user manual - olmar system consists of a pc with 19” screen windows 7, wincc v7.0 sp3 upd( for the...
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Pol. Industrial Somonte III C/ Nicolás Redondo Urbieta 33393 Gijón - SPAIN Tel: 985 32 17 00 Fax: 985 32 38 31
USER MANUAL
CONTROL SYSTEM AND SUPERVISION OF THE AUTOCLAVE
FOR COMPOSITE MATERIALS OLAC 16.2
February 2016
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ÍNDEX
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INDEX
1 INTRODUCTION ....................................................................................... 4
1.1 INTRODUCTION .................................................................................................... 5 1.2 SYSTEM DESCRIPTION ....................................................................................... 5 1.3 APPLICATION ARQUITECTURE. ..................................................................... 5
2 SYSTEM OPERATION ............................................................................... 6 2.1 INTRODUCTION .................................................................................................... 6 2.2 NAVIGATION. ......................................................................................................... 8
3 SCREENS ................................................................................................... 10 3.1 PRESENTATION ................................................................................................... 11 3.2 SYNOPTIC. .................................................................................................................. 12 3.3 RECIPE. .................................................................................................................... 23 3.4 PID. ............................................................................................................................ 29 3.5 LOAD DATA. .......................................................................................................... 36
3.5.1 START OF CYCLE. ........................................................................................ 47 3.5.2 Page 0201. PID Manager ................................................................................. 51
3.6 PROCESS CONTROL. .......................................................................................... 59 3.7 GRAPHICS. .............................................................................................................. 60
3.7.1 Process. ............................................................................................................... 60 3.7.2 Temperature. ...................................................................................................... 61 3.7.3 Pressure and Vacuum. ...................................................................................... 62
3.8 DCP (POWER ANALYZER) ...................................................................................... 63 3.8.1 Screen measures. ............................................................................................... 63 3.8.2 Trends screen. .................................................................................................... 64 3.8.3 Settings screen. .................................................................................................. 64
3.9 MEASURED VALUES. .......................................................................................... 65 3.10 HISTORICAL MAINTENANCE. ....................................................................... 67 3.11 CONTROL VALVES: VACUUM/VENTING. ................................................ 68 3.12 MANUAL CONTROL. .......................................................................................... 69 3.13 REPORTS. ................................................................................................................ 70 3.14 MAINTENANCE SETTINGS/ OLMAR .......................................................... 71
3.14.1 Thermocouples Settings. .................................................................................. 71 3.14.2 Transducers Settings. ........................................................................................ 73 3.14.3 “Olmar”. Security and Control Settings. ........................................................ 75
3.15 EVENTS.................................................................................................................... 79 3.16 ALARMS. .................................................................................................................. 80
3.16.1.1 Manage Buzzer. ............................................................................ 80 3.17 CHANGE LANGUAGE. ...................................................................................... 81 3.18 LOGIN. ..................................................................................................................... 81
USER MANUAL
1 INTRODUCTION
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SYSTEM GENERAL OPERATION
1.1 INTRODUCTION
This manual is aimed at operators of Autoclaves for composite materials.
To enter data in the input fields it is enough to press on them and enter values or desired characters.
1.2 SYSTEM DESCRIPTION
This document describes the operation mode of the supervision system and control developed by Olmar.
The system consists of a PC with 19” screen (Windows 7, Wincc v7.0 SP3 upd5) for the following equipment:
- PLC S7-300 CPU315 (2PN/DP) or S7-400H redundant.
- ET200M for decentralized periphery.
- TSA-II MODEM, SIMATIC TELESERVICE (MPI/DP).
PC will control and supervise the state of the autoclave. With teleservice can remotely access the application in the PLC.
1.3 APPLICATION ARQUITECTURE.
PLC
Wincc
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SYSTEM GENERAL OPERATION
2 SYSTEM OPERATION
2.1 INTRODUCTION
After starting the PC, the system displays this screen.
In this screen you can Access the visualization, configuration and control of every element of the autoclave.
You must enter a username and password to get Access to the application.
From this moment you can navigate through the entire application if you have sufficient
permission.
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SYSTEM GENERAL OPERATION
In the main Menu, you can run the following actions:
“Shutdown PC”: Button to close the application and then turn the computer off.
“Exit Wincc”: Button to close the application.
“Edit recipes on PC”: Button to create recipes and store them in the PC to be able to charge subsequently to the PC.
“File Access”: Button to Access the system folders.
“Management users”: Button for create, modify, or delete users of the application and their corresponding permissions.
• Operator: By clicking on “Operator”, the screen appers to enter the username and the password.
It has three user levels:
- OPERATOR: Belonging to this level users will not have Access to “File”,”Users management” and “Maintenance settings”.The user default is Autoclave, with password “autoclave”.
- INGINEERING: Belonging to this level user will not have Access to “User Management” and “Maintenance settings”. The user default will be Recipe, with password “recipe”.
- SUPERVISOR: This level of user has Access to the entire application, the user default is Olmar. This user level, have Access to all application.
Note: During the start up system may modify the conditions and /or add users.
• Access to the following screens:
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SYSTEM GENERAL OPERATION
Sinóptic, Load Data, Recipes, PID, Screen Control, Trends, Mesured values, Manual control, Reports, Maintenance settings, Events and Alarms.
• Change of language: Button to change the language of the application.
2.2 NAVIGATION.
The following diagram shows the hierarchy of navigation application.
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3 SCREENS
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3.1 PRESENTATION
After starting the PC, the system displays this screen.
Insert the user name and password to gain Access to the different levels of the system. From this moment you can navigate the application according to the permissions of each
level.
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3.2 Synoptic.
Color code: Red: Closed valve, Motor Off, Autoclave pressurized, security door open. Green: Opened valve, Motor On, Autoclave without pressure, security door closed. Elements Description: • V1: Pressurization valve of autoclave, with percentage of opening (%). • V2: Depressurization valve of autoclave, with percentage of opening (%). • V3: Cooling valve of autoclave, with percentage of opening (%). • V5, V6: Purge valve (discharge of battery), with opening all or nothing. • V8: Inlet valve air/water to discharge battery push (air) and thing cooling (air/water). • V4: Seal Cooling valve: opening all or nothing. • Safety door: Indication of door opening safety valve. In this case if the lever is closed (green), opened (red). The cycle and the manual control is possible with the lever closed. • PS001: Indication of pressure in the autoclave, for the permission of door opening. • Door possition: Opened/Closed, Lock./Unlock.: Indication of limit switches of door. The cycle can start with Closed/Lock. (Green). And can´t start the cycle if the door is Open/Unlock. (Red).
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• Hidraulic pump: Indication of status pump that drives the door cylinders. • RT1: Button to enable /disable the group of resistors RT1. In case there are more groups, would have a button by group. • PTA: Indication of the current pressure in the autoclave, in Bar or PSI. (Max., Avg, Min.: Maximum, Average and Minimum) • TTA: Indication of current temperature in the autoclave, in ºC or F. (Max., Avg, Min.: Maximum, Average and Minimum) • TC: Indication of current temperature in pieces in ºC or F. (Max., Avg, Min.: Maximum, Average and Minimum) (TAG: number of maximum and minimum thermocouple) • TTRES: Indication of the current temperature in the resistors groups, in ºC or F. • R: Indica el porcentaje de regulación usado para las Resistencias. • Emergency stop: Indication of status emergency pushbutton (cabinet or autoclave). Red (Activated). • End cycle: Indication that the cycle has finished and not has acknowledged the event. • SETPOINT (T): Indication of current SP for temperature regulation. • SETPOINT (P): Indication of current SP for pressure regulation. • RECIPE: The name of the selected recipe.
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Vacuum system: • Start/Stop Pump B1: pressing this button the vacuum system will be enabled. • Vmc1: valve to achieve the vacuum on the pressure tank. • Vmc2: valve to avoid vacuum excessive on the pressure tank. • PT001(vacuum measurement): Indication of the vacuum pressure on the tank, mbar or InHg. • SETPOINT VACUUM: Setpoint to reach in the pressure tank. mbar or InHg. • V7: Cooling valve of filters in vacuum system, with opening all or nothing.
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To keep in mind about recipes: Each recipe is made up of several segments, each segment is hast two phases: Ramp + Maintenance. The recipe is composed of three areas of configuration AOL, FOL and LOL. The phase ramp ends when: 1.- In the case of heating ramp, when the calculated SP, reaches the SP of the current segment in recipe (Temperature and Pressure) and either the coldest thermocouple of piece (TC MIN selected) or the hottest thermocouple of piece (TC MAX selected) reaches the value of “Minimum temperature” by recipe. 2.- In this case of cooling ramp, when the calculated SP, reaches the SP of the current segment in recipe (Temperature and Pressure) and also when the hottest thermocouple of piece reaches the value of “Maximum Temperature”. The maintenance phase beings at the end of the ramp, and ends when the preset time “Maintenance Time” has finished.
General Parameters (AOL Recipe): These parameters are always the basic recipe with AOL regulation. The FOL and LOL regulations will use with other extras defined ahead.
Recipe Name: Reference text for the name of the recipe (18 characters maximum). Max. Temperature allowed in the recipe: Threshold temperature which prevents the cycle to continue, or failing that start.
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Piece (Load): Maximum Temperature: value to be considered for the completion of the cooling ramp. (2.-). This value generates a warning when a TC reaches this value in ramp. Setpoint Temperature: which should reach the temperature ramp.
ASP=TSP: Set value calculated at the temperature ramp. Minimum Temperature: Value to be considered for the completion the heating ramp. (1.-). Maximum temperature differences: Autoclave/Piece: Maximum difference allowed between “Piece Thermocouple” and “Autoclave Thermocouple”. Exceeded this limit, the system generate an alarm, and reduce the ramp rate to “Minimum speed”. Piece/Piece: Maximum difference allowed between “Piece Thermocouples”. Exceeded this limit, the system the system generate an alarm, and reduce the ramp rate to “Minimum speed”. Temperature ramp: Speed Setpoint: (> 0) speed of the ramp in case of not occur alarms described on previous paragraph “Maximum temperature differences”. Minimum speed: (> 0) speed of the ramp if occur alarms described on previous paragraph “Maximum temperature differences”. Isotherm Alarms: ALARM 1: Time elapsed since hot thermocouple reaches the temperatur tolerance (by recipe), until reaches it the colder thermocouple. For alarm 1 there are two possibilities that are described below. A: Automatic. M: Manual. A --> If colder thermocouple does not reach the minimum tolerance value within that time.
1 – The system generates an alarm. 2 – The cycle pass directly to maintain.
NOTE: This is as if we disables the thermocouples (not disconnect them) that were out of tolerance for the control, but following registering their values and returning to be enabled for the control in the following segment. M --> If Colder thermocouple dos not reach the minimum tolerance value “x” minutes before passing this time.
1 – Generates an alarm “x” minutes before passing this time giving a warning.
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2 – The system will not perform any action. The operator may decide to disconnect these thermocouples, so these are not registered.
NOTE: The operator must be who decides to reconnect the thermocouple when you begin a new ramp. ALARM 2: Time elapsed since you start the ramp until the thermocouple colder reaches minimum temperature tolerance (by recipe).
There are two possibilities which are described below. A: Automatic. M: Manual.
A --> If colder thermocouple does not reach the minimum tolerance value within that time.
1 – The system generates an alarm. 2 – The cycle pass directly to maintain.
NOTE: This is as if we disables the thermocouples (not disconnect them) that were out of tolerance for the control, but following registering their values and returning to be enabled for the control in the following segment. M --> If colder thermocouple does not reach the minimum tolerance value “x” minutes before passing this time giving a warning.
1 – Generates an alarm “x” minutes before passing this time giving a warning. 2 – The system will not perform any action. The operator may decide to disconnect these thermocouples, so these are not registered.
NOTE: The operator must be who decides to reconnect the thermocouple when yo begin a new ramp. Disabled: The system will not take into account any time, therefore will not perform any action or generate any report.
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Control: Select TC(Heating): indicates the type of control to end a rising temperature ramp. Isothem: Maintenance time: duration in minutes of maintenance phase. Pressure: Pressure setpoint: (> 0) pressure value in the autoclave in the ramp phase. Maximum deviation: difference between the pressure value and pressure setpoint. If this value remains a time set in the “settings” screen will produce a warning. Pressure ramp: Speed setpoint: (> 0) pressure ramp speed. Start temperature: autoclave temperature to be start the pressure ramp. Vacuum: Vacuum setpoint: vacuum to keep on vacuum manifold during the current segment. Temperature control: Temperature in autoclave under which we will make a study of the bags break to decide aborto r pause the cycle. Abort --> If we have break alarm of bag and autoclave temperature is below of temperature control.
1 – The system generates an alarm. 2 – The cycle is automatically aborted.
Pause --> If we have break alarm of bag and autoclave temperature is below of control temperature.
1 – The system generates an alarm. 2 – The cycle remains paused until the operator decides to do (in control panel), aborto r
continue.
Carry on --> If we have broken bag alarm and the autoclave temperature is below the control temperature, the control system will not do anything and the cycle will continue normally.
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PID: PID selection to be considered for regulation of the recipe.
Example regulation with AOL recipe: ASP=TSP
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FOL Recipe: This recipe is based on compare at all times the difference between TSP (Theoretical SetPoint) and maximum piece thermocouple. In contrast to this we apply a Factor getting a new Setpoint for Air (ASP). With this we try to seek maximum piece thermocouple gets speed conditions set by recipe.
By clicking on the button “FOL” have the recipe based on the general parameters in addition to :
Factor: Ratio factor for use in heating or cooling ramp. This factor is applied to the difference between the TSP and the TCmax. Dwell: Ratio factor for use int the stabilization phase (normally not applicable) can lead destabilization. This factor is applied to the difference between TSP and TCmax. TSP: Set value calculated on the temperature ramp (by recipe). ASP: Set value calculated on the temperature ramp with correction Factor. The new ASP will be increased or lowered TSP with the correction factor applied to the difference between TSP and TCmax. This is now the new SP to take into account for the air regulation. THHI: Limit value that can take the ASP in the warming. (Ramp). THLO: Limit value that can take the ASP in cooling. (Ramp). THHI: Limit value that can take the ASP in the warming. (Maintenance). THLO: Limit value that can take the ASP in cooling. (Maintenance). Recommendations: Factor (values between 1 and 3) THHI not above the maximum temperature by recipe, THLO not below the minimum temperature by recipe.
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Regulation example Recipe FOL: ASP is the new SP for air regulation.
LOL Recipe: This recipe is based on compare at all times the difference between the TSP (Piece Theoretical Setpoint) and either the piece thermocouple Maximum/Minimum/Average. In contrast to this we apply a factor getting the new air setpoint (ASP). With this we try to get that the selected thermocouple to meet the established speed conditions.
By clicking on the button “LOL” you have a recipe based on the general parameters in addition to:
Setpoint velocity: New setpoint velocity for selected piece thermocouple. Factor: Ratio factor for use on ramps and maintenance. This factor is applied to the difference between TSP and selected TC. TSP: value calculated in ramp for the piece. ASP: calculated setpoint value on temperature ramp with correction Factor. The new ASP will be increased/lowered TSP with correction factor applied to the difference between TSP and selected TC. This is now the new SP to take into account for the air regulation. Limit Gap SP (Piece/Air): Hysteresis value allowed between TSP and ASP. Select TC: TC that we want to comply with the speed setpoint.
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Recommendations: Factor (values from 1 and 3) the sum of TSP and hysteresis must not never be above the maximum temperature to abort the cycle.
Example LOL regulation recipe: ASP is the new SP for the air regulation.
Preview: By pressing “start”, draws the graph of preview of the theoretical cycle created on recipe.
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3.3 RECIPE.
The following describes the way to creation of a new recipe.
Recipe section: this section allows you to create a recipe.
New recipe: Creates a new recipe, opens a Windows in which we will introduce a name, the maximum temperature by recipe, type of recipe, the UOM (units of measurement) that we use and the associated PID. The field Segments number may not be modified, it refers to the maximum numbers of segments defined in 0103, in App settings on the field segments recipe. Once pressed the button, Save will show a Window which will give us the possibility of inserting a comment of creation.
Details: with a select recipe in listing shows us his view editing window, it behaves just as if were double click on the corresponding line.
Copy: with a selected recipe in listing can create a copy of this, we will ask that introduce a name for the copy recipe.
New Version: With a selected recipe in listing allows you to create a new version of this recipe, also the window for adding comments will show us if we add the creation of new version.
Delete: With a selected recipe in listing will move to deleted this recipe, as already indicated above, only the Admin user can still see recipes in that state. Also will show us a window giving us the possibility to add a comment of delete.
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Section Comment:
Write: With a selected recipe add a comment, a window in which we can see the previous comments and at the bottom, a text box in which we can write our comment, once we have finished, click the save button will show us.
Read: With a selected recipe will show us a window only display in which w e will see the comments for this recipe, will be sorted from newest to oldest and we can navigate through them with a navigation bar at the bottom of the window.
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Excel Section:
Export: With a selected recipe we can export in Excel format recipe information, a window will appear for stored which we can select the name and location of the file that will be generated.
Import: Will do the opposite of the previous one, with a selected recipe, when you click on import we will be file to import update with the imported data parameters of the recipe.
Search Section :
Refresh: It serves to refresh the page and listings, it is useful if some time ago that we have loaded the page because it may be the case that other users modifiy or créate recipes and will not see such information until we become a update.
View edit page: This page consists of 3 areas, the menu, the bar´s general parameters, and configuration which once we block the recipe for edition will show at hte bottom a system of calculations.
We may use this window in two modes, view, and editing, to switch between them only have to use the Lock button or unlock the menu, when we block the recipe for editing with lock can edit, when we unlocked with unlock only can see the parameters defined for the recipe.
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On the toolbar of general parameters, located between the menu and the work area you can select unit type for each type of parameters that are going to use, maximum temperature and the associated PID.
In the work area or parameters and settings are all the parameters needed to define the recipe in addition to the calculator the recipe apperars at bottom blocked once.
The calculator provides a quick and easy method to calculate parameters, for each segment, we introduce the initial temperature and the finals to reach in this segment and the time it will take to reach this final temperature, one time press the button calculate will generate the parameters for that segment and will fill us the field of initial temperature of the following with the end of the first.
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The menu is very similar to that already described with small differences which we will discuss.
The save button allows you to save the changes that we made in the recipe parameters whenever we are obviously in the edit mode.
The lock button will allow us to lock the recipe for edition and it is then and only then when we pass to the edit mode, said button will change at that moment by one of unlock which performs the opposite operation, unlock the recipe so that other users can modify it.
The Graph button will show you a window with a graph showing the differences between data stored currently and even unsaved data on screen of the ramps of temperature, pressure and vacuum marking the differences between the two types of data in red color.
You can select data to be displayed using the names on the bottom.
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We can also export graph as an image due to the icon in upper right of three horizontal bars.
A region of the graph may be extended by dragging with the mouse and selecting the desired area that will show us a new reset button to return to the view default zoom.
To enlarge the graph to full screen use the button of the square located in the upper right corner of the Windows next to the blade to close the window.
The report button allows us to generate a report of the recipe in which appears the configuration for this, will show us a window in which we will be able to indicate the location of the generated file.
In the section change status have two the first approved buttons will allow us to change the status of the recipe whenever we have it locked to approved, while the second obsolete will change the status to obsolete.
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3.4 PID.
You have the choice of editing up to 50 PID´s to then be selected in each recipe.
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PID:
KP --> Proportion constant P=KP x ERROR ERROR (difference between ASP and PV)
TI --> Integral time constant.
TD --> Derivative time constant. (Not applicable in Olmar autoclaves).
BM --> Dead band for the performance of the devices. (Heating, Cooling, Pressurization, Depressurization.). NOTe: This is a simple explanation. For more information find out about theory of PID´s.
The percentage of resistances or cooling valve will be the add of P+I.
Cycle time and Factor:
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Variables used to control (ON/OFF) pulses of resistances.
Cycle time: Period for signs of impulses (Resistances).
Example: If the percentage of resistances is 50%.
Factor (%): Reduction factor applicable at the time of application of the signal. (85% for this example).
PV:
For heat as cool cna be chosen that you probe both want to contemplate as the value of the process for the regulation.
TTA Min TTA Avg. TTA Max. MAX: TTA Avg. or TC Max MAX: TTA Max or TC Max TTA001 TTA002
INITIAL (Temperature controller management): These values do not cease to be small brake or acceleration in its cumulative integral of
the PID (in the case of heating or maintenance) or the percentage of the cooling valve (in the case of cooling or maintenance). Not forget that %R=P+I (in positive) and that %V=P+I (in negative). The regulation of temperature is done with a shared PID (positive warming, negative cooling) in this way the system may not be heating and cooling at the same time.
Cycle time = 10s Ti. activated R = 8,5s
Ti. On R = 4,25s Ti. Off R = 5,75s
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It will separate the first segment of the 15 remaining as it is considered that this requires a special attention.
INITIAL SEGMENT:
- Initial A: (Accelerator) Integral value at the beginning of the ramp of the initial segment. Always in absolute value. This value will be applied if the setpoint temperature by recipe in the first segment is greater than the “Minimum Temperature”.
- Initial B0: (Brake) Integral value (in absolute value and the existing value factor) when we got to the final value of the first heating ramp by recipe, and can anticipate “x” degrees.
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- Initial C: (Accelerator) Integral value (in absolute value and the existing value factor) when you end the maintenance (or less foretaste “x” seconds) and starts a new warming segment.
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Other Segments: - Initial B: (Brake) Integral value (in absolute value and the existing value factor)
when we got to the final value of the first heating ramp by recipe, and can anticipate “x” degrees.
- Initial D: (Accelerator) Integral value (in absolute value and the existing value factor) when you end the maintenance (or less foretaste “x” seconds) and starts a new heating segment.
- Initial E: (Brake) Integral value (in absolute value and the existing value factor) when we got to the final value of the first cooling ramp by recipe, and can anticipate “x” degrees.
NO: Disables adjust function of integral part.
COOLING AND WARMING CONTROL, HEATING BY PHASES: We will distinguish three phases in a segment of warming.
F1: Warming ramp in which the prescribed value (TSP) has not reached the set temperature by recipe.
F2: Ramp has finished, still waiting for TC Min orTc Max. F3: Maintenance.
In these phases, we will have the option of allowing cool or not and how we want to cool down.
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NOTE: This part of the control starts to act when we are in the negative part of the PID (cooling).If we were on the positive side (heating), and you allow cool in the corresponding phase, only actuary the cooling fine valve, controlled by hysteresis values, which will be explained later in the security and control settings section.
Min. Temp: Cooling is posible if the value of process is greater than this value. (only
applicable in Fase 1).
Air up to (%) : If the % of the cooling valve is less than this value, the system will cooling with fine cooling valve (air/water).
Pulsating to (%): If the % of the cooling valve is between “Air to” and this, the cooling function will be executed to pulse with the cooling valve.
Time Open (sec): Time while the cooling valve is open.
Time Close (sec): Time while the cooling valve is closed.
NOTE: If the % of cooling valve is greater than the “Pulsating to”, the cooling function will be executed with the corresponding % of cooling valve.
On cooling the system only let´s have a phase.
F4: For all cooling ramp. At this stage we will have the option of allowing heating or not and how we want to cool
(if we choose not to heat obviously will not deactivate cooling operation mode).
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3.5 LOAD DATA.
Once we have defined the PID and the recipe, we will make a charge through the page Load Manager.
In this case is responsable for the management and configuration of Loads. There are two types of page, Listings and Edit View.
Listings page: This page is divided into 3 main sections, menu, tabs of listings and listing.
First we will describe the existing tabs, they correspond to the various states in
which a load can be found during its life cycle. Each tab you have the list of loads.
The edited state list loads in that state, it´s those newly created loads or who are in issue.
Approved state list loads in that state, it is those that are approved and which therefore can be selected to start cycles, list of loads in that state can return to be edited.
The obsolete state list loads in that state, are loads that are no longer in use but which are kept as a reference, should be noted that a load, can only be passed to this state if you are not using in a cycle.
The deleted state list loads in that state, are definitively removed loads, really will not be a definitive deletion, because the admin user will be the only one who can see the loads in this list but will be for other users as if they don´t exist.
The following is the listing itself, obviously one by each tab showing the loads in that particular state.
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Selecting a line, by clicking on it, you can perform various operations through the menu, and if we double click on it, it would show us the view edit page of load difference pages for PID´s and recipes is that it does not generate a new page using your browser commands, or unlocked once press the close option in the menu.
When a load is being edited by another user a padlock will be displayed at the beginning of the line, this indicates that this load is blocked for editing will not allow more than one user to modify a specific load at the same time. If we who are blocking this load on the padlock icon is also displayed a pencil. Passing the mouse over the padlock and waiting a bit will show us a tooltip which will indicate use has blocked the load for editing.
In this picture we see the listing, the lock with the pencil icon, as it is the current user that has it locked, and the tooltip indicating the name of the user.
We will describe the menu at the top of the listings page.
Section Load:
New Load: Create a new load, opens a window in which we will introduce a name and select the recipe you want to use which are approved. The recipe will be compulsory or not based on how it is defined in 0103. App settings in the recipe Mandatory field. Once pressed the Accept button will show the edit view page.
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Details: With a sorted load in the list it shows us its view editing Window it behaves as if it were double click on the corresponding line.
Properties: Load selected in the list will show us the creation window so that we can modify both the name and recipe that used the load.
Copy: With a selected load on the list, we can create a copy of this, will we ask you to enter a name for the new load copy.
Delete: With a sorted load in the list will move to deleted this load, as already indicated above, only the admin user can still see the load in that state. Also will show us a window giving us the possibility to add a comment of delete.
Comments section:
Write: with a selected load we´ll add a comment in which we can see the previous comments and at the bottom, a text box in which we can write our comment, once we have finished, press the accept button will show us.
Read: with a selected load will show us a window only display in which we will see the comments for that load.
Excel section:
Export: with a selected load we can export information from the load in Excel format , a window will appear for stored which we can select the name an d location of the file that will be generated.
Import: With a selected load, when you click on import, we will request a file to import updated with the imported data load parameters.
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Search section:
Refresh: Sirve para refrescar la página y los listados, es útil si hace tiempo que hemos cargado la página pues puede darse el caso en que otros usuarios modifiquen o creen Cargas y no veremos dicha información hasta que hagamos un refresco.
View Edit page: This page consists of two areas, menu and the area of editing which is turn divide into five zones.
We may use this window in two modes, view, and editing, to switch between them, only have to use the lock button or unlock of the menu, when we block the recipe for editing with lock can edit, when unlocked with unlock only can see the parameters defined for the load.
The menu is very similar to that already described with small differences which we will discuss.
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The close button will allow us to return to the page of listings of loads, this will change when we block or save that allows you to save the changes that we made in the parameters of the load.
The lock button will allow us to lock the load for edition and is then and then only shen we turn to the edit mode, said button will change at that momento by one of unlock which performs the opposite operation, unlock the load so that other users can modifiy it.
The report button allows us to generate a report of the load in which appears the configuration for this, will show us a window in which we will be able to indicate the location of the generated file.
In the Section Change status have three buttons, first Edited, will allow us to change the status of the load whenever you have it locked to Edited, while the second and third will change to Approved and Obsolete states, respectively.
Sections of Bag and Piece will be activated to move by defining the parameters of the load so that when we have defined the bags and select one of these bags, the section will be activated and will display icons for editing and display, and the same for pieces with the section Piece.
In terms of editing area as we have already mentioned is made up of five parts, in Bags , bags definitions will be listed.
Bag’s Sensors will have list of sensors for the selected stock market and in the area adjacent, sensors will be displayed available sensors to associated with the bag whenever they are not being used by other Bag.
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To add sensors to Bag Sensors list, just select the necessary sensors and drag them toward the first or you can click on add button located at the top whenever we have the load locked for editing. To delete them use button for this purpose at the right top of Bag´s Sensors.
In the right upper part of Sensors we have the option BIND_TR_WM which if enabled, when you select TRs and add them to Bag’s Sensors also added the associated VMs even if they are not selected. The box to the left of the Name column is used to select all and the headers of the columns have the menus described in the common elements of the interface.
As already commented once we believe a bag and we have it selected, the buttons for the bags and pieces will be activated in the menu.
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From these menus will be able from left to right create bags, view its properties and delete them, and add pieces, view its properties and delete them. These menus are enabled and disabled depending on whether fear bags or selected pieces.
The maximum number of bags that can be created is defined in 0103. App settings in the field Max number of bags.
At the moment we have a bag or bags created can create pieces, which you can manage thanks to the previous menu and the list of pieces, that area appears.
The last zone use shows the sensors used by type indicating the bag to which they belong.
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Once we have defined the previously indicated necessary, PID, Recipe and Load, we will access the cycle control through the Load Data button.
This will show us the manager loads and under this button to access the Cycle control.
It will show us the home screen of cycle which consists of two areas the main Menu and the data Area.
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The main menu consists of the following elements:
Wheel Sprocket:
It is a status indicator, shows three possible states, red without active cycle, orange waiting for response from PLC, blue cycle in run.
Start:
Cycle starts, type variables in the Wincc and sends a signal to the Wincc start cycle.
Cancel:
Provided that the cycle is not running, Wheel sprocket in orange, can be cancelled.
Name:
Name that will take the cycle by default will show that you have defined in the Web application configuration screen, but it can be edited whenever you note that
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this name must be unique, for example: There can be a two cycles with the same name.
Load:
Selection of the load between the already defined and approved in the application.
Recipe:
Selection of the recipe from the already defined an approved in the application. If enabled, the feature of Recipe Mandatory defined in the configuration of the Web application, the recipe is selected automatically and can´t be modified.
The data Area is made up of 4 tabs, Load, Recipe, Graph and PID, which display data when we have selected the load and the recipe in the main menu.
Load tab shows the defined structure for loading in tree and you must define the
properties of parts, so you select the piece and the data are inserted in the right window, once you must press the button Piece to save the information.
The other tabs are simply informational, to visualize the parameters, defined in the recipe and the PID, as well as showing the graph of the recipe.
We will describe the menu at the top of the listings page.
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In the upper part of the Wincc there is a button called, comments once press you
commentary Windows will appear.
In this window we will have a text field to enter the new comment, a list of the
previous comments at the bottom with a navigation bar to go from one page to another if there.
We will have an option called Alert PLC, that sends a signal to PLC, indicating that a new comment has been created. The Write button saves the new comments, and the Refresh button will cause a refresh of the list at the bottom.
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If you write a comment during the execution of a cycle, this comment will appear in the comments.
3.5.1 START OF CYCLE.
To start a cycle, the following steps are performed.
1.- Edit in Olmar Web Application load data.
2.- Once completed, load data and the identifier of the new cycle will be displayed.
3.- Go to controller screen by pressing “Control cycle”.
Once in the control screen we can:
4.- See that cycle to perform name is correct.
5.- Select the recipe to run during the cycle, and can review it along with your PID once selected.
6.- Press button to start the cycle. Before confirming the beginning of the cycle, the system displays a careen of initial conditions, which must be checked before starting the cycle.
Essential signals (in Green) to start a cycle:
- Cycle not running. - Security door.
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- Emergency stop. - Voltage control contactors. - Air command. - Turbine OK. - Any RT enabled. - Vacuum system 1 OK. - Battery cooling system OK. - Seal Cooling system OK.
Signals depending on the cycle that you want to perform:
- Any TTA enabled. - Any PTA enabled. - Any TC enabled. - Any TR enabled. - Vacuum test OK.
It is recommended before a cycle, the vacuum test to check through the pilot is correct. - PROFIBUS OK. Profibus communications ok.
Finally, once checked all conditions start them, press the new button “Start cycle” and this will begin.
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REGULATION LOOPS.
In this screen you can view or control in manual mode the regulation of the process.
In the curves you can view both the PV (process value), and TSP (Theoretician SetPoint), the ASP (Calculated SetPoint), SCAL (% of Resistors), SENF (% Cooling valve), AIR (Fine Cooling valve (Air/Water).
Before accessing the cycle control to run a cycle, it will be necessary to have previously configured a recipe, a PID, and Load.
To Access this screen go into settings and once inside will click on Setpoints.
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Generation of a new PID:
Select an existing PID list and once pressed the button Save, will generate a new versión with the current settings introduce in the Wincc. If instead of a PID from the list you enter manually it will generate a completely new one.
Configuration of a PID, through the module 2 Equipment, on page PID manager.
3.5.2 Page 0201. PID Manager There are two pages types, are responsible for the management and configuration of the PID, these screens are the listings, which lists the PID´s in the various states of the cycle, and the edit view in which you can view or setup the definitions of the PID.
Listings Page: This page is divided into 3 main sections, menu, tabs of listings and listing.
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First we will describe the existing tabs, they correspond to the various states in which a PID can be found during its life cycle. On each tab, we will have the listing of the PID´s that are in a given state.
The edited state lists the PID´s in that state, it´s those newly created PID or who are in issue.
The approved state, list the PID in that state, it is those PID are approved and therefore selectable for configuring recipes. The PIDs in this state can never be edited, it would be necessary to create a new PID versión.
The obsolete state lists the PIDs in that state, they are PID that are no longer in use but that are saved as reference, should be noted that a PID may only be passed to this state if there is no recipe that makes reference to this.
The Deleted state, lists the PIDs in that state, are PID deleted definitely, really will not be a definitive deletion, because the Admin user will be the only one who can see the PIDs in this list but will be for other users as if a they were not.
The following is the listing itself, obviously one by each tab showing the PID in that particular state.
It consists of 4 columns that show the name of PID as well as units of measurement (UOM) for each type, selecting a line, by clicking on it you can perform various operations through the menu, and if we double click on each line, it show us the view page editing of PID.
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When a PID is being edited by another user a padlock will be displayed at the begining of the lines, this indicates that this PID is blocked for editing is not allowed more than one user to modify a particular PID at the same time. If we are blocking that PID in the padlock icon is also displayed a pencil. Passing the mouse over the padlock and waiting a bit will show us a Tooltip which will indicate that user has blocked PID for editing.
In this picture we see the listing, the lock with the pencil icon, as it is the current user that hast it locked, and the tooltip indicating the name of the user.
We will describe the menu at the top of the listings page.
Section PID:
New PID: creates a new PID, will display a window in which we will introduce a name and UOM we will use.
Details: with a selected PID in the list it shows us its view editing window, it behaves as if it were double click on the corresponding line.
Copy: with a selected PID list can create a copy of this, we will ask that introduce a name for the new PID copy.
New Version: with a selected PID in the list you can create a new versión of PID, additionally adding comments window will show us if we add the creation of new versión information.
Delete: with a selected PID in the list will move to deleted this PID, as already indicated above, only the Admin user can still see the PIDs in that state.
Section Comments:
Write: with a selected PID add a comment, a window in which we can see the previous comments and at the bottom, a text box in which can write our comment, once we have finished, click th Save button will show us.
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Read: with a selected PID will show us a window only display in which we will see the comments for that PID, will be sorted from newes to oldest and we can navigate through them with a navigation bar at the bottom of the window.
Excel Section:
Export: with a selected PID can export information in Excel format PID, a window will appear for stored which we can select the name and location of the file that will be generated.
Import: It will do the opposite to the previous, but in two modes, we can have a PID selected or not, when we do click on Import show us a window that will give us two options, create a new one from the file you import (Create new) or modify an existing one with the data from the file (Update selected) in concrete which have selected, if not, this option appears disabled.
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If you choose to create a new one ask us the name of the new PID and the file which we will choose by clicking on the button Browse, finally press the button Upload Excel. If we choose to Update selected only we will be file to import.
Search section:
Refresh: It serves to refresh the page and listings, it is useful if some time ago athat we have loaded the page because it may be the case that other users modify or create PID and we will not see such information until we become a refresh.
View edit page: This page consists of 3 areas, the menu, the units bar, and the window parameters and configuration which in turn is divided into 4 sections which you can change size if we let the mouse cursor in one of the bars of separation, which will cause the cursor to change to one of resizing, by clicking an dragging will modify the size at our convenience.
We may use this window in two modes, view and editing, to switch between them only have to use the Lock button or Unlock the menu, when we block the PID for editing with Lock can edit, when we unlocked with Unlock only can see the parameters defined for the PID.
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In the units bar located between the menu and the work area you can select unit type for each type of parameters that are going to use.
In the work area or parameters and settings are all the parameters needed to define the PID.
The menu is very similar to that already described with small differences which we will discuss.
The save button allows you to save the changes that we made in the PID parameters whenever we are obviously in the edit mode.
The lock button will allow us to lock the PID for Edition and is then when we turn to the edit mode, this button will change at that moment by one of Unlock which performs the opposite operation, unlock the PID so that other users can modify it.
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The report button allows us to generate a report of the PID in which appears the configuration for this, will show us a window in which we will be able to indicate the location of the generated file.
In the section Change status, have two buttons, the first Approved will allow us to change the PID status whenever you have it locked to Approved, while the second Obsolete will change the status to Obsolete.
After you configure a PID, pass to set up a recipe via the Recipe manager.
As for the PIDs there are two types of page, the listings and the edit view with very similar functions.
Listings page: This page is divided into 3 main sections, menu, tabs of listings and listing. First
we will describe the existing tabs, they correspond to the various states in which a recipe can be found during its life cycle. In each tab you will have list of the recipes that are in a given state.
In edit state, it is newly created recipes or that are in issue.
The approved state, list the recipes in that state, it´s those recipes that are approved and which therefore can be selected to setup loads or start cycles.
The recipes in this state, can never be edited, it would be necessary to create a new version of the recipe.
The obsolete state list the recipes in that state, are recipes that are no longer in use but which are kept as a reference, should be noted that a recipe may only be passed to this state if there is no charge that refers to this.
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The deleted state, list recipes in that state, are definitely deleted recipes, really will not be a final deletion at all, because the Admin user will be the only one who can see the recipes in this list but will be for other users as if they were not.
The following is the listing itself, obviously one by each tab displaying recipes in that particular state.
It consists of several columns, that show the name of the recipe, type, number of segments, as well as units of measurement, for each type, used PID and a date.
Selecting a line, by clicking on it, you can perform various operations through the menu, and if we double click on it it would show us the view edit.
When a recipe is being edited by another user a padlock will be displayed at the beginning of the line, this indicates that this recipe is blocked for editing because he is not allowed more than one user to modify a specific recipe at the same time.
If we who are blocking this recipe in the padlock icon is also displayed a pencil. Passing the mouse over the padlock and waiting a bit will show us a tooltip which will indicate user has blocked the recipe for editing.
In this picture we see the listing, the lock with the pencil icon, as it is the current user that has it locked, and the tooltip indicating the name of the user.
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3.6 PROCESS CONTROL.
In this screen the current segment in which the cycle is displayed in Green. You can make changes of recipe only in the current segment. These changes will not be
saved in the original recipe, and will be lost once finished this segment. We can also do the following operations:
Abort cycle: By pressing this button the cycle will be aborted. All elements will be closed, or may turn off, and must finish the cycle manually. Stop cycle: By pressing this button the cycle will be retained, Setpoints calculations are paused. End of segment: This button will jump to the next segment. In addition of viewing time of the ramp or maintenance of the current segment and the total elapsed time of the cycle.
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3.7 GRAPHICS.
3.7.1 Process.
(1) With this button you can choose the process curves to show.
(2) Sample support in real time, explaining the management of this screen.
(3) Will have to choose the color of curves and the time period to show. (By pressing the “stop” button).
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3.7.2 Temperature.
(1) With this button you can choose thermocouples curves to show.
(2) This button shows two bars to determine a range, and then with the button (3) appears the table of statistics showing the average.
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3.7.3 Pressure and Vacuum.
(1) Pressure and vacuum curves can be selected to show with this button.
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3.8 DCP (Power Analyzer)
3.8.1 Screen measures. In this screen we can visualize the measures corresponding to voltage, intensity,
frequency and powers.
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3.8.2 Trends screen. In this screen we can view the graphs corresponding to each for voltaje, intensity,
frequency and powers.
3.8.3 Settings screen. In this screen we can adjust different display and measurement ranges both for
voltage, intensity, frequency and powers.
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3.9 MEASURED VALUES.
In this screen you can see all the values of the temperature and pressure sensors, as well as instant thermocouples of piece rates. (1) You can enable (red) or disable (blinking red) current thermocouples of the cycle.
(2) the instantaneous values of the speed of the piece thermocouples. If this value exceeds the fixed on recipe plus the margin entered, appears an alarm and the field will blinking red.
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3.10 HISTORICAL MAINTENANCE.
In this screen we can see the state of the main elements of the autoclave with respect to its proper maintenance.
Total columns, we can see:
Days, hours, minutes and seconds total operation.
Total number of starts.
NOTE: these values can never be changed by the user. The control columns, we can see:
Days, hours, minutes and seconds for maintenance of the machine.
Total number of starts for the maintenance of the machine.
NOTE: these values must be entered by the user with respect to that recommended by the manufacturer of each item. For more information refer to the General Manual, in the maintenance section.
The partial columns, we can see:
Days, hours, minutes, and seconds partial operation.
Partial number of starts.
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NOTE: when these values exceed the values of control the system creates an alarm and flashing red background of the name of the element (1). In this case it should be the maintenance of that element, and later reset the partial counter by clicking on the corresponding “Reset” button.
3.11 CONTROL VALVES: VACUUM/VENTING.
Mode: All (1): If you select “CLOSE”, all the valves will be closed, it shall be shown in yellow (2). If you select “VACUUM”, all vacuum valves will open and from the venting will be closed. If you select “VENTING”, all vent valves open and those of vacuum will be closed. If “AUTO” is select all valves shall pass to auto mode, it will be indicated in Green. Mode: Individual (3): Firs it is necessary to select valve (2). His name will be indicated (3) on the screen. Second we select automatic or manual mode. Third select vacuum, vent or close. Finally if you want to return to the automatic mode turns to press Automatic/Manual.
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3.12 MANUAL CONTROL.
(1) Select the element to be controlled. (2) The selected item is shown in the pop-up screen. (3) Selection of control mode (Auto/Manual). While in Manual can open and close the valves and start/stop the engines. Certain valves will need to enter the percentage of opening them. (4) Will pop up a screen to enter the value. Once pressed ‘enter’ key must confirm this value by pressing the “Yes” button, already in red.
To leave all items in automatic mode, only it will necessary to press the button all “Automatic”.
Note: The yellow color indicates that the element is in manual mode.
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3.13 REPORTS.
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3.14 MAINTENANCE SETTINGS/ OLMAR
3.14.1 Thermocouples Settings. In this screen you can access the calibration of thermocouples. Only for authorized personnel.
Zero value: The user will introduce the new Zero (1) and then press “Accept” button in the thermocouple for calibration (2). Span value: The user will enter the new value of Span “Accept” button in the thermocouple for calibration (4).
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Reset: To delete the settings, press the “Accept” button in the thermocouple to restore (5).
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3.14.2 Transducers Settings. In this screen you can access the calibration of thermocouples. Only for authorized personnel.
Zero value: The user will introduce the new Zero (1) and then press “Accept” button in the transducer for calibration (2). Span value: The user will enter the new value of Span “Accept” button in the transducer for calibration (4). Reset: To delete the settings, press the “Accept” button in the transducer to restore (5).
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3.14.3 “Olmar”. Security and Control Settings. Only for authorized personnel. PID parameters:
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In this screen can modify in real time (during a cycle) the values of the current PID
(including the Initial) deciding the user save or not these changes in the PID.
All of these fields have been explained in the section edit PID, with the exception of the hysteresis of the fine cooling Valve (air/water).
When we are in the positive part of the temperature control (heating), and allow to cool in the corresponding phase, only actuary fine cooling valve controlled by hysteresis values.
Hysteresis ON: When the VP ≥ SP +H.ON open fine cooling valve.
Hysteresis OFF: When the VP ≤ SP +H.OFF close fine cooling valve.
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Safety Settings door/Autoclave/Pieces: Autoclave Safety Settings:
• Maximum Pressure: maximum allowable pressure in the autoclave. Stop the process. • Maximum Temperature: maximum allowable temperature in the autoclave. Stop the process. • Maximum Temperature for cooling: Reached this temperature (above than T. Max.), the process is stopped. Starts the turbine and cooling system.
• Time of surveillance gap of pressure: Time during which it is checked that that the VP of pressure not away from SP a value prescribed by recipe. If this time is exceeded a warning is generated.
Maximum pressure with nitrogen (not applicable): Maximum N2 (%) for setting in autoclaves that pressurize with N2 + Air.
Security Gate Settings:
• Atmosferic pressure setting: Admitted as atmospheric pressure. Below this value it will be permitted to open the door. • Security time end of cycle: Safety time (min) from the end of the cycle until the permission of door opening. • Maximum allowable temperature: Below this value it will be allowed to open the door. • Air battery discharge time: Time that remains fine cooling valve open (for the discharge of the autoclave) once completed the cycle, if this takes place the fine cooling with air. If it takes place with water this value must be zero.
• Battery discharge time: If we have to download with air, time remaining open discharge valves once completed air discharge. If we don´t have donwload with air, time remaining open discharge valves one the cycle has been completed.
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Security Part Settings:
• Advance isotherm time: Advance time to maximum time that not must elapse (by recipe), since enter the thermocouple hot until it enters the colder, in isotherm, this generates a warning.
• Pressure of vent: First security pressure on transducers of the bags. If this pressure is reached, the bag goes to vent, to retrieve the value of Hysteresis vacuum maintenance.
• Closing pressure (Break): Second security pressure on transducers of the bags. If this pressure is reached, close the valves vacuum and venting, for the rest of the cycle.
• Hysteresis vacuum maintenance: Hysteresis value required for the opening of the air valve of the boiler.
Security Vacuum settings:
• Maximum pressure in the manifold: Security pressure in the manifold vacuum (value less than the setting for the safety valve). If this pressure is reached, the vacuum pump stops.
• Vacuum Hysteresis: dead band for control vacuum and venting valves. Files settings:
• Data archiving time: How often are archived data from the system.
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• Reading cancelled in TC / TR offline: It only allows to register thermocouples / transducers used in the cycle and which are not switched off. The rest of sensors they will have zero value.
• Hysteresis Air Valve: Hysteresis value for opening or closing the air valve. • Hysteresis for alarm excess thermocouple speed: If the instant speed of the thermocouple of piece exceeds the setting value (by recipe) over this hysteresis appears an alarm and will be reflected on the screen of “Measured values”, by a red flashing.
3.15 EVENTS.
This screen logs all manual adjustments or modifications made by the user of the machine. Also recording stages of ramp or maintenance of the cycle.
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3.16 ALARMS.
This screen records the system alarms.
Red indicates new alarm.
Blue means that the alarm has disappeared but has not been acknowledge.
Grey indicates that the alarm has been acknowledge but still is active.
3.16.1.1 Manage Buzzer.
In this screen you can choose that group of alarms activate or not the siren.
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3.17 CHANGE LANGUAGE.
Clicking on the button automatically changes the language of the application of Wincc.
3.18 LOGIN.
This button is accessed to the desired user login.