS101". Cause 2 and effect 2 are deactivated and "NS101" is unlocked. 8. Repeat steps 5 to 7 for the additional active causes of the "Valve closed" links. 9. Click on the block icon of pump "NS101". The faceplate is displayed. 10. Start the pump. 11. Click on the block icon of pump "YS101". The faceplate is displayed. 12. Close valve "YS101". Cause 2 becomes active and activates effect 2. Pump "NS101" is stopped and locked. 5.3 Scenario B Response at reaching the maximum fill level If the maximum fill level in the reactor is reached, the valves in the inflow are closed and locked. The pumps are stopped and locked. 1. Start by activating the pumps in the inflow in order to reach the maximum fill level. 2. Open the Logic Matrix Viewer. 3. Set "Status = active" as a filter. You will now see the active causes. Cause 1 is active. Causes 2 to 4 are active as a result of cause 1. To resolve the cause for the activation of cause 1, the fill level must be lowered again. 4. Start pump "NS106". 5. Stop pump "NS106" after the maximum fill level is undershot again. Cause 1 and effect 1 become inactive, as the "Maximum level" cause is no longer active. The causes 2 to 4 and the effects 2 to 4 are still active, because the valves have not been reopened. 6. Open the valves "YS101", "YS102" and "YS103" to deactivate all causes and effects. Entry ID: , V1.1, 06/

34 Siemens AG 2018 All rights reserved 5 Controlling the application 5.4 Scenario C Response at reaching the upper alarm limit for the fill level. 5.4 Scenario C Response at reaching the upper alarm limit for the fill level. The alarm limit for the upper fill level was configured to 495 liters in chapter 3. This value can be changed by the operator. Note The logged in operator must have the appropriate authorization to change the limits. Detailed information on the operator authorization of Logic Matrix can be found in chapter "OS Connection" of the Equipment Manual "Process Control System ". 1. Open the Logic Matrix Viewer. 2. Open the faceplate of cause 1. Cause 1 is a OR logic operation of "LS102" and "LI101". In the faceplate, you can identify the current fill level. 3. Switch to the Limit View of cause Move the limit below the current fill level. Cause 1 is active due to violation of the above alarm limit. 5. Set the limit back to its original value. 6. Open the valves in the review in order to deactivate causes 2-4. Entry ID: , V1.1, 06/

35 Siemens AG 2018 All rights reserved 5 Controlling the application 5.5 Scenario D - Response at reaching the minimum fill level 5.5 Scenario D - Response at reaching the minimum fill level A minimum fill level is required to operate the agitator. If this is undershot, the agitator is stopped and locked. 1. Start the agitator NS Start pump "NS106" (open valve YS104 if "NS106" is locked). 3. Open the Logic Matrix Viewer and set filter according to active causes. 4. Cause 6 and effect 6 become active as soon as your tank is empty (LS103 active). The agitator is stopped. 5. Click on the magnifying glass symbol of effect 6. The faceplate of effect 6 is displayed. The intersection between cause 6 and effect 6 was configured as "overridable" ("V"). 6. Click on "Override". 7. Click on "Set". Entry ID: , V1.1, 06/

36 Siemens AG 2018 All rights reserved 5 Controlling the application 5.5 Scenario D - Response at reaching the minimum fill level 8. Click on "OK". The effect is overridden. The agitator is unlocked. The agitator can be started. 9. Start the agitator. 10. Open the faceplate of "LS103". 11. Switch to the Parameter view and activate the simulation. 12. Switch back to Standard view. 13. Set the process value to "Disabled". Cause 6 and effect 6 are no longer active. The override function has been cancelled. 14. Set the process value to "Active". Cause 6 and effect 6 are reactivated. The agitator is stopped and locked. 15. Open the faceplate of effect 6 and activate the Bypass. The agitator is unlocked. The agitator can be started. 16. Start the agitator. 17. Set the process value in the faceplate of "LS103" to "disabled". Cause 6 and effect 6 become disabled. The Bypass remains active. 18. Set the process value in the faceplate of "LS103" to "active". Cause 6 and effect 6 become active. The agitator is not stopped and locked because the Bypass remains active. For the effect to take effect, you have to reset the Bypass. Entry ID: , V1.1, 06/

37 Siemens AG 2018 All rights reserved 5 Controlling the application 5.6 Scenario E Response at reaching the temperature upper alarm limit in the heating circuit 5.6 Scenario E Response at reaching the temperature upper alarm limit in the heating circuit If the temperature of the heating circuit exceeds the upper limit, pump "NS104" is stopped and locked and valve "YC131" is closed and locked. 1. Open valve "YC131". 2. Start pump "NS104". The temperature in the heating circuit continues to rise until the alarm limit on two of the three sensors is exceeded (2oo3). Cause 7 and effect 7 become active. When the pump is stopped and the valve is closed, the temperature drops again below the limit. The effect remains active because the logical operation has been configured to "latching" ("S") and must be reset. 3. Open the Logic Matrix Viewer. 4. Set the filter "Status = Active" for the effects. 5. Click the "Reset symbol" in effect 7. "YC131" and "NS104" are unlocked. Besides monitoring the upper limit, the analog values of cause 7 are compared to each other to identify any deviation. If the deviation on two of the three sensors is too high, cause 7 becomes active. 6. Open the faceplate of "TI112". 7. Activate the simulation. 8. Set the process value to 23 C. 9. Repeat steps 6 to 8 for the process tag "TI123". Set the process value to 18 C. The cause and effect are reactivated. Entry ID: , V1.1, 06/

38 Siemens AG 2018 All rights reserved 5 Controlling the application 5.7 Scenario F Response at reaching the temperature upper alarm limit in the reactor 5.7 Scenario F Response at reaching the temperature upper alarm limit in the reactor The temperature in the reactor is monitored by the sensors "TI121", "TI122" and "TI123". A cause is created for each sensor. All causes act on effect 1. Cause 8 (TI121) acts directly non-latching on effect 1. Cause 9 and 10 act nonlatching on effect 1 according to the majority principle. 1. Open the valves in the inflow and outflow. 2. Start the pumps in the inflow and outflow. The level in the reactor remains constant. 3. Open the Logic Matrix Viewer. 4. Filter according to causes 8 to 10 (Number = 8, Number = 9, Number = 10) 5. Open the cause details of cause Change the upper alarm limit to 19 C. Cause 9 becomes active. Effect 1 remains inactive. 7. Repeat steps 5 and 6 for cause 10. Cause 10 becomes active. Effect 1 also activated because cause 9 is also active. 8. Restore the starting position. 9. Repeat steps 5 and 6 for cause 8. Cause 8 becomes active. Effect 1 also becomes active because cause 8 acts directly on effect 1. Entry ID: , V1.1, 06/

39 Siemens AG 2018 All rights reserved 6 References 6 References Table 6-1 Topic \1\ Siemens Industry Online Support \2\ \3\ SIMATIC Process Control System PCS 7 Readme V8.2 (online) \4\ Configuration manual SIMATIC Process Control System 7 History Table 7-1 Version Date Change V1.0 05/2016 First edition V1.1 06/2018 Update of a screenshot Entry ID: , V1.1, 06/