03-03-14 Functionality BRAUMAT Classic

SIEMENS
BRAUMAT Classic

Short Description
Functionality

Author: Siemens AG, A&D CC F&B, Erlangen, Germany
Siemens AG, A&D AS PA PM, Karlsruhe, Germany
Datum: 14.03.03

Author:
Name Department City Phone Email

Guenther Fischer A&D CC F&B Erlangen +49(9131) 98-1548 fischer.guenther@siemens.com
Karlheinz Ntscher A&D AS PA PM Karlsruhe +49(9131) 98-1608 karlheinz.noetscher@siemens.com

BRAUMAT Classic 1 / 52 Automation and Drives
Control System Siemens A&D CC F&B / Germany
03-03-14_Functionality_BRAUMAT_Classic.doc 14/03/03
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Table of Contents

1 INTRODUCTION TO BRAUMAT ............................................................................................................ 5
1.1 GENERAL ................................................................................................................................................. 5
2 HIERARCHY................................................................................................................................................ 6
2.1 AUTOMATION HIERARCHY....................................................................................................................... 6
3 ARCHITECTURE HARDWARE............................................................................................................... 7
3.1 SYSTEM ARCHITECTURE.......................................................................................................................... 7
4 ARCHITECTURE SOFTWARE ................................................................................................................ 8
5 PROCESS DISPLAYS.................................................................................................................................. 9
6 SYSTEM MODULE ICM.......................................................................................................................... 10
6.1 MODULES .............................................................................................................................................. 10
6.1.1 System Module .............................................................................................................................. 10
7 SYSTEM MODULE CONTROLLER...................................................................................................... 11
7.1 MODULES .............................................................................................................................................. 11
7.1.1 System Module .............................................................................................................................. 11
8 PROCESS DISPLAYS................................................................................................................................ 12
8.1 MODULES .............................................................................................................................................. 12
8.1.1 System Module .............................................................................................................................. 12
9 TOOLS......................................................................................................................................................... 13
9.1 MODULES .............................................................................................................................................. 13
9.1.1 System Module .............................................................................................................................. 13
10 ORDER SYSTEM................................................................................................................................... 14
10.1 MODULES .............................................................................................................................................. 14
10.1.1 Technology Modules ..................................................................................................................... 14
11 RECIPE SYSTEM.................................................................................................................................. 15
11.1 MODULES .............................................................................................................................................. 15
12 OPTIONS TO BRAUMAT .................................................................................................................... 17
12.1 MODULES .............................................................................................................................................. 17
13 EVENT AND TROUBLE SHOOTING................................................................................................ 18
13.1 MODULES .............................................................................................................................................. 18
14 STEP LOGS............................................................................................................................................. 19
14.1 MODULES .............................................................................................................................................. 19
15 MAINTENANCE.................................................................................................................................... 20
15.1 MODULES .............................................................................................................................................. 20
16 TRENDING............................................................................................................................................. 21
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16.1 MODULES .............................................................................................................................................. 21
17 SYSTEM CONFIGURATION............................................................................................................... 22
17.1 CONFIGURATION.................................................................................................................................... 22
18 COMMON FUNCTIONS....................................................................................................................... 23
18.1 FUNCTION RELATED MAIN MENU ......................................................................................................... 23
18.2 LOOP-IN ALARM.................................................................................................................................... 24
18.3 ADDITIONAL ATTRIBUTES TO BRAUMAT OBJECTS............................................................................. 24
18.4 GRAPHICAL SOURCE VIEW .................................................................................................................... 25
18.5 ADDITIONAL INTERVENTION AND CHANGE LOGS.................................................................................. 26
18.5.1 Open change log ........................................................................................................................... 26
18.5.2 Change log view............................................................................................................................ 26
18.6 ENTITIES / DEVICE MODES .................................................................................................................... 27
18.6.1 Entity Groups ................................................................................................................................ 27
18.6.2 Additional ICM Mode Description................................................................................................ 27
18.6.3 Group and Individual Device Modes ............................................................................................ 27
19 ENGINEERING...................................................................................................................................... 29
19.1 PLANT DIGITALS.................................................................................................................................... 29
19.1.1 Trending tab.................................................................................................................................. 29
19.1.2 Parameter tab................................................................................................................................ 30
20 VISUALIZATION.................................................................................................................................. 31
20.1 PROCESS IMAGES ................................................................................................................................... 31
20.1.1 Real Values in Process Images ..................................................................................................... 31
20.1.2 Dynamic Application Call ............................................................................................................. 31
20.1.3 Faceplates ..................................................................................................................................... 31
20.1.3.1 Plant ICM Faceplate.............................................................................................................................. 31
20.1.3.2 Plant Analog Faceplates (analog input)................................................................................................. 33
20.1.3.3 Plant Analog Faceplates (analog output)............................................................................................... 34
20.1.3.4 PID Controller Faceplate....................................................................................................................... 35
20.1.3.5 Message Faceplate ................................................................................................................................ 36
20.1.3.6 Status-byte Faceplate ............................................................................................................................ 36
20.1.3.7 Entity Faceplate..................................................................................................................................... 36
20.1.3.8 Unit Control Faceplate .......................................................................................................................... 37
20.1.4 Indirect Addressing of Faceplates................................................................................................. 39
20.1.5 Tags in Process Images................................................................................................................. 39
20.1.6 Image Variable View..................................................................................................................... 40
20.2 TAG SEARCH TOOL (GLOBAL VARIABLE SEARCH) ................................................................................ 41
20.3 PROCESS IMAGE EDITOR........................................................................................................................ 42
20.3.1 General.......................................................................................................................................... 42
20.3.2 File - Menu.................................................................................................................................... 42
20.3.3 Edit Menu...................................................................................................................................... 42
20.3.4 Resources - Menu.......................................................................................................................... 42
20.3.5 Variable - Menu ............................................................................................................................ 43
20.3.6 Tools - Menu ................................................................................................................................. 43
20.3.7 Align and Distribute Variables...................................................................................................... 43
20.3.8 Copy Variables.............................................................................................................................. 44
21 RECIPE SYSTEM.................................................................................................................................. 45
21.1 RECIPE HIERARCHY................................................................................................................................ 45
21.1.1 Area............................................................................................................................................... 45
21.2 RECIPE CATEGORY................................................................................................................................. 45
21.3 MASTER RECIPE..................................................................................................................................... 45
21.4 SEQUENCE OVERVIEW........................................................................................................................... 47
21.5 STREAMS ............................................................................................................................................... 48
21.5.1 Open an Order List ....................................................................................................................... 49
21.5.2 Create a new order........................................................................................................................ 49
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21.5.3 Release Batch................................................................................................................................ 50
21.5.4 Change a stream for a given batch ............................................................................................... 51
21.6 VESSEL Q_ING....................................................................................................................................... 52
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1 Introduction to BRAUMAT Classic

1.1 General

BRAUMAT is a powerful process
management and information
system for breweries. It is optimized
for automation and supervision of
processes in the batch processing
industry. It was developed by
BRAUMAT PCU (Process Control
Unit) for the process control level
and BRAUMAT IOS (Information and
Operation System) for process
management. The system
guarantees operational reliability as
well as the protection of your
investment.

Operational reliability

Back-up strategy (recipes, archives, reports, configuration data... are stored redundantly on
two IOSes)
Log function
Extensive on-line help system
Password (levels 2 ... 255)
Presentation close to reality via a high graphical resolution (1024 x 768 pixel)
Process-oriented

Protection of your investment

Worldwide deployment of BRAUMAT systems
Adaptable system scope
Network-able, distributed system, possibility of modular expansion
Use of international standard hardware (Intel-PC, TCP/IP, SIMATIC)
Open system (Windows NT)
User-friendly recipe generation according to ANSI/ISA-S88.01 standard
Modern user interface (Windows Standard)
Integration of Windows
TM
applications ( WORD, EXCEL, ACCESS, )
Use of all standard graphics tools (Corel DRAW, DESIGNER, )
Networking via TCP/IP and SIMATIC NET - Industrial Ethernet - H1
Development and transfer to SIMATIC S7 and the use of standard function blocks of S7 library
Combination of SIMATIC S5 and SIMATIC S7 in one installation
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2 Hierarchy

2.1 Automation Hierarchy

A Company has to handle diverse tasks of automation and organization. For these different tasks,
integrated systems are used. The automation hierarchy and the corresponding BRAUMAT systems
represent these levels.

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3 Architecture Hardware

3.1 System Architecture

Process management level BRAUMAT-IOS

The process management level uses
BRAUMAT IOS systems for monitoring and
archiving process data. The systems are
based on standard components such as PC
hardware and WINDOWS
TM
operating
systems completed with BRAUMAT system
configuration software.
BRAUMAT combines user-friendly, intuitive
operator control and a wide range of
functionality. On-line connection to other
WINDOWS
TM
applications (MS-EXCEL, MS-
ACCESS, ...) is easily done.

Process control level BRAUMAT-PCU

For process control, BRAUMAT PCU systems are installed. They consist of
the programmable controllers SIMATIC S7-400 (CPU 417-4DP) and the
appropriate technological modules. They are responsible for control and
supervision of processes and acquisition and processing of measured
values.

Communication systems

Communication between BRAUMAT systems is done by using an efficient industry bus based on
SIMATIC NET - Industrial Ethernet - H1. Additionally, the PC-based BRAUMAT - IOSes can use all
types of TCP/IP communication systems. This ensures a maximal open system that can be integrated
into existing computer networks.

Back-up devices

Back-up devices are used to avoid a
breakdown of the system.
All process displays are kept
redundantly on every IOS
Message log, step logs and batch
data are stored in 2 IOSes
The decentralized structure (Industrial
Ethernet) guarantees high reliability

Configuration
BRAUMAT is configurable and integrates an engineering tool to support the generation and
documentation of application components.
For project engineers and operators, BRAUMAT offers standardized process control objects for a clear
and reproducible structuring of the system.
It is a uniform system throughout the plant with technological functions.
The BRAUMAT configuration of the communication between technological objects in IOS and PCU is
completely independent (Plug and Play solution).
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4 Architecture Software


User interface

The user interface follows generally accepted guidelines for user interfaces on WINDOWS
TM
.
Operating elements such as windows, menus and icons are used. Operations are made via keyboard
and mouse, control panels and dialog boxes. This leads to a uniform user interface that makes
learning and operating as easy as with other WINDOWS
TM
programs.
Important frequently used functions are shown in the symbol bar and are also accessible via function
keys.

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5 Process Displays


Process displays

Full graphics
and high-
resolution
display of
process images
make them
appear very
close to reality.
Background
images are
designed by
using any
graphics tools
that are
compatible to
Windows and
that are able to
create bitmap
files. Display
generating
superposes
these
background
images with
dynamic
objects
representing
on-line process
data and
technological
objects.
Technological
objects are
operated via
special dialog
boxes.

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6 System Module ICM

6.1 Modules

6.1.1 System Module

Individual control modules (ICM)

For ICMs, BRAUMAT contains standard objects for control, locking and monitoring of actuators,
valves, motors, slide valves, etc. The configuration of ICMs generates the corresponding messages
and a detailed display with the following functions:
Status display of ICM
ON-OFF signal using manual mode
Acceptance of faults/messages
Note function
Diagnosis of the corresponding interlocks (PLC program code) via display of 'block status'
Standard objects for controllers are also available. They are designed as PID or a three-step
software controller. Standard loop displays with suitable graphic primitives and operator
panels are available as well.

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7 System Module Controller

7.1 Modules

7.1.1 System Module

PID / STEP - Controller

Standard objects for controllers are available. They are designed as PID or a three-step
software controller. Standard loop displays with suitable graphic primitives and operator
panels are available as well.

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8 Process Displays

8.1 Modules

8.1.1 System Module

Process displays and their generation

The plant's on-line process data is displayed in full graphics.
Operation of technological objects by using particular dialogs.
For the selection of other process displays, panels, objects or menus are used.
Of course 'freezing' and printing of current process images are possible.
Arbitrary Windows programs (exe-files) can be started out of process displays
Background images can be designed using all Windows-compatible tools that create bitmap
files (*.bmp).
Symbols for ICMs are available in the extensive symbol library that can be freely extended by
the operator.

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9 Tools

9.1 Modules

9.1.1 System Module

Integrated PCU-Engineering Tool

BRAUMAT is configurable and includes an engineering tool to support generation and documentation
of application components. For project engineers and operators, BRAUMAT offers standardized
process control objects for a clear and reproducible structuring of the system.
Status display of all SIMATIC blocks (OB, PB, SB. FB, FX)
Program blocks are stored on hard disk. The on-line status information is continuously
updated by PCUs.
Editing of all PCU data blocks (DB/DX) throughout the network
Storing / loading of recipes or any STEP 5 blocks from IOS hard disk to PCU RAM or vice
versa.

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10 Order System

10.1 Modules

10.1.1 Technology Modules

Order System

The order system offers:
Easy specification of number and sequence of production orders and batches
Entry of additional production parameters with automatic adjustment of recipes to the optimum
batch size
Changes to defined order-specific production and process parameters
Display of batch sequence with the most important order parameters
Visualization of order status
Display of batch tracking

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11 Recipe System

11.1 Modules


Graphical Recipe System according to S88.01 standard

The recipe system concentrates on the following elements:
The basic recipes define process handling (sequences and alternatives) by grouping diverse
basic operations (what's to be done). In the list of components (parts list), raw materials
required for producing a recipe are described (what's to be taken).
The component list describes the components of raw material (list of pieces) that are used for
productions according to a special recipe.
The master recipe characterizes processing parameters (time, temperature, pressure, etc).
These parameters for basic operations can be entered dynamically (by orders, recipe types,
manual input).
Integration of user-friendly, extensive recipe generation and management systems. The recipe
system is standardized according to ANSI/ISA-S88.01 standard. Operator control and
visualization is done graphically and in list form.

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12 Options to BRAUMAT

12.1 Modules


Silo / Tank Data Management

Assignment of raw material to silos and tanks.
Balancing of raw materials and components of silo and tank farms.
Specification of silos and tanks to be used by weighing systems.
Visualization of important silo and tank states.
Archiving of historical silo and tank data.

Weighing and Proportioning

Fully automated weighing of several components.
Reproducible accuracy.
Uniform operator control of different weighing systems (i.e. SIWAREX, Toledo, HBM).
Specification of components for silos, weighing systems.
Definition of weighing parameters (i.e. set-point: Coarse / fine dosing, tolerances,
calibration...).
Proportioning via volume and flow meter.

Route Control

Production plants often have numerous production routes. CIP programs must be controlled
concerning their production course. The module route control offers:

technological engineering of production and CIP routes
a diagnostic overview for service and operation
documentation of all routes using cross-reference lists

When planning sub-routes, the application itself generates the necessary interlocking programs for
ICMs.
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13 Event and Trouble Shooting

13.1 Modules


Event and Trouble Shooting

Faults and process signals can be displayed and selected by types.
Comments can be added to faults.

Event Logs

Events are all faults and manual interventions by the operating staff. Messages and faults are stored in
day-specific files and can be evaluated by different criteria.

Message Log

All faults, events and manual interventions of each batch can be displayed and are stored in daily files.
The selection of messages by different criteria is possible. These daily files can be used for any other
evaluation purpose as well.

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14 Step Logs

14.1 Modules


Sequence Step Logs

Configurable data of current recipe processing in plant sections are stored and can be printed out (list
of basic operations - date, starting time, setpoint and real values).

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15 Maintenance

15.1 Modules


Maintenance Data

Preventive maintenance leads to increased operational reliability. The maintenance module offers:
Registration and visualization of operating hours and switch cycles
Supervision of freely-configurable maintenance intervals with user-defined messages

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16 Trending

16.1 Modules


Trending System

All measured values (related to batches or orders) can be stored in a curve archive. The curve archive
offers the following functions:
Process-oriented, trigger-able and batch-specific archiving of measured values in short-term
(RAM) or long-term archives (files)
Time-dependent storing of non-batch values
Fade in of set-point curves to evaluate actual value curves
Visualization and logging as full graphics curves with variable (manual) or automatic scaling of
axes
Selection of different analog/digital values per group to be displayed
Integrated tools like a curve ruler for better readability

Editing of set-point curves (graphical or via tables)

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17 System Configuration

17.1 Configuration

System configuration

BRAUMAT can be adapted to any size of installation - from a stand-alone to a company-wide
extensive network system. The configuration can be changed and expanded. The BRAUMAT client-
server structure allows an expansion by any amount of PCs and PLCs.

Fast Ethernet 100MHz Fiber Optic
Fast Ethernet 100MHz Fiber Optic
Operator Terminals Client Operator Terminals Client
MES-System
Data-Managem.
Primergy
Process Data Management
TCP/IP
Server
redundant
Server
redundant
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18 Common Functions

18.1 Function Related Main Menu

The main menu is designed and structured as follows:

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18.2 Loop-In Alarm

Depending on the selected message in the alarm window, the program automatically calls a pre-
defined process image for this BRAUMAT object.

18.3 Additional Attributes to BRAUMAT Objects

Each BRAUMAT object contains the following additional standard attributes:
Description of the functionality (Inlet Valve on T45 for CO2 Supply)
Physical location in the plant (On Gas Block 4, underneath Tank FV1)
I/O Address (I 25.2/Q 25.2)

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18.4 Graphical Source View

In the BRAUMAT Parameterization it is possible to fetch data from one module to another module
without using program code. The following example shows a typical BRAUMAT module link
documentation.

CIP: Speed Control CIP Pre Run Pump

Functionality: Depending on the status of two different flags the CIP pump will fetch the actual speed
setpoint for the frequent converter from three different sources.
Starting from an analog/digital signal the graphical source view will show where and how the value is
used in the different BRAUMAT modules.
For example: The wort heater is controlled by a PID temperature controller. This controller will receive
the process setpoint from a Digital Function Module (DFM) which is used from the Basic Operation
Heating. This BOP is part of the Recipe Procedure Wort Production and is used within different
brands.
The explorer tree shows always the fetch direction, this means BRAUMAT shows the source.

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18.5 Additional Intervention and Change Logs

The functionality of logging all events, alarms, operator interventions or parameter changes during
production is very important for all food and beverage producers, specially for a brewery.
The intervention and change log program is developed in such a manner, that it is possible to add this
functionality to previous BRAUMAT versions without interrupting the production.
The log archive is daily structured.

18.5.1 Open change log

Example of the open dialog of change logging:

18.5.2 Change log view

The user can change the layout of the change log. Each column of the archive can be selected or
deselected.
Example of change logging view:

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18.6 Entities / Device Modes

18.6.1 Entity Groups

The entity engineering function allows additional to the definition of device groups, the definition of
entity groups.
Entities are used for maintenance interlocking functions and for process interlocking functions. A
section of plant can only be a part of one entity, i.e. a portion of line can only be in one entity, and it
cannot be a member of two entities. However any device may be a member of two entities. The
entities should be defined according to the following two main criteria:

Device (Valves/Motors) and units can be part of an entity group.
One device can be member of maximum two entities.

18.6.2 Additional ICM Mode Description

Icon view
The icon view of an ICM displays the actual state of the ICM. Eight states can be displayed.
Additional to these states the mode can displayed in two different styles.

Style Example description
Mode border

For each ICM mode a separate color can be defined. The width of the
border can be defined.
Mode signal

The signals are stored in the system. For each mode a special signal
is defined. The automatic mode has no signal.
Both

The two styles can be used at one time.

18.6.3 Group and Individual Device Modes

Maintenance Mode
The operator can set an ICM in maintenance mode, e.g. when the ICM is not available or defect. Once
in maintenance mode the device cannot be activated either manually or automatically by the control
system. For safety reasons the maintenance mode should be used as an administrative tool only.

Affected by Maintenance
If an ICM is set in maintenance mode, the rest of the devices that belong to the same entity are in
maintenance mode as well.
The device can be used in off/de-forced position.
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Reserved for Automatic

One ICM can be used by two different routes. So in the ICM faceplate two route ID's can be displayed.
If the ICM is not used by RCS the fields will be empty.
A typical faceplate example:

Individual Device Modes
The amount of ICM modes are increased to following modes:

Individual Device Mode Forcing Enable
If the valve/motor is in a mode that allows the system to override a programmed interlock,
great care should be taken when using this override.

Individual Device Mode Simulation
This mode sets a valve/motor in a mode that allows an automatic program to operate
when a valve or motor has reported an error or failure.
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19 Engineering

19.1 Plant Digitals

This Faceplate is a BRAUMAT standard module to display digitals.

BRAUMAT uses TIMER modules for digital input/output signals. The faceplate can be used in the
process images.

19.1.1 Trending tab

Within the digital faceplate a trending function is realized. The three signals are:

Digital input
Delayed positive output signal
Delayed negative output signal


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19.1.2 Parameter tab

In this tab the normal parameterization of the digital can be done. The values can be changed after the
CheckBox "Change" is active. For this function a high user level is necessary.


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20 Visualization

20.1 Process Images

20.1.1 Real Values in Process Images

Application Data in S7-Real (Floating Point -) Format can be shown in the process images.

20.1.2 Dynamic Application Call

BRAUMAT delivers the possibility to start applications via activating special variables in the process
images. The application itself and call parameters can be defined. The parameters can be dynamic.
A typical example is given in the trend application. It is possible to start an unit related trend
application depending on the actual batch number.

20.1.3 Faceplates

BRAUMAT offers following faceplates: ICM, PID, analog input/output, digital input/output, Entities, unit
control, status byte and message faceplates.

20.1.3.1 Plant ICM Faceplate

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Icon ICM - State
There is one bitmap selectable for the ICM Icon-state. The 3 status bits (activated, feedback OFF and
Feedback ON) derive eight states (state 1 - 8). Eight different bitmaps are assigned to these eight
states.

Activated Feedback OFF Feedback ON Watchdog Time
Running
Action
Comment
State 1 no yes no no Not Active
State 2 yes - no yes During Opening
State 3 no no yes yes During Closing
State 4 yes no yes no Active
State 5 no no - no error
State 6 yes - no no error
State 7 no no - no error
State 8 yes yes/no no no error

Icon ICM - Mode

Mode indication via icon frame
The ICM Mode is displayed by the color of the frame. The colors and the width of the frame are free
selectable:
Maintenance
Affected By Maintenance
Reserved By Automatic
Idle/Automatic
Manual
Mode indications via separate symbol
Alternative the mode can be indicated via a symbol next to the icon on the right hand sight:
Maintenance (wrench in red color)
Affected By Maintenance ( wrench in white color)
Reserved By Automatic (gearwheel)
Idle/Automatic (no Symbol)
Manual (Hand)
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20.1.3.2 Plant Analog Faceplates (analog input)

Additional Functions:
Icon flash: In case of simulation, the faceplate flashes during icon state.
Trending: The "Trend-tab" shows the actual analog value.
Addressing: The "About-tab" shows the address, location and description information of
the device.
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20.1.3.3 Plant Analog Faceplates (analog output)

Trending tab of the faceplate

Icon flash: In case of simulation, the faceplate flashes during icon state.
Trending: The "Trend-tab" shows the actual analog value.
the device.
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20.1.3.4 PID Controller Faceplate

Extended view of the controller faceplate
In this tab some parameters of the PID controller can be changed. For the change a high user level is
necessary.
Trending tab of the PID controller faceplate

Icon flash: Actual value out of limit value causes the faceplate flashes during icon state.
Trending: The "Trend-tab" shows the actual, setpoint and output value
the device.
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20.1.3.5 Message Faceplate

The Faceplate shows selectable Alarms, Events and Messages in process images.

20.1.3.6 Status-byte Faceplate

The status-byte Faceplate allows visualizing up to 255 bit maps. The visualized bitmap depends on
the value of the status byte.

20.1.3.7 Entity Faceplate

The entity faceplate is used for parameterization and adjustment of an entity. An entity is described as
a data set in the PCU. For this data set a template is engineered on the IOS for the faceplate. One
value of the data set can be defined as a status variable. For this value for each bit can be set a name.

Entity-related data may be displayed and/or edited, by using an Entity Online Data Editor. A standard
dialog is available, to view and/or change data related to every Entity. E.g., a tank Entity may have
values like material, filling status, etc.
A typical example: by clicking on the i-Button of Kettle-Whirlpool 6, the dialog opens showing the
corresponding Properties. By clicking on the Status-Tab, a list of all status signals is presented.

Example for tank entity data

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20.1.3.8 Unit Control Faceplate

Icon view
The icon representation type contains:
a bitmap with representation of the sequencer status
the operation dialog
In the process diagram the selected bitmap is represented. Via the Bitmap the status of the sequence
is indicated in the right lower edge.

Idle run

Current

Starting
is not indicated
Re-Starting

Intermittent

Interrupting

Stopped

Stopping

Broken off

Interrupting

Stopped

Stopping

Ready

After the pressing of the left mouse button the operating dialog opens itself.

Operation dialog
Overview
The operating dialog divides into 3 parts:
1. Global functions
2. Allocation and calls to the batch
3. Sequence control
4. Recipe operation and their operation

Two more windows for the setpoint displays can expand
the dialog.
The operating dialog is possible in the representation type 'icon' only.
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Display

In this version without importance
Call of the application plant overview
Allocation
Here the current allocation of the unit is displayed.
Call of the control recipe view for the current batch of the unit
Signaling of the process parameters for the batch
Signaling of the input list of the batch
The operating dialog is expanded by the sequencer-related set
points.

Sequence
The name of the sequence is indicated.
Status
The status of the sequence is indicated.
Signaling
The status display of the sequence is indicated.
Start of the sequence. After pressing the button the dialog recipe
selection is opened. Plant overview
Abort of the sequence
Sequence re-starting
Stopping sequence
Step selection; After pressing the button the dialog step
selection is opened
System equipment list
Skipping over synchronization

Recipe operation
The dates are indicated for the current step.
Step operation
Restarting step
Stopping step
Switch operation step to pause
Stopping step
Abort step
Acknowledge operating request
the text of the operating request is indicated in the display field above
the recipe operation
Only relevant for the variant with EPE creating as FC. It is
branched out to the status program for the block.
The operating dialog is expanded by the step-related set points.
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Setpoint window

The sequencer setpoints or the step-related setpoints are indicated in the window. The setpoint can be
changed directly in the window. If the setpoint SP is a type of "text", a dialog for the further selection of
the setpoint cell can be opened. The size and column width of the setpoint windows can be changed.
The concerning adjustments are stored. The windows for the setpoints of the step and the sequencer
have different adjustments.

Line view with title
This view shows a sequence corresponding to the plant overview. It is not distinguished between
'Iconized view' and 'Operating dialog'
Overview

The buttons correspond to those of the operating dialog.

Line view
This view corresponds to the view 'line with title', however without the heading. The two views are for a
table provided within the process figure.
The setpoint windows are opened always only for a sequence. If the setpoint window is opened for a
further sequence, the currently opened one is closed so before.

Window view
In this view the operating dialog is displayed immediately. In the view no header line is indicated and
the dialog is not movable. Otherwise the signaling and the operation are just the same as in the
operating dialog.

20.1.4 Indirect Addressing of Faceplates

A faceplate address subscribing is possible similar to indirect addressing in the process images.

20.1.5 Tags in Process Images

Process images should not be overloaded with information. But it is also important to get more
information if required. BRAUMAT has a second layer including tag names of the designed variables.
This information can be shown on screen alternatively or print out if required.

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Example for tags in the process image

20.1.6 Image Variable View

An user dialog which provides all information of the existing variables in the image can be called. If
selecting one variable in the table, the relating variable will be shown with a blue frame.

The operator can set a filter for the variables in the image (for example only ICMs). The actual
selected tag in the list is flashing on the image.

Example of image variable view

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20.2 Tag Search Tool (Global Variable Search)

The tag search function allows the operator to search for a specific BRAUMAT object. The object can
be assigned to a specific process display. After a successful search the related picture will be called
and opened.

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20.3 Process Image Editor

20.3.1 General

Definition of the visualization surface
Administration of static background images
Connect process variables
Create executable process diagrams
While processing the same file of several users (IOSes) simultaneously the consistency of
the dates is guaranteed when the last storing attains validity in each case.
Every IOS has its own images; i.e. it is independent of different IOSes (Redundancy). The
images can be loaded by a different IOS after having requested.

20.3.2 File - Menu

New
- Create a new document
Open
- Open an existing document
Save
- Safes open document under same file name
Print the active document
Switch in the runtime system

20.3.3 Edit Menu

Cut
- Removes selected texts or graphics from the document and copy them in the clipboard.
Select all
- Select the entire list of variables
Align
- as stated below
Copy
- Copy selected objects

20.3.4 Resources - Menu

Background image
Loading
- Load a background image which has already been created
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Dyeing
- Dye the current background image.
20.3.5 Variable - Menu
Selection
- In this condition object can be dialed or selected.
Information
- The information can be made visible in the application process diagrams in the menu
Process images\Variables information.
Image change
- Determining alternation to different process diagrams
Exec-FB
- Connect executable Function block
Exec-IOS
- Connecting executable PC file
Static text
- Static assigned text
Value
- Connect an integer variable or real variable
Hexadecimal
- Connect a hexadecimal variable
Bit
- Connect a bit variable
ICM
- Boarded one of a single control element
Text
- Connecting process value display through text outputs
Line
- Connect a line
Bar
- Process value display in the form of bars (level or upright)
Sound
- Connect one variable with file *.wav
Control
- Operation dialog Faceplate

20.3.6 Tools - Menu

Via the item 'Configure tools' in the 'Options' Menu programs can be added which are
started via this menu later. Reference: Here graphics tools like Paint Brush or Micrografx
Designer can be linked. If a background image is loaded in the image construction, these
programs can be loaded by clicking the requested tool. Establish the option plotter
program in the menu options under tools. The dialog enables to start graphic-independent
application as for example MS-EXCEL without problems from this menu.

20.3.7 Align and Distribute Variables

The alignment of objects requires one dominant variable. This dominant variable will be the last
selected.
Left
- Shift variables, that the left border lines will be arranged in one vertical line
Top
- Shift variables, that the top border lines will be arranged in one horizontal line
Bottom
- Shift variables, that the bottom border lines will be arranged in one horizontal line
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Right
- Shift variables, that the right border lines will be arranged in one vertical line
Center horizontal
- Shift variables, that the objects will be centralized in one horizontal line
Center vertical
- Shift variables, that the objects will be centralized in one vertical line
Distribute horizontal
- Shift variables, that the objects between the left and the right in the row, will have the
same horizontal distance
Distribute vertical
- Shift variables, that the objects between the bottom and the top will have the same
vertical distance
The alignment functions can be used via menu or toolbar.

20.3.8 Copy Variables

It is possible to copy variables including their properties in the images editor. The variable image will
be placed next to the source variable.
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21 Recipe System

The BRAUMAT Recipe System is modular in structure and comprises a number of interfaces that
provide the user with the necessary tools to create, organize and review the recipes. Furthermore, the
recipe system provides the user the ability to monitor control recipes during execution.

The recipe system generates unit dependent control recipes in conjunction with the batch system,
which are loaded into the PCU at the start of the corresponding sequence.

21.1 Recipe hierarchy

21.1.1 Area

The highest level in the physical structure defines the area.
For each area one BRAUMAT recipe server is needed (or with redundancy a server pair).

21.2 Recipe category

The highest hierarchy level for the recipe is the recipe category.
One recipe category combines all master recipes (brands) that have similar functions e.g. the lager-
wort production in the brewhouse, CIP brewhouse.
All master recipes of one category share the same set of process parameters (values are master
recipe specific) but not necessarily the same recipe procedure. There is no 1:1 relation required
between recipe categories and process cells.

The recipe categories are defined global for the complete beer production. Maximal 255 categories per
site can be defined; the recipe categories shall be unique numbers in the complete brewery (1-255).
For all batch processes the category, the recipe, order number and batch number serve as key for
data archiving. Since most of the data selections work with these keys, a structured definition of
categories is required.

21.3 Master Recipe
The master recipe is an object that combines the process inputs, process parameters and recipe
procedure. On starting a batch, a runtime version of the master recipe is constructed (control recipe)
from the various components and is downloaded to the PCU for execution.

The master recipe can be designed and tailored to suit the process and plant. At minimum it will
comprise of a recipe header and a recipe procedure. Depending on the design, it may also include
process parameters and a process input.
Recipe Header: The header defines the relationship between the recipe procedures
and process parameters.
Recipe Procedure: The recipe procedure provides the structure for storing the operations
or steps that have to be executed at run time in a chronological
manner. It also stores parameters relating uniquely to this recipe
procedure.
Process Parameters: The process parameters can be used to store process values (time,
temperatures etc) that are specific for a master recipe but not for the
recipe procedure. BRAUMAT allows different recipe procedures to
access these parameters by symbolic referencing.
Process Input: The process-input function can be used to separately store quantity
values of specific ingredients that are required to process a varying
amount of a product. Again, this allows different recipe procedures to
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access these parameters by symbolic referencing. Component List is
also known as Process Inputs.

The example below shows how different process parameters can be used with a common recipe
procedure to make up different master recipes. Component lists are not considered in this
configuration.
Process Parameters X
Recipe Procedure A
Process Parameters Z
Process Parameters Y
Master Recipe 1
Master Recipe 2
Master Recipe 3

It is also possible to design the master recipe using a one to one ratio of procedures and parameters.

Master Recipe 2
Recipe Procedure B Process Parameters Y
Process Parameters X Recipe Procedure A
Master Recipe 1

Alternatively, the master recipe can be designed with a single recipe procedure component.

Recipe Procedure B
Recipe Procedure A
Master Recipe 1
Master Recipe 2
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21.4 Sequence Overview

Detailed program monitoring is done via Sequence Overview.

This application displays a list of sequences, with the actual step executing for every sequence. There
will be several lists that may be displayed. In the BH, lists for CIP and for each brewing line will be
available. In Beer Processing, lists for CIP and for transfer programs will be available. There is a
function, which allows showing only the running sequences in the actual view.

The actual set points and actual values for the running step, as well as the corresponding Event View
Page of the selected sequence will be displayed, as shown.

Sequence Overview application
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21.5 Streams

At the present planning state for the brewery, there is no need to implement streams. The reason is
that e.g. in the brewhouse two lines work independently. The vessels and devices that serves both
lines (e.g. hops extract dosing) also not offer alternatives for the two lines, since all these devices are
unique.
The stream function is therefore not required. Nevertheless if changes of the planning will be done this
feature can gain importance and is therefore shortly described.

Recipe Procedures are made up of Recipe Unit Procedures, which are linked together by
synchronizations and alternatives. In the following example, EOP124 (SB124) of the mash tun
reaches Alter.10 and starts kieve 1 (Sequence 10) or kieve 2, depending on the alternative value
supplied by EOP124..

Example of synchronization in a Recipe Procedure

As shown in the example, if there is more than one option to start a sequence then an alternative is
needed. Although only one sequence, either unit 10 or unit 12 will be executing at runtime, all
sequences will be shown in the recipe. The streaming function activates a filter on the recipe, so that
for a given stream, only the relevant sequences will be shown.
A stream must be selected before starting any given batch with any given recipe. The stream tells the
recipe, which sequences are going to be used in production of that batch.

It is possible to change the stream for a given batch at runtime. Only those streams that are possible
at that time are shown for selection. E.g., before EOP124 starts either one of the kieves, both
corresponding streams will be exchangeable.

The following screenshot sequence shows the procedure to create a new order in the Batch Schedule
application to start a batch in the Brewhouse. A stream is selected and changed for this batch.

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21.5.1 Open an Order List

In the following Figure, the Order List for Production is opened.

Open Order List for Production (Brewhouse).

The following Figure shows the opened Order List (Production).

Display of Order List for Production.

21.5.2 Create a new order

In the following Figure, a new order to produce batch number 00001 is created, using Recipe HG1072
and Stream M2. The corresponding bitmap for this Stream is displayed on the right side, including
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M2, MV-2, K7, UB-7 and WHP-7. In this dialog, only primary streams (designed for start) may be
selected.

Create a new order and select a Stream.

21.5.3 Release Batch

The following Figure shows how the new batch, which is initially locked, is released. The first
sequence of the Stream will be started, as soon as the Start Mode Conditions are met (as soon as
possible).

Release the order, so that the system can start the batch.

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21.5.4 Change a stream for a given batch

A Stream for a given batch may be changed by clicking on the Line Name (M2) as shown in the
following Figure.

View the actual stream (M2)

If the batch is not running, only the primary streams may be selected. If the batch is running, only
streams may be selected that fulfil the following rule: All running units must be in the actual and the
new stream. By selecting M3 in the following Figure, the corresponding bitmap for that Stream will
be shown.

Change from stream M2 to stream M3.
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21.6 Vessel Queuing

The functionality of Queuing defines possible sources and possible targets of transfer processes.
In all processes, not only in the brewing industry, we will find transfers between tanks or vessels with:

one source and more than one target
more sources and one target
more sources and more targets
more sources and more targets

and additionally you can have one or more dosing processes, we call this

secondary sources (one or more parallel)

CWS1 Y1
P1
P2
Brewhouse output area
Yeast tanks
Fermentation tanks
V1 V2
V3
V4
V7
V8
V9 V10
V12
Y2
F1 F2
V11
F3 F4
Y3 Y4
Gully
Water
V5
V6
V13
V14 V15 V16 V17
V18
CWS2
Water
V30

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