Minas Option4 en

CEMAT Objects CEMAT V9 MinAS Option4
THE CEMAT V9 MINERALS LIBRARY 5

CEMAT Blocks for General Functions (System Chart) 6
CEMAT Objects 7
GENERAL FUNCTIONS 9
CEMAT OBJECT FUNCTIONS 11
Exercises in Area „E50 System Test‟ 12
Group and drive functions 15

Example 1: 'Transport out of bin E52-3B1' 15
Creating CFCs and blocks based on Template charts 18
Tagnames and Asset Code (ACS or HAC) 18
Block Properties and message definition 21
Connection to the I/Os – Standard Signals of the drives 25
Group link (essential) 28
Drive interlocks 33
Using interlock blocks for visualization of interlocking conditions 36
APL Interlock blocks 36
CEMAT Interlock blocks 36
General rules for all interlock functions 36
How to use the APL Interlock blocks with CEMAT 38
How to use the CEMAT Interlock blocks 39
Group connections for Automatic control 41
Start-up-Warning 44
Summary: Block interfaces of C_DRV_1D, C_DRV_2D, C_DAMPER and C_VALVE 45
Summary: Block interfaces of C_GROUP and C_MUX 49
Annunciation block functions (Part I) 51

Example 2: 'Drive fault annunciation' 51
Creating annunciation blocks for an existing drive and Property settings 53
Connection to the I/Os 56
Group/Object link (essential) 57
Block interconnections and Parameter settings 59
Example 3: 'Enable messages' 62
Creating a CFC and a block with proper Property settings 64
Summary: Block interfaces of C_ANNUNC and C_ANNUN8 68
Process Feedback block functions 70

Example 4: 'Speed Monitor of a drive' 70
Creating a process feedback block for an existing drive and Property settings 72
Summary: Block interfaces of C_PROFB 78
Measuring value functions 79
Copyright  Siemens AG. All Rights Reserved. 1

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D:\Training\Training Manuals\V90\CEM_V90\EINSTEIGER\ENGLISCH\CEMV9OBJECTS_MinAS_Option4_en.doc
CEMAT V9 MinAS Option4 CEMAT Objects
Example 5: 'Belt Conveyor Flow measurement' 79

Creating the measured value blocks and Property settings 80
Adaptation of measuring range and limits 84
Display of the measured value in the drive faceplate (optional) 87
Analog value archive (optional) 88
Summary: Block interfaces of C_MEASUR 91
Route functions 92
Example 6: „Selection of the transport destination via route modules‟ 92
Creating the route blocks and Property settings 93
Group/Route link (essential) 94
Group and Route connections for Automatic control 96
Uninterrupted route change-over 99
Summary: Block interfaces of C_ROUTE 101
Annunciation block functions (Part II) 102

Example 7: 'Silo level annunciation' 102
Creating CFC and blocks with proper Property settings 104
Example 8: 'Annunciation for group status call' 109
Creating an annunciation block for an existing group and Property settings 110
Bag Filter (Warning Motors) 113

Example 9: „Adding a bag filter to the existing group‟ 113
Creating CFC and blocks with proper Property settings 115
Exercises in Area: 'Training' 120
Selection functions 122

Example 10: 'Pump in Stand-by mode' 122
Creating CFCs and blocks with proper Property settings 124
Connection to the I/Os – Standard Signals of the drives 125
Selection Change 127
Group connections for Automatic control 128
Summary: Block interfaces of C_SELECT 130
Using Process feedback blocks for pressure supervision 131

Example 11: Pressure supervision 131
Creating a process feedback block for an existing drive and Property settings 132
Using Annunciation blocks for pressure supervision (optional exercise) 138

Example 12: 'Pressure supervision' 138
2 Copyright  Siemens AG. All Rights Reserved.

Creating annunciation blocks for an existing drive and Property settings 139
Positioning function of C_DAMPER 145

Example 13: 'Fan and Damper' 145
Creating CFCs and blocks with proper Property settings 146
Simulation of the I/Os for Contactor feedback and Limit Position 149
Drive interlocks and Group connections for Automatic control 150
SIMOCODE Adapter function 152

Example 14: 'C_DRV_1D with SIMOCODE' 152
SIMOCODE example 153
Summary: Block interfaces of C_SIMOS 154
Variable Speed Drives 155

Example 15: SINAMICS, ROBICON and other VSD drives 155
Additional Block interfaces in C_DRV_1D for setpoint function 155
Example for the connections to SINAMICS Adapter block C_SINA: 156
Adapter to non-CEMAT blocks 157

Example 16: 'Connecting non CEMAT blocks directly to the group (or route)' 157
Required block connections in the CFC 157
Required status information from the non CEMAT block 159
Creating a configuration file for the non CEMAT block 160
Summary: Block interfaces of C_ADAPT 161
Analog value selector 162

Example 17: 'Connecting multiple measurements to a drive' 162
Creating an analog value selector and connecting it to the drive 162
Summary: Block interfaces of C_ANASEL 164
CEMAT SETTINGS IN THE PCS 7 PROJECT 165
CEMAT V9 Project Standards 166
CONFIGURATION OF THE CEMAT BLOCKS AND FACEPLATES 167
General settings in the System Chart SYSPLCxx 167

Acknowledgement modes 168
Warning mode 171
PLC Number ° 171
Sequence-Test 172
Option for customizing texts 173
Supplement for „Still faulty‟ message 174
General functions 174
Settings for Feature bits and OS Permissions 175
Adaptation of the blocks regarding Operating mode and Periphery 176

Settings for Local switch and MCC 176
Operation mode change 177

Operator authorization levels 178

Feature bit setting for “Switch to manual mode” 179
OS_Permission for “Switch to manual mode” 179
Operator authorization levels in WinCC 180
Instance Specific Operator authorization levels 180
Feature Master Concept 181

Feature Master blocks 181
Configuration mode and Consistency check 184
Error numbers 186
Considerations regarding Feature bit settings 187
Master Library – Templates 191
Feature bits and OS Permissions 192

Feature bits of C_DRV_1D 192
Feature2 bits of C_DRV_1D 193
OS Permissions of C_DRV_1D 194
Template Example 195
Using group link for mode change and feedback 196
Individual connections for mode change and feedback 197
Mode change and feedback derived from Group link 197
Definition of Variable texts 198
Configuration of the HMI functions 200

Generation of Process Pictures 200
Picture Navigation 201
Block icon definition 203
LafargeHolcim Symbols Library 204
ENGINEERING TOOLS 206

Generation of Data for Info Dialog 206
New check Tool „CEMATCheckTool.exe‟ 207

THE CEMAT V9 MINERALS LIBRARY
The CEMAT V9 Minerals library Minerals_Cemat_V9000 contains three S7-Program folders:
S7-Program Minerals_Cemat is the main folder and it contains the Standard-Symbols, a block
container and a chart container.
The standard symbols include the blocks and memories used in CEMAT. During the setup
of a new project the standard symbols must be copied into the symbols file of each AS.
The block container contains the Minerals_Cemat blocks and its infrastructure. All blocks
are needed and during the setup of a new project all blocks must be copied into the block
container of the AS.
The chart container contains the system chart SYSPLC00 and possibly derivations of it.
The derivations are named with “Option”, as e. g. Option4, which shows that certain
parameter settings within these blocks are adapted in order to comply with special
customer‟s requirements.
The blocks in the System chart must be called once in each AS, some at the beginning,
some at the end of the OBs.
During the setup of a new project the system chart must once be copied into each AS and
renamed according to the AS number (e. g. SYSPLC01).
S7-Program Cemat_AddOn contains additional blocks like adapters for SIMOCODE, SINAMICS
or ROBICON, Send/Receive blocks for PLC-PLC communication, etc. These optional blocks
may need to be adapted for the project and they are therefore not know-how protected.
S7-Program Templates contains example CFCs, small applications with typical connections
between drives, measurements and annunciation blocks. These template charts can be used
when defining the process tag types for a project.
During the engineering blocks from other Libraries such as PCS 7 AP Library V90 are required
in addition (e. g. for PID controllers).
After the setup of your project, in Catalog CEMAT you will find the General functions (called in
system chart) and the CEMAT objects.

CEMAT Blocks for General Functions (System Chart)
Block name Description

OB1_SYS1 ILS and CEMAT System functions
(Beginning of OB1)
OB1_SYS2 CFC_ILS System functions
(End of OB1)
OB100_SYS1 CFC_ILS PLC restart
(Beginning of OB100)
OB35_SYS1 ILS System functions
(Beginning of OB35 - 100ms)
OB35_SYS2 ILS System functions
(End of OB35 - 100ms)
C_PUSHBT General Functions
C_FB_PLC CEMAT PLC-Object
C_OB1SY1 System functions CEMAT
(Beginning of OB1)
TIME_BEG Time begin (for cycle time calculation)
TIME_END Time difference (for cycle time calculation)
CPUDIAG System Diagnosis
C_CNT100 CEMAT 100ms counter
C_M_DRV_1D C_DRV_1D Feature master block
C_M_DRV_2D C_DRV_2D Feature master block
C_M_DAMPER C_DAMPER Feature master block
C_M_VALVE C_VALVE Feature master block
C_M_ANNUNC C_ANNUNC Feature master block
C_M_ANNUN8 C_ANNUN8 Feature master block
C_M_PROFB C_PROFB Feature master block
C_M_PROFBx C_PROFBx Feature master block
C_M_MEASUR C_MEASUR Feature master block
C_M_ROUTE C_ROUTE Feature master block
C_M_GROUP C_GROUP Feature master block
The blocks in the System Chart are called only once. By inserting the System Chart the blocks
are already installed in the correct sequence in certain runtime groups.
The position of the runtime group must be checked, they must always be installed at the
beginning or at the end of the corresponding OB.

CEMAT Objects

C_DRV_1D Unidirectional drive
C_DRV_2D Bi-directional drive
C_DAMPER Damper
C_VALVE Valve
C_SIMOS SIMOCODE Adapter Block (AddOn)
C_SINA SINAMICS Adapter Block (AddOn)
C_ROBI ROBICON Adapter Block (AddOn)
C_ANNUNC Annunciation
C_ANNUN8 Annunciation with 7 Alarms
C_PROFB Process feedback block
C_PROFBx Process feedback block
C_MEASUR Measuring Value
C_STAT8 Status display of up to 8 Signals
C_ROUTE Route
C_GROUP Group
C_MUX For objects which belong to more than 2 groups/routes.
C_SELECT Selection
C_INTLK2 Interlock with 2 inputs

C_ADAPT Adapter Module

C_ANASEL Select one out of 16 analog values
C_RelMod Show related modules
C_STORAG Storage module
C_STO_MA Storage module (Master for Multi chamber)
C_TIS_B Bool Variable for TIS

C_TIS_N Integer Variable for TIS
C_TIS_S String Variable for TIS


C_P_MAT CEMAT SPC Material Manager
C_P_MGR CEMAT SPC Manager
C_PC_8I CEMAT SPC Data collector: 8 Setpoints and Process value
C_PC_8R CEMAT SPC Data collector: 8 Setpoints and Process value
C_PC_8B CEMAT SPC Data collector: 8 Setpoints and Process value
C_PD_AI CEMAT SPC Data distributor: Absolute, INT
C_PD_AR CEMAT SPC Data distributor: Absolute, REAL
C_PD_RR CEMAT SPC Data distributor: Relative, REAL
C_PD_RTR CEMAT SPC Data distributor: Relative, Totalizing, REAL
C_PD_B CEMAT SPC Data distributor: BOOL
C_PD_S CEMAT SPC Data distributor: Storage Selection
C_PM_AI CEMAT SPC Recipe module: Absolute, INT
C_PM_AR CEMAT SPC Recipe module Absolute, REAL
C_PM_RR CEMAT SPC Recipe module: Relative, REAL
C_PM_RTR CEMAT SPC Recipe module: Relative, Totalizing, REAL
C_PM_B CEMAT SPC Recipe module: BOOL
C_PM_S CEMAT SPC Recipe module: Storage Selection
The CEMAT Objects must be called as many times as the function is needed.

GENERAL FUNCTIONS
CEMAT requires a number of General Functions which are mainly obtained through blocks in
System Chart. Via inserting the system chart into the chart folder during the setup of the project,
all blocks contained in the system chart have automatically been inserted at the right position in
the runtime sequence.
The blocks in System Chart need to run at the beginning/end of the OB. The runtime groups for
these blocks are therefore called OBx_START and OBx_END. The application program must be
called between OBx_START and OBx_END.
Many blocks in the System Chart are standard and don‟t require any configuration. Only some
blocks like e. g. C_FB_PLC and the Feature Master blocks need to be configured in order to
define Acknowledgement mode, text definitions and Standard values for Feature bits and OS
Permissions.
In the training project this has already been done and the configuration part is explained at the
end of the training manual under “Configuration of the CEMAT blocks and Faceplates”
The system chart SYSPLC00_Option4 has been renamed according to the PLC No, e. g.
SYSPLC01 for PLC No. 1. The PLC number must be unique within the complete control system.
Exercise 0.1: Preparations
All CEMAT blocks have to be inserted into OB1 between OB1_START and OB1_END. Make
sure that the new CFCs are inserted to the correct position:
Open any chart and then open the Runtime Editor. Select in the MAIN_TASK (OB1) the last
Runtime Group before OB1_END and select it as “Predecessor for the Next Chart Insertion”.
With these settings the next Chart will automatically be inserted before OB1_END.

General Module Structure
Periphery signals Annunciations (invisible)

(Process image inputs)
To the Operator station
Field, MCC,
Control desk, Mimic
Input interface
Visualisation status
(interlocking conditions) ModulTag
(invisible)
C_FUNCTION TASK
- when to start
Description G-No./Task-No. To the Operator station
- when to stop
- which protection
etc.
Release Functions
Output interfaces
Feature Bits
OS Permissions Module flags for internal
connections
Process values
- Start/stop delay
- Limit values Periphery signals
etc. (Process image outputs)
Lamps, Contactors,
Relays
Commands (invisible)
From the operator station
Group/ route link

Group/ route link
Connection to the
Connection to the subordinated objects
groups and routes

CEMAT OBJECT FUNCTIONS
The PCS 7 Multiproject is configured and contains one partial project with an AS (AS1), one
partial project with an Engineering Station (ES) and one project Library (Tng_Lib).
Different Areas are defined:
Area Demo contains the Clinker Transport Example (used for Demo purpose)
Area E50 System Test contains the LafargeHolcim System Test Example
Area Examples contains additional Example Applications
Area System contains the System chart and a Picture with general functions
Area Test contains some additional test pictures (not relevant)
Area Training contains exercises for the training, not belonging to LafargeHolcim
Systest
All Exercises for this Training will be carried out in Area „E50 System Test‟ and in Area „Training‟

Exercises in Area „E50 System Test‟
The following engineering example (Group E51) will be developed step by step during the
training.
For each block type the important functions and interfaces are explained. Step by step the
necessary connections will be carried out and then the functions can be tested.
Engineering example „Group E51‟:
Group E51-100 is used for the transport out of Bin E52-3B1 into Silos E51-3S1 or E51-3S2. Two
route modules are used for the selection of the destination.

List of Motors and Instruments:
ACS or HAC Equipment (who) Location (where) Device (what) Block Type F/W
E51-3S1.L2 Concrete Silo E51-3S1 Level switch max. C_ANNUNC F
E51-3S1.L1 Concrete Silo E51-3S1 Level Measurement C_MEASUR
E51-3S1.T1 Concrete Silo E51-3S1 Temperature C_MEASUR
E51-BC1.M1 Belt Conveyor below E51-3B1 C_DRV_1D F
E51-BC1.S1 Belt Conveyor below E51-3B1 Speed monitor C_PROFB F
E51-BC1.D1 Belt Conveyor below E51-3B1 Drift Switch 1 C_ANNUNC F
E51-BC1.R1 Belt Conveyor below E51-3B1 Rope Switch 1 C_ANNUNC F
E51-BC1.F1 Belt Conveyor below E51-3B1 Flow Measurement C_MEASUR ---
E51-BC2.M1 Belt Conveyor below E51-BC1 C_DRV_2D F
E51-BC2.S1 Belt Conveyor below E51-BC1 Speed Monitor C_PROFB F
E51-BF1.C1 Bag Filter to E51-BC2 Frequency Converter C_DRV_1D W
E51-FN1.M1 Fan E51-BF1 C_DRV_1D W
E51-FN1.TU Fan E51-BF1 Temperature C_MEASUR ---
E51-MW1.V1 Distribution Gate above E51-3S C_VALVE F
E51-MW1.X1 Distribution Gate above E51-3S Position switch open --- ---
Position switch
E51-MW1.Y1 Distribution Gate above E51-3S --- ---
closed
E51-RF1.M1 Rotary Feeder below E51-3B1 C_DRV_1D F
E51-RF2.M1 Rotary Feeder E51-BF1 C_DRV_1D W
E51-RF2.S1 Rotary Feeder E51-BF1 Speed Monitor C_PROFB W
E51-SG1.M1 Slide Gate below E51-3B1 C_DAMPER F
E51-SG1.X1 Slide Gate below E51-3B1 Position switch open --- ---
Position switch
E51-SG1.Y1 Slide Gate below E51-3B1 --- ---
closed
Groups and Routes:
Transport out of Bin
E51-100.00 C_GROUP ---
E52-3B1
E51-101.00 To Silo E51-3S1 C_ROUTE ---
The signals for the above listed equipment are already assigned to I/O addresses and entered in
the symbols file. In each exercise you find a list of inputs and outputs to be used.
A hardware configuration for the I/O periphery exists as well.

Simulation and test:
For the test of the exercises the inputs can be simulated via buttons on the screen (as there is
no real periphery available).
Via this buttons simulation flags are set/reset. In an already prepared simulation program
SIM_TRAINING (FC1399), which must be called before the other applications, the status of the
flags is transferred to the inputs.
Simulation Buttons in E50_G.pdl
With “Show” and “Hide” you can display or hide the simulation buttons.
Use left mouse click to toggle the signals.

Group and drive functions
Example 1: 'Transport out of bin E52-3B1'
In the first example the basic drive functions will be explained based on a material transport.
The application consists of the following objects:
Transport out of Bin
E51-100.00 C_GROUP ---
E52-3B1
E51-MW1.V1 Distribution Gate above E51-3S C_VALVE F
E51-BC2.M1 Belt Conveyor below E51-BC1 C_DRV_2D F
E51-BC1.M1 Belt Conveyor below E51-3B1 C_DRV_1D F
E51-RF1.M1 Rotary Feeder below E51-3B1 C_DRV_1D F
E51-SG1.M1 Slide Gate below E51-3B1 C_DAMPER F

Each drive/device is connected to Periphery signals which are simulated in this example via
Buttons in the Process Picture, or in some cases directly in the program.
I/O list:
Tag name Comment Address

E51_MW1_V1_U Distribution Gate Valve no local isolated I 29.0
E51_MW1_V1_S Distribution Gate Valve no local Stop I 29.1
E51_MW1_V1_G Distribution Gate Valve Local Start I 29.2
E51_MW1_X1 Distribution Gate Position switch open I 30.0
E51_MW1_Y1 Distribution Gate Position switch closed I 30.1
E51_MW1_V1_K Distribution Gate Valve Available I 45.0
E51_MW1_V1_D Distribution Gate Valve Switch ON Q 41.2
E51_BC2_M1_U Belt Conveyor Motor no local isolated I 15.0

E51_BC2_M1_S Belt Conveyor Motor no local Stop I 15.1
E51_BC2_M1_GX Belt Conveyor Motor Local Start X direction I 15.2
E51_BC2_M1_GY Belt Conveyor Motor Local Start Y direction I 15.3
E51_BC2_S1 Belt Conveyor Speed Impulse Speed Pulse I 16.0
E51_BC2_M1_K Belt Conveyor Motor Available I 41.0
E51_BC2_M1_T Belt Conveyor Motor no thermal overload I 41.1
E51_BC2_M1_RX Belt Conveyor Motor Running I 41.2
E51_BC2_M1_RY Belt Conveyor Motor Running I 41.3
E51_BC2_M1_DX Belt Conveyor Motor Switch ON X direction Q 40.1
E51_BC2_M1_DY Belt Conveyor Motor Switch ON Y direction Q 40.2
E51_BC1_M1_U Belt Conveyor Motor no local isolated I 13.0

E51_BC1_M1_S Belt Conveyor Motor Local Stop I 13.1
E51_BC1_M1_G Belt Conveyor Motor Local Start I 13.2
E51_BC1_M1_K Belt Conveyor Motor Available I 40.0
E51_BC1_M1_T Belt Conveyor Motor no thermal overload I 40.1
E51_BC1_M1_R Belt Conveyor Motor Running I 40.2
E51_BC1_M1_D Belt Conveyor Motor Switch ON Q 40.0
E51_RF1_M1_K Rotary Feeder Motor Available I 47.0

E51_RF1_M1_T Rotary Feeder Motor no thermal overload I 47.1
E51_RF1_M1_R Rotary Feeder Motor Running I 47.2
E51_RF1_M1_U Rotary Feeder Motor no local isolated I 17.0
E51_RF1_M1_S Rotary Feeder Motor no local Stop I 17.1
E51_RF1_M1_G Rotary Feeder Motor Local Start I 17.2
E51_RF1_M1_D Rotary Feeder Motor Switch ON Q 42.0


E51_SG1_M1_K Slide Gate Motor Available I 49.0
E51_SG1_M1_T Slide Gate Motor no thermal overload I 49.1
E51_SG1_M1_RX Slide Gate Motor Running X direction I 49.2
E51_SG1_M1_RY Slide Gate Motor Running Y direction I 49.3
E51_SG1_M1_U Slide Gate Motor no local isolated I 18.0
E51_SG1_M1_S Slide Gate Motor no local Stop I 18.1
E51_SG1_M1_GX Slide Gate Motor Local Start X direction I 18.2
E51_SG1_M1_GY Slide Gate Motor Local Start Y direction I 18.3
E51_SG1_X1 Slide Gate Position switch open I 19.0
E51_SG1_Y1 Slide Gate Position switch closed I 19.1
E51_SG1_M1_DX Slide Gate Motor Switch ON X direction Q 42.2
E51_SG1_M1_DY Slide Gate Motor Switch ON Y direction Q 42.3
The following simulation buttons can be used in order to change the signal status:
Contactor feedback and Position feedback are not simulated by buttons because these signals
depend on the Contactor ON command and are therefore difficult to switch "in time". The
simulation will be carried out in the CFC of the drive function.

Creating CFCs and blocks based on Template charts
For each Project 'control module types' or 'process tag types' must exist. In the Project Library
'Tng_Lib' you find a Hierarchy folder 'Templates_nnn', containing a set of Template charts for
the Training.
The blocks used in the template charts contain the project specific settings which specify the
behavior of the blocks (e. g. regarding mode change or local switch). These are mainly the
settings in the Feature bits and OS Permissions, but could also be other definitions as well.
The template charts may contain individual blocks or more complex functions (like a Belt
Conveyor or a Bucket Elevator).
In case of the Training Project only individual blocks are prepared, because the linking of the
blocks is part of the exercises ;-)
Tagnames and Asset Code (ACS or HAC)
According to the ACS (Asset Codification System) the Tagname of the equipment is built as
follows:
Group number Asset Unit Component number
1 2 3 - 4 5 6 7 . 8 9 10
Example for a Belt conveyor drive in E51 Group: E51-BC01.M01:

Group number : E51
Asset Unit: BC01
Components number: M01
According to the HAC (Holcim Asset Code) the Tagname of the equipment is built as follows:
Group number Asset Unit Component number
1 2 3 - 4 5 6 . 7 8
Example for a Belt conveyor drive in E51 Group: E51-BC1.M1:

Group number : E51
Asset Unit: BC1
Components number: M1
In the Training Examples, the separator between Group number and Asset Unit is replaced by
“_”, because if working with engineering Tools like Excel, “-“ is not always useful.
The separator “/” between Chart name and block name is a must!
Chart name Block name
1 2 3 _ 4 5 6 / 7 8
The tagname of the Belt conveyor drive in PCS 7/CEMAT will therefore be: E51_BC01/M01.
Nevertheless the Equipment name, to be displayed in the process picture must be E51-BC01!

According to CEMAT Engineering rules, the length of the tagname is limited to 20 characters
(which is not a problem with HAC anyway!)
For Dampers, Valves and Bi-directional drives, according to HAC:

X stands for Forward, In, Up, Open, Right, On, North, East and 1
Y stands for Reverse, Out, Down , Close, Left, Off, South, West and 2
Important note: In the CEMAT functions for Damper, Valve and Bi-directional Drive (especially
! in the functions blocks) the directions are named with Direction 1 and Direction 2, where:
Direction 1 (closed) corresponds to Direction Y
Direction 2 (open) corresponds to Direction X

Exercise 1.1: Creating new charts and inserting the blocks
In the plant hierarchy of AS1 in the Area 'E50 System Test ' you find a subfolder „E51‟. This
subfolder will be used for the group 'Transport out of bin E52-3B1'.
For the example above you need to create 6 charts, naming them as follows:
E51_MW1
E51_BC2
E51_BC1
E51_RF1
E51_SG1
E51_100
Each chart will be used for one drive/device and one additional chart for the group. In the
Runtime Editor, automatically a runtime group is created with the same name. Make sure that
the Runtime groups are inserted between OB1_START and OB1_END.
It is recommended to insert the drives in the start order and to call the group at the end.
For each drive the corresponding block must be inserted. Proceed as follows:
- Open the template chart VALVE from 'Tng_Lib', Folder 'Templates_nnn'.

The description beside the block shows the settings of Feature bits and OS Permissions.
The same settings shall be used for each instance.
- Open chart E51_MW1, copy block C_VALVE from the template chart and insert it into
the chart of the Distribution Gate.
- Repeat this step for each drive/device and for the group, using the block from the
corresponding template chart.
Caution: When inserting new CEMAT blocks, do not drag and drop the block directly from the
! block folder, otherwise the settings for Feature bits and OS Permissions must be adapted for
each instance.

Block Properties and message definition
The Properties of the block must be entered for each object. These are block name, comment,
block icon and message definition.
The block properties can be entered via the Properties dialog in the CFC or via the Process
object view.
Name:
The name (instance name) is the second part of the tag name of the CEMAT object. Following
the HAC rules the instance name is e. g. “M1”.
The name can either be entered in the block properties in the CFC or in the process object view
in folder 'Blocks', column 'Block'.
Caution: The tag name (Chart name + block name) must not exceed 20 characters!
!

Comment:
The comment contains the designation of the equipment, e. g. “Belt Conveyor”. This text is later
on available in WinCC as internal variable #comment and will be displayed in the faceplate of the
object. The maximum length of the comment is 40 characters.
According to HAC the designation consists of Equipment (who), Location (where) and Device
(what). As this does not fit into 40 characters, only Equipment and Device will be used in the
comment text. The location will be given as additional information via Info-Dialog.
The comment can either be entered in the block properties in the CFC or in the process object
view in folder 'Blocks', column 'Block comment'.
Under “OCM possible” you find the settings regarding WinCC:
Create Block Icon:

Template picture @PCS7Typicals_CemV9_001_004.PDL contains different block icons for each
block type. The number you find beside the icon corresponds to the index and must be entered
in the block properties in the CFC.
The index can either be entered in the block properties in the CFC or in the process object view
in folder 'Blocks', column 'Block icon'.
The difference in block icons 1-4 for the drives is only in the position of the operation mode
indication:
1 – Operation mode left

2 – Operation mode below
3 – Operation mode right
4 – Operation mode above

Messages...
Each CEMAT block internally uses one or more ALARM_8 or ALARM_8P function(s), whose
signals are already predefined in the CEMAT standard. To show the block comment also in the
alarm line, the block comment must be available for each signal under Special properties 
Messages… in tab “Additional Texts”, Consec. No. 5.
There are two possibilities to enter the block comment:
- You may either use the Message definition in the CFC, copy the block comment and
paste it under Special properties  Messages…to each message in row 5.
- In Order to show the Location information (where Text) in the message system, this text
must be entered under Special properties  Messages…to each message in row 9.-
- An easier method is to use the process object view, tab “Messages” and to copy the
column “block comment” into column “Free Text 1”.
The Location information (where text) must be entered into column “Free Text 5”.
If column “Free Text 1” does not appear you have to change the setting in the SIMATIC
Manager under Options  Customize  Columns  Process Object View  Messages.

Exercise 1.2: Entering the block properties and the message definitions
- Enter the block properties for each block:
Chart name Block name Comment Block Icon

E51_100 00 Transport out of bin E52-3B1 2
E51_MW1 V1 Distribution Gate 1
E51_BC2 M1 Reversible Belt Conveyor 1
E51_BC1 M1 Belt Conveyor 1
E51_RF1 M1 Rotary Feeder 1
E51_SG1 M1 Slide Gate 1
- Open the properties dialog and enter the block name, the comment and the number of
the block icon. (You can also make the definitions in the process object view).
- Add the message definition for each Signal, either via "Messages" Dialog or in the
process object view:
- Copy the block comment to 'Additional Texts', 'Consec. No. 5'
or via Process Object view to „Free Text 1‟
- Enter the Location information (where text) to 'Additional Texts', 'Consec. No. 9'
or via Process Object view to „Free Text 5‟.

Connection to the I/Os – Standard Signals of the drives
Each drive/device block has a number of inputs and outputs for connection to the periphery
(MCC signals or Field signals). The following Signals are evaluated by the different block types:

MCC Signals:
Comment I/O C_DRV_1D C_DRV_2D C_DAMPER C_VALVE

Contactor feedback on I (R) FbkRun (RY) FbkRun1 (RY) FbkRun1 *) (R) FbkRun *)
(RX) FbkRun2 (RX) FbkRun2 *)
Electrical available ok I (K) ElAvail (K) ElAvail (K) ElAvail (K) ElAvail
Thermal overload / I (T) Overload (T) Overload (T) Overload (T) Overload
mechanical overload ok
Contactor ON O (D) ContOn (DY) ContOn1 (DY) ContOn1 (D) ContOn
(DX) ContOn2 (DX) ContOn2
*) Contactor feedback Supervision for C_DAMPER and C_VALVE is optional and can be
enabled via Feature.bit27 (C_DAMPER) or Feature.bit17 (C_VALVE). By default the supervision
is disabled.
Field Signals:
Comment I/O C_DRV_1D C_DRV_2D C_DAMPER C_VALVE

Local Isolated I (U) AutModLo (U) AutModLo (U) AutModLo (U) AutModLo
Stop local: I (S) StopLoc (S) StopLoc (S) StopLoc (S) StopLoc
field switch stop signal
Start local: I (G) StartLoc (GY) StrtLoc1 GY) StrtLoc1 (G) StartLoc
Field switch start signal (GX) StrtLoc2 (GX) StrtLoc2
Limit position direction 1 I (ZY) FbkPos1 (Y) FbkPos1
Limit position direction 2 (ZX) FbkPos2 (X) FbkPos2
Torque switch direction 1 I (TY) TorqSw1
Torque switch direction 2 (TX) TorqSw2
Internal Limit Positions I (Y) IntPos1
(X) IntPos2

Exercise 1.3: Connecting the standard signals according to the I/O list to the blocks
On page 17 and 18 you find the I/O list for the blocks. The symbols already exist in the Symbols
file. (Memories are used instead of inputs because of simulation via HMI).
Connect the signals to the corresponding block.
Inputs which don't exist remain without connection (e. g. Torque switches). They will
automatically have the default status.
Contactor feedback of C_DRV_1D and C_DRV_2D as well as Limit Positions of C_DAMPER

and C_VALVE must be simulated; otherwise the block generates a fault.
- Contactor feedback of the drives could be simulated as well by connecting output

ContOn to input FbkRun.
The limit positions of the valve can be simulated by connecting output ContOn to input
FbkPos2 (open position) and the inverted output ContOn to input FbkPos1 (close
position).
- For the contactor feedback in exercises of group E51, no simulation button is foreseen,
but all contactor feedbacks for unidirectional and bidirectional drives as well as the limit
positions for the valves are simulated internally.
In this case please connect the inputs and outputs from the signal list above.
- For the simulation of the damper positions simulation buttons exist. In the first step,
please connect the inputs and outputs form signal list above to the block.
Later on you may replace this connection by using the simulation block C_SIMDMP,
which needs the following connections:
Make sure that the Actuator runtime from pos1 to pos2 MovActTi for C_DAMPER and
C_SIMDMP have the same value.

Group link (essential)
The group block is used for starting and stopping the drives in automatic mode and for
supervision of a sequence.
Functions such as summarizing warnings and faults, status call, object list, etc. are derived from
the allocation of the drives, annunciations and measured values to the group via the so-called
Group Link.
In order to make sure that the group link is done; all drives (annunciation blocks/measured
values) which are not linked to a group automatically go to "Out of Service" mode and will not
work.
This means, even if drives are never started/stopped in automatic mode, for supervision function
they must be linked to a superordinated group.
The link is carried out by connecting output G_LINK of the group to input GR_LINK1 (for the first
group) or GR_LINK2 (for the second group).
If the drive belongs to more than two groups a C_MUX block must be inserted before the drive.
Caution: GR_LINK1 is used as "Main Group" in the runtime system.

!

The object list of the group will show the following structure:
E51_100/00 out of bin 3B1

E51_MW1/V1 Distribution Gate
E51_BC2/M1 Reversible Belt conveyor
E51_BC1/M1 Belt conveyor
E51_RF1/M1 Rotary Feeder
E51_SG1/M1 Slide Gate
Exercise 1.4: Link between Group and drives
Carry out the link between the group and the drives by connecting output G_LINK of the group to
input GR_LINK1 of all drives.
Exercise 1.5: Compile and download functions
After this, compile the CFC and download the Program to the AS. (Compile and Download for
Changes only!)
Carry out the OS Compile as well. Select the following scope of compilation:

Open the OS Project. During the compilation of the OS the following data has been created in
WinCC:
- In the tag management under “Internal variables” for each block three variables have
been created (.#blocktype, .#comment und .#areaname).
- In the tag management under “SIMATIC S7 PROTOCOL SUITE“, a number of variables

have been created according to the variable definition of the drive, which are required for
the visualization. In case of a real AS you find these variables under “Named
Connections“ in the program container of the PLC.
In this case PLCSim is used and you will find the variable under "Industrial Ethernet" in
the program container of the PLC.
- In the Graphics Designer the new block Icons have been inserted in process picture
E50_G.pdl (in the upper left corner).
- In the Alarm Logging the messages for the new drive have been added.
- In the Picture Tree, the Process Picture has been inserted and the summarizing
indications have been updated.
After the OS compilation, carry out the following steps:
- Open the process picture and move the block icons to the desired position.
- The LafargeHolcim block icons need further modifications in some attributes in order to
give the proper indication.
All drive blocks (motors, dampers, valves) are represented by the equipment name,
Therefore the following Properties under “General” need to be adapted:
- Enter the equipment name (e. g. E51-BC1) to Attribute “TagOut”
- The Tooltip text by default shows the block comment. If anything else is desired, you
have to enter this text as well.
The group block icon may need adaptation as well regarding text display, by default the
Tagname is shown which is often not very meaningful.
- Enter the text (e.g. out of bin 3B1) under Property “General”, Attribute “TagOut”.
- In LafargeHolcim Standard the equipment itself shows “green” for “running” and “grey”
for “stopped”.
This can be achieved using an extended status display function by linking different
bitmaps to the Variable STATUS2 of the object.
Details for STATUS2 are explained in the object description under “OS Variable Table”.
Some examples for status displays can be found in picture C_Holcim_Symbols.pdl.
In process picture E50_G.pdl the status display for the equipment already exist and thy
only need to be linked to the correct variable, as e. g. E51_BC1/M1.STATUS2.
- Save the process picture.

Exercise 1.6: Test the drive functions in local mode and in manual mode
Start the OS Runtime and test the functionality of the application:
- Click on the group symbol in order to open the faceplate
- Press button “R” in order to display the related objects. All drives must be marked with a
blue frame for 10 s.
- Open the Object list of the group. If the installation in the Runtime group is correct the
drives should be shown in the start sequence.
- Change the status of ElAvail (K), Overload (T), AutModLo (U) or StopLoc (S) for some
drives and observe the indication in the block icon and in the faceplates.
- Observe the indication in the block icon and the faceplate of the group as well.
- Open the group faceplate and use the status call function of the group in order to get a
list of faults.
- Open a drive faceplate and change the mode to 'Local'.

Use button StartLoc (G) in order to start the drive in local mode. Use button StopLoc (S)
in order to give a local stop.
- Start the drive in local mode and create a fault (e. g. ElAvail (K)). The drive will stop
without giving an alarm.
- Check the Mode indication in the block icon of the group. It must show the letter 'L'.
- Open a drive faceplate and change the mode to 'Manual'. Use the faceplate button 'On'
to start the drive. Use button 'Off' to stop the drive.
- For the running device, create a fault via one of the simulation buttons. Check if the
Alarm message is correct!
- Open the information dialog and enter a note.
- Check the Mode indication in the block icon of the group. If none of the drives is switched
to local mode the group will show the letter 'M'.
- Switch some drives to Local mode, some to Manual mode. Check the summarizing
indication in the group faceplate.
- Use the Group Object list function in order to see list of drives/devices. In this list you can
also see the status of the drive.

- In the button line press button in order to open the „PCS7 measuring point browser‟.
Select 'M‟ for „Manual Mode‟ and 'L‟ for „Local Mode'. You will get a list of drives which
are switched into Manual mode or local mode.
- If the function is enabled, switching the drives/devices into the different modes can also
be carried out group-wise:
Open the group faceplate. Switching all objects to Manual mode is not possible, because
the function is disabled for the group. Switch all objects to Local mode.
Note: According to LafargeHolcim settings, switching to Manual mode is only possible

! for individual objects, not group-wise.
If a drive is running in Automatic mode or in Manual mode, it cannot be switched into
Local mode or non-interlocked manual mode!

Drive interlocks
In the interlocking conditions it is distinguished between process interlocks (start-up interlocks or

operation interlocks) and protections interlocks.
A missing protection interlock switches off the drive with fault. Alarm messages are not
created by the drive block itself. An additional annunciation block must be programmed.
A missing process interlock inhibits start-up of a drive/device or switches off a running

drive/device. No fault is created! In general the process interlocks are effective in automatic
mode and in manual mode as well (depending on feature bit setting). In local mode the process
interlocks are not effective.
The essential (process) interlocks are effective in all modes. A missing essential interlock
inhibits drive start or stops the running device but it does not create a fault for the drive/device.
A missing stop interlock inhibits the stop in automatic mode (e. g. because the feeding device
is still running and must be stopped first).
The status information for drive running RunSig is created in automatic mode and in some
manual modes (dependent on feature bit settings).
The status information for the position PosSig1 and PosSig2 is created in all modes.
Drive parameters for interlocking conditions and status information (running/position):

The following table shows which interlocking condition is effective in which mode:
Interlocking conditions for C_DRV_1D
Operating mode IntProtA IntProtG IntStart IntStaE IntOper IntOpE IntStop

Automatic X X X X X X X
Manual interlocked mode X X X X X X **)
Manual mode with reduced interlocks X X X X **)
Manual mode only protection interlocks X X **)
Manual mode non-interlocked X **)
Local mode ***) X X *) X *)
Interlocking conditions for C_DRV_2D
IntStrt1 IntStaE1 IntOper1 IntOpE1

Operating mode IntProtA IntProtG IntStop
IntStrt2 IntStaE2 IntOper2 IntOpE2
Automatic X X X X X X X
Manual interlocked mode X X X X X X **)
Manual mode with reduced interlocks X X X X **)
Manual mode only protection interlocks X X **)
Local mode ***) X X *) X *)
Interlocking conditions for C_DAMPER
IntProt1 IntStrt1 IntStaE1 IntOper1 IntOpE1

Operating mode
IntProt2 IntStrt2 IntStaE2 IntOper2 IntOpE2
Automatic X X X X X
Manual interlocked mode X X X X X
Manual mode with reduced interlocks X X X
Manual mode non-interlocked X
Local mode X X *) X *)
Inching mode X X X
Positioning mode X X X
Interlocking conditions for C_VALVE
Operating mode IntProtG IntStart IntStaE IntOper IntOpE IntStop

Automatic X X X X X X
Manual interlocked mode X X X X X **)
Manual mode with reduced interlocks X X X **)
Local mode X X *) X *)
X = effective
*) the evaluation of the essential interlocks in local mode can be disabled via feature bit settings.
**) the evaluation of the stop interlock IntStop in manual mode can be enabled via feature bit settings.
***) For LafargeHolcim the Feature2.bit4 = TRUE. Protection Interlock IntProtA is effective in local mode as
well, but can be bypassed via Local Start button (G).

Interlocks between two drives:
For the transport out of bin E52-3B1 the drives must be started in the following order:
1. Open the Distribution Gate E51-MW1

2. Start the Reversible Belt conveyor E51-BC2 in direction X
3. Start the Belt conveyor E51-BC1
4. Start the Rotary Feeder E51-RF1
5. Open the Slide Gate E51-SG1
For stopping the material transport use the reverse order (Slide Gate E51-SG1 must be closed
before stopping E51-RF1. E51-BC2 must be stopped before closing distribution gate E51-MW1).
Exercise 1.7: Drive interlocks for the material transport
Via interlocking conditions it is assured that the drives are started (and stopped) in the correct
sequence:
- The discharging device must be started before the feeding device, and if the discharging
device is not running, the feeding device must be stopped as well. This is achieved via
interlocking condition IntOper.
- If the discharging device is still running, the feeding device must not be stopped. This is
achieved via interlocking condition IntStop.
Add the drive interlocks for the transport group by connecting the running or position signal of
the previous drive to the interlocking condition of the next drive.
Prepare the stop interlock for the drives as well, even if the stop interlock is only considered in
automatic mode.
Compile the CFC and download it into the AS.
Carry out the OS Compile as well; otherwise the structure link information is not available.
In order to test the function:
- Switch the drives to Manual mode and in Local mode and test the interlocks.

Using interlock blocks for visualization of interlocking conditions
If there is only one condition connected to an interlock of the drive (RunSig of one drive
connected to IntOper of the next drive) no further logic is required.
As soon as there is more than one conditions (e. g. two drives must be running) you need to
program AND or OR functions. In order to visualize these functions in the HMI, structure
interlock blocks from APL Library or the new CEMAT interlock blocks can be used.
APL Interlock blocks
The APL Library has 4 interlock blocks of different size. In CEMAT Application program these
interlocks can be used. The faceplates of these blocks have a small adaptation for CEMAT (the
tagname if the connected block is additionally displayed).
Intlk02: for up to 2 inputs

The blocks can be configured as AND or OR function and can also be cascaded. (See
description of APL library).
CEMAT Interlock blocks
Three CEMAT structure interlock blocks exist.
C_INTLK2: for up to 2 inputs

The CEMAT Interlock blocks give much more options for Simulation (bypass) and cascading and
can be used instead of the APL interlock blocks.
It is distinguished between permanent bypass and temporary bypass
General rules for all interlock functions
The interlock block must not create a block icon (uncheck this option in the block properties). In
the HMI the interlock block is exclusively opened via a CEMAT block interface.
Think about, whether you really want to permit Simulation, especially in case of protection
signals. Simulation of process values can be carried out at the CEMAT annunciation blocks, the
process feedback block or the measured value block and will then be indicated in the Object list
of the group.
The Structure interlock blocks do not have an interface to the CEMAT group and are therefore
not shown in the object list.
For the size of interlock block, use as big as necessary. Bigger blocks use more resources (tags
in the tag management) and must therefore be considered as well in the calculation for Process
Objects (second calculation).

Give useful block names and comments to the interlock blocks, as these are visualized in the
runtime system and are a big help for understanding and identification of the function.
For each input (In01, In02, …) you may enter a text (maximum 16 characters), which is also
shown in the runtime system.
'Text 0' is displayed if the signal has status "0".

'Text 1' is displayed if the signal has status "1".

How to use the APL Interlock blocks with CEMAT
The feature "Evaluate first relevant signal" is not enabled by default. The function is very useful
in case of protection interlocks, in order to find out which signal tripped first. In this case
Feature.bit31 must be set. The "FirstIn" information can be reset during the next drive start in
order to clear the indication.
The template chart 'Interlck' contains 8 pre-configured interlock blocks, four AND functions and
four OR functions, one of each size.
They are pre-configured in order not to generate a block icon and in order to memorize the first
relevant signal.

How to use the CEMAT Interlock blocks
The CEMAT Interlock blocks give much more options for Simulation (bypass) and cascading and
can be used instead of the APL interlock blocks.
It is distinguished between permanent bypass and temporary bypass
Permanent bypass means that the input is bypassed until a reset command is carried out. A
permanent bypass can be set with a rising edge on BypIn0x or via faceplate and has to be reset
with a rising edge on RstBypIn0x or via faceplate.
A temporary bypass is meant to be used for unhealthy interlock signals which should get
healthy whilst starting or running a drive within a short period of time (e.g. for maintenance
purposes).
A number of inputs can be selected and will be activated via a common activation button. The
bypass will timeout automatically after the configured time of TmpBypTi (in seconds), or after a
reset via a common Reset button.
Permanent and the temporary bypass cannot be activated at the same time. The activation of
the permanent bypass resets the temporary bypass of the corresponding input, as well as a
rising edge on input RstBypIn0x.
Connection between CEMAT Interlock block and drive block:
Note: In order to get the correct indication at the interlock block the runtime sequence is very
! important and must be correct:
1. Interlocking Condition  2. Interlock block  3. Drive block

Exercise 1.8: Complete the interlocking condition for E51-BC1
In automatic mode Belt Conveyor E51-BC1 can only run if Reversible Belt Conveyor E51-BC2 is
running into direction X or Y. In order to visualize the interlocking condition, insert an Interlock
block and connect it to operating interlock IntOper of E51-BC1.
Either the APL Interlock block or the CEMAT Interlock block can be used.
Example for the implementation with the CEMAT Interlock block:

Group connections for Automatic control
Up to now it was only possible to start and to stop the drives in Manual mode and in Local mode.
Supervision functions of the group did also work.
In Automatic mode the complete transportation group can be started or stopped with a single
command.
With the group start command a start-up warning is given (WarnTi and WaitTi). After this, the
group creates an output CmdOn which is used for starting the drives/devices. The start
command is limited by the start-up command release time CoURelTi.
The group stop command is immediately transmitted to the output PeCmdOff and this output
remains "1" until all drives are stopped. Nevertheless a Shut-down supervision time CoDRelTi
exists. If the group is not stopped completely after this timer elapsed, a warning message is
created.
Time diagram for Group start and stop function
Group Start
Time for startup warning WarnTi
Start-warning horn activated WarnHAct
Waiting time WaitTi
Command ON CmdOn
Permanent Command ON PeCmdOn
Start-warning lamp WarnLAct
Feedback of related objects On FbObjOn
Command OFF CmdOff
Permanent Command OFF PeCmdOff
Feedback of related objects Off FbObjOff
Group active Active
Group start horn time Waiting time elapsed Group completely running Group stop All drives
elapsed Start of drives stopped

The following connections are needed between the group and the drives/devices:
The start/stop command of the group must be transmitted to each drive.
- All drives get the start command at the same time.

 Connection of output CmdOn of C_GROUP to input StartAut of the drive/device.
The start sequence depends on interlocking conditions (IntStart, IntOper, IntStaE,

IntOpE).
Caution: Permanent Command ON signal PeCmdOn must not be used for drive start,
! because this signal remains "1" also in case of a fault!
- The stop command must be connected to the drives.

 Connection of output PeCmdOff of C_GROUP to input StopAut of the drive/device.
All motors and valves may get the stop command at the same time. The stop sequence
depends on the stop condition IntStop. As the damper block doesn‟t have a stop interlock
interface, the conditional stop has to be achieved by a logic.
Caution: Command Off signal CmdOff is normally not suitable for stopping the drives
! because this signal remains "1" only for one OB cycle (or as long as the stop button is
pressed.
- Beside the normal (sequential) stop, immediate stop (quick stop) is also possible.
 Connection of output QuicStpQ of C_GROUP to input QuickStp of the drive/device.
For the limitation of the start/stop commands and for visualization the group must get the
information of the drive status:
- The group must receive a feedback that all drives are running.
 Connection of output RunSig or PosSig of the drive/device to input FbObjOn of
C_GROUP.
(A logic is needed to transmit the feedback on of all drives/devices)
- The group must receive a feedback that all drives are stopped.
 Connection of inverted output RunSig or output PosSig of the drive/device to input
FbObjOff of C_GROUP.
(A logic is needed to transmit the feedback off of all drives/devices)
Information like summarizing fault and summarizing warning is transmitted internally from the
drives/devices to the group. This only depends on the Group link and no further connection in
required.
Information such as Mode change commands, Mode feedback and Material fault (group not
empty) can be transmitted internally (via Group Link) from the group to the drive and vice versa,
if the corresponding function is enabled via Feature.bit28.
Note: By default the feature bit for "Group not empty" is not set, because this information is only
! useful for drives involved in material transport.

Connections between group and drive(s):
Exercise 1.9: Connections between group and drives
Adjust the process parameters for Warning time WarnTi, Waiting time WaitTi, Start-up
command release time CoURelTi and Shut down supervision time CoDRelTi.
Carry out all connections for starting and stopping of the drives as well as for feedback on and
feedback off. The start sequence is programmed via interlocking condition (previous exercise).
Via process parameter StaDelTi of the drive, the 'Start command ON in automatic mode'
StartAut can be delayed. Timer StaDelTi is triggered when StartAut is given and all process
interlocks (IntStart, IntOper, IntStaE, IntOpE) are fulfilled.
Via Process parameter StpDelTi of the drive the 'Stop command OFF in automatic mode'
StopAut can be delayed. Timer StpDelTi is triggered when StopAut is given and the Stop
interlock IntStop is fulfilled.
Compile the program and download it to the AS.
OS Compilation is not needed because no modification for the HMI was made.
- Start the group and test the start sequence.
- Stop the group and check, whether the drives stop in the right sequence (with time
delay).
- Simulate some drive faults and check the entry in the alarm line and in the Cemat Alarm
List.
- Carry out a status call for the group.
- Test the stop of the conveying line in case of a fault. In order to do this, correct all faults
and start the group. After that stop the second drive by fault (e. g. “not available”). The
discharging drive must continue to run. The faulty drive must show red color and the
feeding drive must stop immediately.

- Make sure that the damper is also closed in case of immediate stop and in case of a fault
of rotary feeder E51-RF1.
- Test the mode change options for running and non-running devices.
Start-up-Warning
The group block has two outputs for the connection to a Start-up-warning:
- Output WarnHAct will be set to “1” after giving the Group Start Command and can be
used to trigger a HORN in the field.
- Output WarnLAct stays “1” within the complete start period and can be used to trigger a
LAMP in the field.
The drive blocks have only one output for the connection to a Start-up-warning:
- Output WarnAct will be set to “1” after giving a Start Command in Manual mode or in
Local mode (if configured).
Both, the outputs of the Group and the outputs of the drives are linked to common outputs in
order to trigger the Horn and the Lamp in the field. The signals must be connected with an OR
Function.
Signals for the start-up warning:

EC1_2W1_G1_D Warning start up Start notice light switch on Q 10.0
EC1_2W1_G2_D Warning start up Start notice acoustic switch on Q 10.1
Exercise 1.10: Start-up warning
In hierarchy folder “E51” create an additional chart for the start-up-warning and rename it to
EC1_2W1.
For the start-up-warning lamp you have to link the output WarnLAct of the group together with
the output WarnAct of all drives to the hardware output EC1_2W1_G1_D.
For the acoustic signal of the start-up-warning you have to link the output WarnHAct of the group
together with the output WarnAct of all drives to the hardware output EC1_2W1_G2_D.
In order to display the start-up-warning in the process picture the outputs are already linked to a
status display in E50_G.pdl.
After compile and download you may start the group (and/or an individual device) in order to see
whether it works properly.

Summary: Block interfaces of C_DRV_1D, C_DRV_2D, C_DAMPER and C_VALVE
Interfaces and parameters of C_DRV_1D
ModuleTag
C_DRV_1D MAIN_TAS
Unidirectional drive 1/23
1 = contactor feedback on 0 BO FbkRun RunSig ST Running signal
1 = electrical availability ok 1 BO ElAvail DynFlt BO dynamic fault (not acknowledged)
1 = therm. Overload/mech. overload ok 1 BO Overload Fault BO Fault
1 = field switch ready 1 BO AutModLo LaStopRe ST Last Stop Reason
0 = stop local: field switch stop signal 1 BO StopLoc WarnAct BO Start-up-warning (local or manual)
1 = start local: field switch start signal 0 BO StartLoc RunSigSp BO Running signal sporadic drive
1 = Start Interlock essential ok 1 ST IntStaE SimActQ BO 1 = simulation activated
1 = Start Interlock ok 1 ST IntStart AutoAct BO Automatic mode
1 = Operation Interlock essential ok 1 ST IntOpE ManuAct BO Manual mode
1 = Operation Interlock ok 1 ST IntOper LocalAct BO Local mode
1 = Protection Interlock ok 1 ST IntProtG OoSAct BO Out of Service mode
1 = Protection Interlock (only remote) ok 1 ST IntProtA ContOn BO contactor ON
1 = Stop interlock ok 1 ST IntStop O_LINKQ ST Link to slave objects
1 = Sporadic on 1 ST Sporadic ErrorNum I Error Number
Process Feedback (e. g. speed monitor) 1 ST ProFB
1 = Monitor only; operated by local box 0 BO MonOnly
1 = switch to automatic mode 0 BO AutModOn
1 = switch to manual mode 0 BO ManModOn
1 = switch to local mode 0 BO LocModOn
0 = force to Out of Service mode 1 BO OoSModOn
1 = enable stand-by mode 0 BO StaByEn
1 = enable messages 1 BO MsgEn
1 = Start command ON in auto. mode 0 BO StartAut
1 = Stop command OFF in autom. mode 0 BO StopAut
1 = Stop: quick stop (only Auto and Manu) 0 BO QuickStp
Status from Simocode 16#0 ST SimoStat
Call Subcontrol Faceplate ANY SubCFp
1 = General fault Subcontrol 0 ST SubCFlt
Analog Value Input (General use) 0 ST AV
Analog Value Status + Unit % ST AV_Stat
Analog Value in % 0 ST AV_Perc
time for feedback monitoring 2 I FbkMonTi
time for feedback off monitoring 2 I FbkOffTi
time for start delay 0 I StaDelTi
time for stop delay 0 I StpDelTi
time for start up warning 10 I WarnTi
Operator Permissions 1 ST OS_Pern
Status of various features 1 ST Feature
Status of various features 1 ST Feature2
Link to group or route 0 ST GR_LINK1
Link to C_MUX 0 ST MUX_LINK
Link to another object 0 ST O_LINK

ModuleTag
C_DRV_2D MAIN_TAS
Bidirectional drive 1/23
1 = contactor feedback on direction 1 0 BO FbkRun1 RunSig1 ST Running signal direction 1
1 = contactor feedback on direction 2 0 BO FbkRun2 RunSig2 ST Running signal direction 2
1 = electrical availability ok 1 BO ElAvail DynFlt BO dynamic fault (not acknowledged)
1 = therm. Overload/mech. overload ok 1 BO Overload Fault BO Fault
1 = field switch ready 1 BO AutModLo LaStopRe ST Last Stop Reason
0 = stop local: field switch stop signal 1 BO StopLoc WarnAct BO Start-up-warning (local or manual)
1 = start local: field switch start sig. dir.1 0 BO StartLoc1 RunSigS1 BO Running sig. dir. 1 sporadic drive
1 = start local: field switch start sig. dir.2 0 BO StartLoc2 RunSigS2 BO Running sig. dir. 2 sporadic drive
1 = Start Interlock essential dir. 1 ok 1 ST IntStaE1 SimActQ BO 1 = simulation activated
1 = Start Interlock dir. 1 ok 1 ST IntStrt 1 AutoAct BO Automatic mode
1 = Operation Interlock essential dir. 1 ok 1 ST IntOpE1 ManuAct BO Manual mode
1 = Operation Interlock dir. 1 ok 1 ST IntOper1 LocalAct BO Local mode
1 = Start Interlock essential dir. 2 ok 1 ST IntStaE2 OoSAct BO Out of Service mode
1 = Start Interlock dir. 2 ok 1 ST IntStrt 2 ContOn1 BO contactor ON direction 1
1 = Operation Interlock essential dir. 2 ok 1 ST IntOpE2 ContOn2 BO contactor ON direction 2
1 = Operation Interlock dir. 2 ok 1 ST IntOper2 O_LINKQ ST Link to slave objects
1 = Protection Interlock ok 1 ST IntProtG ErrorNum I Error Number
1 = Protection Interlock (only remote) ok 1 ST IntProtA
1 = Stop Interlock ok 1 ST IntStop
1 = Sporadic on 1 BO Sporadic
Process Feedback (e. g. speed monitor) 1 ST ProFB
1 = Start command ON in auto. mode dir.1 0 BO StartAut1
1 = Stop command OFF in autom. mode 0 BO StopAut
Call Subcontrol Faceplate ANY SubCFp
1 = General fault Subcontrol 0 ST SubCFlt
Analog Value in % 0 ST AV_Perc
time for feedback off monitoring 2 I FbkOffTi
Direction change delay time 10 I DirChaTi

Interfaces and parameters of C_DAMPER
ModuleTag
C_DAMPER MAIN_TAS
Damper 1/23
1 = contactor feedback on direction 1 0 BO FbkRun1 PosSig1 ST Limit position 1 signal
1 = contactor feedback on direction 2 0 BO FbkRun2 PosSig2 ST Limit position 2 signal
1 = limit position direction 1 0 BO FbkPos1 DynFlt BO dynamic fault (not acknowledged)

1 = limit position direction 2 0 BO FbkPos2 Fault BO Fault
1 = electrical availability ok 1 BO ElAvail LaStopRe ST Last Stop Reason
1 = therm. Overload/mech. overload ok 1 BO Overload WarnAct BO Start-up-warning (local or manual)
1 = field switch ready 1 BO AutModLo SimActQ BO 1 = simulation activated
0 = stop local: field switch stop signal 1 BO StopLoc AutoAct BO Automatic mode
1 = start local: field switch start sig. dir.1 0 BO StartLoc1 ManuAct BO Manual mode
1 = start local: field switch start sig. dir.2 0 BO StartLoc2 LocalAct BO Local mode
1 = Start Interlock essential dir. 1 ok 1 ST IntStaE1 OoSAct BO Out of Service mode
1 = Start Interlock dir. 1 ok 1 ST IntStrt 1 ContOn1 BO contactor ON direction 1
1 = Operation Interlock essential dir. 1 ok 1 ST IntOpE1 ContOn2 BO contactor ON direction 2
1 = Operation Interlock dir. 1 ok 1 ST IntOper1 O_LINKQ ST Link to slave objects
1 = Protection Interlock dir. 1 ok 1 ST IntProt1 ErrorNum I Error Number
Torque switch direction 1 0 BO TorqSw1
1 = Start Interlock essential dir. 2 ok 1 ST IntStaE2
1 = Start Interlock dir. 2 ok 1 ST IntStrt 2
1 = Operation Interlock essential dir. 2 ok 1 ST IntOpE2
1 = Operation Interlock dir. 2 ok 1 ST IntOper2
1 = Protection Interlock dir. 2 ok 1 ST IntProt2
Torque switch direction 2 0 BO TorqSw2
1 = Monitor only; oparated by local box 0 BO MonOnly
Monitoring time from pos 1 to pos2 90 I MovMonTi
Time limit switch delay 2 I LSDelTi
enable inching 0 BO InchEn

Interfaces and parameters of C_VALVE
ModuleTag
C_VALVE MAIN_TAS
Valve 1/23
1 = contactor feedback on 0 BO FbkRun PosSig1 ST Limit position 1 signal
1 = limit position direction 1 0 BO FbkPos1 PosSig2 ST Limit position 2 signal
1 = limit position direction 2 0 BO FbkPos2 DynFlt BO dynamic fault (not acknowledged)
1 = electrical availability ok 1 BO ElAvail Fault BO Fault
1 = therm. Overload/mech. overload ok 1 BO Overload LaStopRe ST Last Stop Reason
1 = field switch ready 1 BO AutModLo WarnAct BO Start-up-warning (local or manual)
0 = stop local: field switch stop signal 1 BO StopLoc RunSigSp BO position signal sporadic valve
1 = start local: field switch start signal 0 BO StartLoc SimActQ BO 1 = simulation activated
1 = Start Interlock essential ok 1 ST IntStaE AutoAct BO Automatic mode
1 = Start Interlock ok 1 ST IntStart ManuAct BO Manual mode
1 = Operation Interlock essential ok 1 ST IntOpE LocalAct BO Local mode
1 = Operation Interlock ok 1 ST IntOper OoSAct BO Out of Service mode
1 = Protection Interlock ok 1 ST IntProtG ContOn BO contactor ON
1 = Stop Interlock ok 1 ST IntStop O_LINKQ ST Link to slave objects
1 = Sporadic on 1 BO Sporadic ErrorNum I Error Number
No feedback contact 1 0 BO NoFbk1
No feedback contact 2 0 BO NoFbk2
1 = Start command ON in auto. mode 0 BO StartAut
1 = Stop command OFF in auto. mode 0 BO StopAut
Monitoring time from pos 1 to pos2 10 I MovMonTi
Time limit switch delay 0 I LSDelTi

Summary: Block interfaces of C_GROUP and C_MUX
Interfaces and parameters of C_GROUP
ModuleTag
C_GROUP MAIN_TAS
Group 1/23
1 = Start Interlock ok 1 ST IntStart CmdOn BO Command ON
1 = Operation Interlock ok 1 ST IntOper CmdOff BO Command OFF
1 = switch-off interlock ok 1 ST IntSwOff PeCmdOn BO Permanent Command ON
Fb of related objects on 0 BO FbObjOn PeCmdOff BO Permanent Command OFF
Fb of related objects off 1 BO FbObjOff RunSig ST Running Signal
Fb of related object(s) in local 0 BO FbObjLoc OffSig ST Output feedback OFF
Fb of related object (s) in manual 0 BO FbObjMan AutModOn BO 1 = Automatic mode ON
Fb of related object(s) in out of Service 0 BO FbObjOoS ManModOn BO 1 = Manual mode ON
1 = dyn. fault material (not empty) 0 BO MatFlt LocModOn BO 1 = Local mode ON
1 = Start command ON in auto. mode 0 BO StartAut Active BO 1 = Group Active
1 = Stop command OFF in auto. mode 0 BO StopAut QuicStpQ BO 1 = Quick stop out
1 = Stop: quick stop (only Aut and Manu) 0 BO QuickStp DynFld BO dynamic fault (not ackn.)
Time for startup warning 10 I WarnTi Fault BO Fault
Waiting time 15 I WaitTi DynWarn BO Dynamic warning (not ackn.)
Start up command release time 300 I CoURelTi Warn BO Static warning signal
Shut down supervision time 300 I CoDRelTi StopFlt BO 1 = Group stop fault (no FbObjOff)
Operator Permissions 1 ST OS_Pern SimActQ BO 1 = simulation activated
Status of various features 1 ST Feature NotEmpty BO Group not empty
IntBypas BO Group interlock Bypassed
AckGr BO 1 = Acknowledge Groupwise
WarnLAct BO 1 = Start-warning lamp
WarnHAct BO 1 = Start-warning horn activated
G_LINK ST Link to routes/objects
ErrorNum I Error Number

Interfaces and parameters of C_MUX
ModuleTag
C_MUX MAIN_TAS
For Link to more than 2 groups/routes
1/23
Connect w ith MUX_Out 0 ST MUX_IN MUX_OUT ST Connect to MUX_LINK
Caution: Using C_MUX blocks the runtime sequence gets crucial, especially if connecting the
same C_MUX block to more than one CEMAT Object. The only valid order is as follows:
1. Child Objects (all Annunciations, Process Feedback blocks, Measurements and Subcontrols
which are linked via O_LINK to the drive)
2. C_MUX block (single C_MUX or cascaded C_MUX blocks)
3. Parent Objects (C_DRV_1D, C_DRV_2D, C_DAMPER and C_VALVE) and all Annunciations
and Measurements with direct link to Groups or Routes
4. Corresponding Routes
5. Corresponding Group
Make sure that this sequence is strictly followed and that it is not “interrupted” by the connection
to a different C_MUX block or by any direct connection to a Group or Route!!!

Annunciation block functions (Part I)
Example 2: 'Drive fault annunciation'
The example 'Transport out of bin E52-3B1' will be extended by annunciation blocks for the
protection interlocks of drive E51-BC1.
Both, the pull rope switch and the belt drift switches are protection interlocks for the drive but the
function is different:
- The pull rope switch is an emergency stop of the drive and must be effective immediately
and in all operation modes.
- The drift switch must be effective only in remote (automatic mode and manual mode). In
local mode it must not be effective.
The belt drift switch can be by-passed in local mode by pressing Local Start button
StartLoc (G).
To avoid immediate reaction, in case of a belt drift switch a two-level alarm is created: If a
fault occurs, after 3 seconds a warning is generated. If the fault remains longer than a
certain time (e.g. 10s) an alarm is generated and the drive is switched off.

Additional objects:
HAC Equipment (who) Location (where) Device (what) Block Type F/W
E51-BC1.R1 Belt Conveyor below E51-3B1 Rope Switch 1 C_ANNUNC F
Each annunciation block is connected to a Periphery signal which is simulated in this example
via Buttons in the Process Picture.
I/O list:

E51_BC1_D1 Belt Conveyor Drift switch no drift I 14.0
E51_BC1_D2 Belt Conveyor Drift switch no drift I 14.1
E51_BC1_R1 Belt Conveyor Rope switch OK I 14.2

Creating annunciation blocks for an existing drive and Property settings
In the Project Library 'Tng_Lib' in Hierarchy folder 'Templates_nnn', you find a template chart
with different annunciation blocks C_ANNUNC. In the first two blocks with name 'R' and 'D' the
Feature bits and OS Permissions are configured for motor protections.
Block 'R' is configured for creating Fault messages and can be used for all signals connected to
the general protection interlock IntProtG of the drives.
Block 'D' is configured for creating two-level-alarms (first warning and then fault messages) and
can be used for signals like drift switches. Drift switches must be connected to protection
interlock IntProtA of the drives (can be bypassed via button StartLoc (G) in local mode); because
in order to correct the belts position a local start is needed.
For the example above, one block of type 'R' and two blocks of type 'D' must be copied from
template chart ANNUNC into the existing chart E51_BC1.
After creating the blocks, the block properties (block name, comment, block icon and message
definition) must be entered for each object.
The C_ANNUNC block internally uses an ALARM_8 function, where SIG1, SIG2 and SIG8 are
used. SIG1 is the message in case of an alarm, SIG2 is the message in case of a warning and
SIG8 is used for “Still faulty”.
In difference to the drives and groups, for annunciation blocks the message texts for SIG1 and
SIG2 are not yet defined and have to be engineered.

The message class “Alarm – above” or “Warning – above” is fixed and con not be changed.
As for the drives additional engineering is also required for the block comment: The block
comment must be copied into “Additional Text 5” (= “Free Text 1”).
In order to show the Location information (where Text) in the message system, this text
must be entered under Special properties  Messages…to each message in “Additional text 9”
(= “Free Text 5”).
Caution: The Message text for annunciation blocks must not exceed 16 characters.
!
object view.

Exercise 2.1: Adding the annunciation blocks in chart E51_BC1 and entering block properties
and message definitions
Chart E51_BC1 already exists and contains motor M1. The rope switch and the drift switches
belong to the same equipment and, following the HAC, they must have the same equipment
name. For this reason the annunciation blocks must be inserted in the same chart as the drive.
For each process signal for protection interlock one annunciation block must be inserted.
Proceed as follows:
- Open the template chart ANNUNC from 'Tng_Lib', Folder 'Templates_nnn'.

The description beside the blocks shows function and the settings of Feature bits and OS
Permissions.
- Open chart E51_BC1.
- Copy block 'R' from the template chart ANNUNC and insert it into chart E51_BC1.
- Copy block 'D' from the template chart ANNUNC and insert it into chart E51_BC1.
Duplicate this block.
- Make sure that the blocks are inserted at the correct position in the runtime editor,
preferable before the drive block.
If a C_MUX block is used, you need to pay special attention to the runtime sequence:
1. All Annunciation blocks which are linked via O_LINK to the drive
3. Parent Objects (e. g. C_DRV_1D)
Make sure that this sequence is not “interrupted” by the connection to a different C_MUX
block or by any direct connection to a Group or Route!!!

E51_BC1 D1 Belt Conveyor Drift switch 1
E51_BC1 D2 Belt Conveyor Drift switch 1
E51_BC1 R1 Belt Conveyor Rope switch 1
- Enter the 'message text' for SIG1 and SIG2, e. g. "Belt drift".

Connection to the I/Os
Rope switch and drift switch are binary process signals which must be connected to input InSig
or InSigB of the C_ANNUNC block.
Input InSig is of format STRUCTURE and can be used for the binary connection from another
CFC block or from Channel driver block Pcs7DiIn, but not for the direct connection to a binary
signal from the Symbols file.
Input InSigB is of format BOOL and can be used for the connection to a binary Signal from the
Symbols file.
Connection of a binary signal from the Symbols file to InSigB:
Connection of binary signal via APL Channel driver block to InSig:
Connection of binary signal via a converter block to InSig:

Exercise 2.2: Connecting the process signals according to the I/O list to the blocks
On page 52 you find the I/O list for the blocks. The symbols already exist in the Symbols file.
(Memories are used instead of inputs because of simulation via HMI).
Connect the signals to input InSigB of the Annunciation block.
Group/Object link (essential)
The group block is used for supervision of a sequence. Operating modes, faults or warnings of
the drives, annunciations and measured values are shown as summarizing indications in the
group block icon and faceplate.
The group link is an essential function and in order to make sure that the group link is done; all
drives, annunciation blocks and measured values which are not linked to a group automatically
go to "Out of Service" mode and will not work.
In case of annunciation blocks belonging to a drive, the drive is already linked to the group via
GR_LINK1 or GR_LINK2 (or via a C_MUX block). Instead of linking the annunciation block to
the group, it may be linked to the drive via Object link. Therefore output O_LINKQ of the drive
must be connected to input O_LINK of the annunciation block.

The result is that in the Object list of the group, the Annunciations are displayed one level below:

E51_BC1/D1 Belt conveyor Drift switch
E51_BC1/R1 Belt conveyor Rope switch
Carry out the link between the drive and annunciation block by connecting output O_LINKQ of
the drive to input O_LINK of both annunciation blocks.

Block interconnections and Parameter settings
Beside the Group and Object link, further connections are needed between drive and
annunciation block, in order to stop the drive in case of a faulty process signal.
Output OutSig of all annunciation blocks with signals for general protection (in all modes) must
be connected to the protection interlock IntProtG.
Output OutSig of all annunciation blocks with signals which allow bypass in local mode must be
connected to protection interlock IntProtA.
If more than one process signal exists for the same protection, structure interlock blocks must be
inserted.
In order to trigger the message with the dynamic fault of the motor the output DynFlt must be
connected to input MsgTrigg of the annunciation block.
Message trigger can be achieved via input MsgTrigg or internally via O_LINK (if Feature.bit16 is
set). If Feature.bit16 = TRUE, the input MsgTrigg does not need to be connected.
For the two-level-alarm process parameter WaDelTi must be adjusted. WaDelTi contains the
time between warning and alarm. Parameter OutOnDTi delays the warning itself.
In order to activate the warning for two-level-alarms of the drift switch, the output RunSig of the
motor must be connected to input ActWarn of the annunciation block.
The warning activation can be achieved via input ActWarn or internally via O_LINK (if
Feature.bit17 is set). If Feature.bit17 = TRUE, the input ActWarn does not need to be
connected.
Simulation option should be given for the drift switches but not for the rope switches. The
permission for the simulation is enabled/disabled via OS Permission bit15.

An additional text definition is required for status call function and for the indication in the
faceplate:
- Parameter InSig.Value has properties 'Text 0' and 'Text 1'. Both texts are used in the
faceplate of the C_ANNUNC block. Text 0 is additionally used for status call function and
must be similar to the 'message text' entered into the message configuration before.
- Parameter OutSig.Value has a property 'Text 1'. This field can be used for a short
description such as '+D' or '+R' which is displayed in the faceplate.
Exercise 2.4: Connections between drive and annunciation blocks and configuration of the
process parameters and variable texts.
Carry out the connections between the drive and the three annunciation blocks.
Check the feature bit settings for the annunciation blocks.
Adjust the process parameters for 'On delay time' OutOnDTi and 'Delay between warning and
alarm message' WaDelTi for the Belt drift annunciation.
Add the variable texts via parameter InSig.Value and OutSig.Value. For InSig.Value 'Text 0',
copy the text from the message configuration (in order to have the same event text for alarm and
status call).
Compile the OS.
- The LafargeHolcim block icons need further modifications in some attributes in order to
give the proper indication.
All annunciation blocks are represented by the Component code and number,
Therefore the following Properties under “General” need to be adapted:
- Enter the component code and number (e. g. D1) to Attribute “TagOut”
- The Tooltip text by default shows the block comment. If anything else is desired, you
have to enter this text as well.
Remark: In LafargeHolcim Standard the block icons for the annunciation blocks don‟t
show up on the screen if everything is ok. Only if a fault occurs the symbol gets visible.
- Save the process picture.

- Stop the group. Create a Rope switch fault while the drive is not running. You must see
only static indications and no alarm should be created.
- Create a Drift switch fault while the drive is not running. You must see only static
indications and no alarm should be created. The fault will immediately lead to a red
indication.
- Try to start the drive in local mode while the drift switch is faulty. The drive will remain
running as long as button StartLoc (G) is pressed.
- Start the drive in automatic or in manual mode. Create a Rope switch fault and check the
fault message.
- Start the drive in automatic or in manual mode. Create a Drift switch fault. It must lead
first to a warning message and after 10 seconds to fault message.

Example 3: 'Enable messages'
In the following example an annunciation block is used in order to give an alarm for a "power
supply failure". At the same time the messages of the drives, annunciations and measured
values must be suppressed, otherwise the operator gets a huge amount of simultaneous and
misleading alarms.
Additional objects:
EC1-PS1.F1 Control Power . C_ANNUNC F
The annunciation block is connected to a Periphery signal which is simulated in this example via
a button in the Process Picture.
I/O list:

M_EC1_PS1_OK Control Power M 2251.0

The following simulation button can be used in order to simulate a power failure:
If the status of "PS" is changed to "0-Signal" all other inputs are internally forced to "0-Signal" at
the same time, in order to simulate "loss of control power".

Creating a CFC and a block with proper Property settings
with different annunciation blocks C_ANNUNC. On the third sheet you find an example for power
supply supervision.
The block with name 'F' is preconfigured in order to create (red) fault messages.
After creating the blocks, adjust the block properties (block name, comment, block icon and
message definition).
Exercise 3.1: Creating a new chart for the Power supply supervision, inserting an annunciation
block and entering block properties and message definitions
Plant hierarchy AS1, Area 'E50 System Test' contains subfolder 'E50'. Into this subfolder add a
new chart for the 'power failure' annunciation and name it as follows:
EC1_PS1
Insert an annunciation block via the following procedure:

Permissions.
- Open chart EC1_PS1.
- Copy block 'F' from the template chart ANNUNC and insert it into chart EC1_PS1
- Make sure that the block is inserted at the correct position in the runtime editor
(preferable before the other transport group objects).

EC1_PS1 F1 Loss of Control Power in EC1 1
- Enter the 'message text' for SIG1 and SIG2, e. g. "Failure".

The signal "Control Power" is a binary process signal which must be connected to input InSig or
InSigB of the C_ANNUNC block. As the signal is of format BOOL und the block input InSig is of
format STRUCTURE, the CFC Editor does not allow a direct connection to a binary input signal
Therefore use input InSigB.
Connect the signals to input InSigB of the corresponding Annunciation block.
The power supply signal belongs to the Transport group and for supervision function
(summarizing indications, status call and object list) the annunciation block must be linked to this
group via Group link interface.
In some applications the power supply signals cannot be assigned to a specific group, but the
group link is a must! In this case we recommend creating an additional "Supervision group" only
for those signals.

EC1_PS1/F1 Power Supply
Carry out the link between the group and the annunciation blocks by connecting output G_LINK
of the group to input GR_LINK1 of the annunciation block.

Beside the Group and Object link, no further connections are needed between group and
annunciation block.
In order to suppress the messages in case of a power failure the 'Power supply OK' signal must
be connected to input MsgEn of all drives, annunciation blocks and measuring values with the
same feeding.
In addition, a text definition is required for status call function and for the indication in the
faceplate:
description such as '+F' which is displayed in the faceplate.

Exercise 3.4: Connections to Enable Messages and variable texts.
Connect the power supply signal to input MsgEn all drive and annunciation blocks of the
transport group (except for the annunciation block for Power Supply failure!).
status call).
Compile the OS.
- Adapt the Properties under “General” and save the Process Picture.
- Start the group and create a Power supply failure. All drives will stop but you should get
only one alarm for Control Power Failure.

Summary: Block interfaces of C_ANNUNC and C_ANNUN8
Interfaces and parameters of C_ANNUNC
ModuleTag
C_ANNUNC MAIN_TAS
Annunciation 1/23
Input Signal (Stucture) 1 ST InSig OutSig ST output signal ok
Input Signal (boolean) 1 ST InSigB DynFlt BO dynamic fault (not acknowledged)
process signal (real status w/o logic) 0 BO ProcSig Fault BO Fault/warning
1 = supervision enabled 1 BO SupOn SimActQ BO 1 = simulation activated
1 = switch to automatic mode 0 BO AutModOn Warn ST 1 = Annunciation Warning Active
0 = force to Out of Service mode 1 BO OoSModOn ErrorNum I Error Number
1 = message trigger 1 BO MsgTrigg
1 = enable dynamic fault 1 BO DynFltEn
1 = don't include in Gr. Summarizing Ind. 0 BO GrFltLck
1 = don't incl. in Gr. Sum. Ind. + Stat. call 0 BO GrStaLck
1 = Activate warning (two-level-alarm) 0 BO ActWarn
Supervision delay time (s) 0 I SupOnTi
OutSig On delay time (s) 0 I OutOnDTi
OutSig Off delay time (s) 0 I OutOfDTi
Delay between warning and alarm msg. 0 I WaDelTi
Annunciation repeat time 0 I RepTi

Interfaces and parameters of C_ANNUN8
ModuleTag
C_ANNUN8 MAIN_TAS
Annunciation 1/23
Input Signal 1 1 ST InSig1 OutSig1 ST output signal no. 1 ok
Supervision ON signal 1 1 ST SupOn1 OutSig2 ST output signal no. 2 ok
1 = message trigger no. 1 1 BO MsgTrig1 OutSig3 ST output signal no. 3 ok
Supervision ON signal 2 1 ST SupOn2 OutSig5 ST output signal no. 5 ok
1 = message trigger no. 2 1 BO MsgTrig2 OutSig6 ST output signal no. 6 ok
Supervision ON signal 3 1 ST SupOn3 Fault BO Presence of active alarms
1 = message trigger no. 3 1 BO MsgTrig3 Warn BO Presence of active warnings
Input Signal 4 1 ST InSig4 SimActQ BO 1 = simulation activated
Supervision ON signal 4 1 ST SupOn4 ErrorNum I Error Number
1 = message trigger no. 4 1 BO MsgTrig4
Input Signal 5 1 ST InSig5
Supervision ON signal 5 1 ST SupOn5
Supervision delay time signal 1 (s) 0 I SupOnTi1
Out Signal 1 on delay time (s) 0 I OutOnDT1

Process Feedback block functions
Example 4: 'Speed Monitor of a drive'
In the example 'Transport out of bin E52-3B1' a speed monitor supervision will be added for belt
conveyor E51-BC1.
The speed monitor is a process feedback of the belt conveyor. The process feedback must be
"1" some time after the drive has been started and it must be "0" some time after the drive has
been stopped. If the process feedback trips while the drive was running the fault is created
immediately.
Additional objects:
E51-BC1.S1 Belt Conveyor below E51-3B1 Speed monitor C_PROFB F
The process feedback block is connected to a Periphery signal which is simulated in this
example via Buttons in the Process Picture.

I/O list:

E51_BC1_S1 Belt Conveyor Speed Monitor I 13.3
Button S1 switches the Speed monitor signal to “1” as soon as the drive is started.
Button S1_f forces the Speed monitor signal to “1”, independent of the drive start.

Creating a process feedback block for an existing drive and Property settings
with different process feedback blocks C_PROFB. The blocks with name 'S1', 'S2' and 'S3' are
configured for different versions of Speed Monitors.
- Block 'S1' can be used for a binary process feedback which, once the equipment is
running provides a continuous 1-Signal. The block is configured for supervision in ON
and OFF direction.
- Block 'S2' can be used for a binary process feedback which, once the equipment is
running produces pulses. The block is configured for supervision in ON and OFF
direction.
- Block 'S3' can be used for an analog process feedback. After the startup of the
equipment the speed value must exceed the Startup OK limit StUpLim and after stopping
the equipment the speed value must go below the Shutdown OK limit ShDoLim. The
block is configured for supervision in ON and OFF direction.
For the example above, block type 'S1' must be copied from template chart PROFB into the
existing chart E51_BC1.
After creating the block, the block properties (block name, comment, block icon and message
definition) must be entered. The message definition is similar to C_ANNUNC block.
object view.

Exercise 4.1: Adding the process feedback block in chart E51_BC1 and entering block
properties and message definitions
Chart E51_BC1 already exists and contains motor M1 and the three annunciation blocks D1, D2
and R1. The speed monitor belongs to the same equipment and must be inserted in the same
chart.
For inserting the process feedback block proceed as follows:
- Open the template chart PROFB from 'Tng_Lib', Folder 'Templates_nnn'.

Permissions.
- Copy block 'S1' from the template chart PROFB and insert it into chart E51_BC1.
- Make sure that the block is inserted at the correct position in the runtime editor,
1. Process Feedback block with O_LINK connection to the drive

E51_BC1 S1 Belt Conveyor Speed Monitor 1
- Enter the 'message text' for SIG1 and SIG2, e. g. "Process Feedback".

In case of a binary process feedback signal, the symbol must be connected to input InSig or
InSigB of the C_PROFB block.
Symbols file.
Connection of a binary signal from the Symbols file to InSigB
Connection of binary signal via APL Channel driver block to InSig:
Connection of binary signal via a converter block to InSig:
In case of an analog process feedback signal, the symbol must be connected to input PV of the
C_PROFB block. The values for Startup OK limit StUpLim and Shutdown OK limit ShDoLim
must be adjusted.
Exercise 4.2: Connecting the process feedback signal according to the I/O list to the block
On page 71 you find the I/O list for the block. The symbol already exists in the Symbols file.
(A memory is used instead of an input because of simulation via HMI).
Connect the signal to input InSigB of the Process feedback block.

As the process feedback blocks always belong to a drive and the drives must be linked to a
group or route, the process feedback block does not have a GR_LINK1 or GR_LINK2 interfaces.
In this case output O_LINKQ of the drive must be connected to input O_LINK of the process
feedback block.
The result is that in the Object list of the group, the Process feedback block is displayed one
level below the drive, together with the drift switch and rope switch:

E51_BC1/S1 Belt conveyor Speed Monitor
Exercise 4.3: Link between Group, drive and process feedback block
Carry out the link between the drive and process feedback block by connecting output O_LINKQ
of the drive to input O_LINK of the process feedback block.

Output ProFB of the process feedback block must be connected to input ProFB of the drive
block.
During the startup of the drive the supervision starts after the 'on delay time for monitoring'
PFOnDTi has elapsed.
If the off delay monitoring is enabled (via Feature.bit30) the process feedback must be "0" after
the 'off delay time for monitoring' PFOfDTi has elapsed.
Input Message Enable MsgEn must be connected with the signal for power supply supervision!
Message enable can be achieved via input MsgEn or internally via O_LINK (if Feature.bit16 is
set). If Feature.bit16 = TRUE, the input MsgEn does not need to be connected.
According to LafargeHolcim Engineering Rules the fault status must be kept until new startup of
the drive. This function is enabled vie Feature.bit14, which must be TRUE.
In this case the indication remains red until the next successful start of the motor.
faceplate:
faceplate of the C_PROFB block. Text 0 is additionally used for status call function and
description such as '+S' which is displayed in the faceplate.

Exercise 7.4: Connections between drive and process feedback block and configuration of the
Carry out the connections between the drive and the process feedback block.
Check the feature bit settings for the process feedback block.
Adjust the process parameters for 'On delay for monitoring start' PFOnDTi and 'Off delay for
monitoring stop' PFOfDTi.
status call).
Compile the OS.
- Start the drive and check the process feedback supervision function via simulation of S1.
- Stop the drive and check the process feedback supervision function via simulation of S1.
- After this test you may switch the process feedback supervision to simulation or simulate
the input in the CFC, otherwise in every drive startup or stop you have to make sure that
the status of S1 changes as well.

Summary: Block interfaces of C_PROFB
Interfaces and parameters of C_PROFB
ModuleTag
C_PROFB MAIN_TAS
Process Feedback block 1/23
Input Signal (Structure) 1 ST InSig ProFB ST Process feedback to the drive
Input Signal (boolean) 1 BO InSigB OutSig ST 1 = output signal ok
Input Signal (Analog) ST PV Fault BO Fault
1 = enable messages 1 BO MsgEn SimActQ BO 1 = simulation activated
On delay for monitoring (start) (s) 10 I PFOnDTi ErrorNum I Error Number
Off delay for monitoring (stop) (s) 15 I PFOfDTi
Tolerance value for Process Feedback 50 I ProFbTol
Startup OK Limit 100 R StUpLim
Shut down OK Limit 0 R ShDoLim

Measuring value functions
Example 5: 'Belt Conveyor Flow measurement'
In the example 'Transport out of bin E52-3B1' add the measuring value blocks for the following
measurements:
 E51-BC1 Belt Conveyor Flow measurement

 E51-3S1 Silo level
 E51-3S1 Silo temperature
The percentage value of the Flow as well as the physical value shall be displayed in the
faceplate of the drive E51-BC1.M1.
Additional objects:
E51-BC1.F1 Belt Conveyor below E51-3B1 Flow Measurement C_MEASUR ---
E51-3S1.T1 Concrete Silo E51-3S1 Temperature C_MEASUR

I/O list:

E51_BC1_F1 Belt Conveyor Flow measurement IW 1028
E51_3S1_L1 Concrete - Silo Level IW 1040
E51_3S1_T1 Concrete - Silo Temperature IW 1044
Range and limits:
Tag name Range Unit (Phys) LL L H HH

E51_BC1_F1 0.0 – 20.0 t/h
E51_3S1_L1 0.0 – 25.0 m 2.0 23.0
E51_3S1_T1 0 – 200 °C 130 150
The measured value block is normally connected to a Periphery signal (either directly or via a
channel driver block), but in this example the Belt conveyor flow measurement will be simulated
by a simulation block (see exercises).
Creating the measured value blocks and Property settings
with a three measured value blocks C_MEASUR. Block "X1" is configured for direct connection
to the Analog input via parameter MV_Card. Block "X2" is configured for the connection via PCS
7 Channel driver block Pcs7AnIn. Block "X3" is configured for simulations via the test block
MEAS_TEST which is only used for Demos and in the training (not in real projects).
The Feature bits and OS Permissions are configured accordingly.
For the flow measurement, the C_MEASUR block must be copied from template chart MEASUR
into the existing chart E51_BC1.
The measurements for Silo level and Silo temperature must be inserted into chart E51_3S1
definition) must be entered.
The C_MEASUR block internally uses an ALARM_8 function, where SIG1 to SIG6 are used. In
order to display the text in the alarm line, you have to enter the block comment of the measured
value into folder “Additional Text”, Consec. No 5 and Consec. No 9.
object view.

Exercise 5.1: Adding a measured value blocks and entering block properties and message
definitions
Chart E51_BC1 already exists and contains motor M1. The flow measurement belongs to the
same equipment and has the same equipment name. For this reason the measured value block
must be inserted in the same chart.
Proceed as follows:
- Open the template chart MEASUR from 'Tng_Lib', Folder 'Templates_nnn'.

Permissions.
- Copy block 'X3' together with "X3_SIM" from the template chart MEASUR and insert it
into chart E51_BC1.
1. All measured value blocks which are linked via O_LINK to the drive
- Enter the block properties for the measured value block:

E51_BC1 F1 Belt Conveyor Flow measurement 1

The Silo level measurement and the Silo Temperature measurement belong to Silo E51-3S1 and
must be inserted in the same chart.
For the Silo measurements proceed as follows:
- Create a new chart and name it E51_3S1.
- Open the template chart MEASUR from 'Tng_Lib', Folder 'Templates_nnn'.

Permissions.
- Open chart E51_3S1.
- Copy block 'X2' from the template chart MEASUR and insert it two times into chart
E51_3S1.
- Make sure that the blocks are inserted at the correct position in the runtime editor. (The
new runtime group should be called before the group.)
- Enter the block properties for the measured value block:

E51_3S1 L1 Concrete Silo Level 1
E51_3S1 T1 Concrete Silo Temperature 1

Analog process signals may be directly connected to input MV_Card of the C_MEASUR block or
e. g. via a Channel driver block Pcs7AnIn to input PV of the C_MEASUR block.
Direct connection of the periphery signal to input MV_Card:
Input ReadCard must be set to 1-Signal in order to read from input MV_Card.
Connection of an analog input via APL Channel driver block:
Input ReadCard must be set to 0-Signal in order to read from input PV.
For the connection to the APL Channel driver block, the output PV_Out of block Pcs7AnIn must
be connected to input PV of the C_MEASUR and additionally output Bad of block Pcs7AnIn
must be connected to input Bad of C_MEASUR.
Scale beginning and Scale end of the measured value is transmitted via output ScaleOut of
C_MEASUR to input Scale of block Pcs7AnIn.
The Substitute value of the measured value is transmitted via output SubValDr of C_MEASUR to
input SubsPV_I of block Pcs7AnIn.

Adaptation of measuring range and limits
By default the measuring range is set to 0 – 100 and the default unit is %. All low limits are set to
0 and all high limits are set to 100, which means, the limit supervision is not activated.
Via input PV_OpSca the values for Scale high and Scale low must be entered and input UNIT
must contain the physical unit.
If the limit Scale differs from 0-100, the limit values must be adapted as well.

Exercise 5.2: Adapting Scale, Unit and limit values and simulation of the process signal
Adapt the Scale low and high value via input PV_OpSca according to the range of the measured
value (see page 80).
Change the unit via input UNIT to 't/h'.
Adapt the limits according to the requirements (see page 80).
At this step, normally the analog input is connected to the measured value block (either directly
via input MV_Card or indirectly via input PV.
For this training exercise, no analog input exists and we will use the simulation block MEAS_TST
which was already copied together with C_MEASUR. Output MV of the simulation block is
connected to input PV of C_MEASUR in order to simulate the process value:
The simulation block can be parameterized e. g. in order to give a peak during startup of the
drive and after this altering values between START and END values, in form of a SINUS.
For the flow measurement, after E51-BC1 has been started we want to simulate a ramp and
while the drive is running the value should dither around 10 or 11.
- Adjust values for START and END to a value within the measuring range.
 Set the value 10 and 11.
- Connect output RunSig of the drive to input RAMP and inverted to input RESET_0.
 Value MV will be reset if the motor is not running; it will follow a ramp after drive has
been started.
- Set parameter DITH_ON to "1", change DITHER value to 0.1

You will get a small alteration of the signal.

In case of measured value blocks belonging to a drive, the drive is already linked to the group
via GR_LINK1 or GR_LINK2 (or via a C_MUX block). Instead of linking the measured value
block to the group, it may be linked to the drive via Object link. Therefore output O_LINKQ of the
drive must be connected to input O_LINK of the measured value block.
The flow measurement will be assigned to the Belt conveyor; the Silo Level and Temperature
measurements don‟t belong to any motor and must be assigned directly to the group.
The result is that in the Object list of the group, the measured value is displayed as follows:

E51_3S1/L1 Concrete Silo Level
E51_3S1/T1 Concrete Silo Temperature
E51_BC1/F1 Belt conveyor Flow measurement
Exercise 5.3: Link between group, drive and measured value block
Carry out the link between the measured value blocks and the corresponding drive or group.

Display of the measured value in the drive faceplate (optional)
Sometimes it is useful to see the measured value (physical value and/or Percentage value) in
the drive faceplate. This is possible via block connections from the measured value block to the
drive:
In order to transmit the physical value to the drive block, output PV_Out of the C_MEASUR block
must be connected to input AV of the drive block and output PV_Stat of the C_MEASUR block
must be connected to input AV_Stat of the drive block.
In order to transmit the percentage value to the drive block, output MV_Perc of the C_MEASUR
block must be connected to input AV_Perc of the drive block.
For the calculation of the percentage value, the measuring range PV_OpSca or the
Normalization values PercLow und PercHigh can be used, depending on the settings of
Feature.bit6.
Exercise 5.4: Adding connections for value display in the drive faceplate and testing the function
Carry out the additional connections for indication of the physical value and the percentage value
in the drive faceplate.
Compile the OS, Open the process picture and move the block icon to the desired position.
- Start the drive and observe the measured value via measured value block and via the
drive faceplate.
- Enable some of the additional functions like 'Hysteresis', 'Smoothing' or 'Gradient

Supervision' (one by one) and play with the function.

Analog value archive (optional)
For Archiving the block output PV_Out.Value must be used. For module E51_BC1/F1 the
WinCC variable „E51_BC1/F1.PV_Out#Value' must be used for an Archive Tag with exactly the
same name.
There are different options for creating a process value archive:
1) Automatic creation of the Archive tag. In this case in the CFC of the corresponding
measurements the Structure variable PV_Out.Value must be selected for "Archiving" and
during the OS Compilation an Archive Tag with this name is inserted into a common
Archive with name 'SystemArchive'.
 Acquisition cycle and Archiving/Display Cycle are set to a default value and must be
adapted afterwards in WinCC Tag Logging.
2) Manual creation of the Archive tag in the Tag Logging of WinCC, using a common
Archive with name 'ProcessValueArchive'.
 In the Tag Logging under Archive name 'ProcessValueArchive' an Archive Tag must
be created for E51_BC1/F1.PV_Out#Value.
Acquisition cycle and Archiving/Display Cycle must be configured.
3) Manual creation of the Archive tag in the Tag Logging of WinCC, using multiple Archives
(Archive splitting per Area).
 In the Tag Logging under the Area Specific Archive, e. g. 'Clinker' an Archive Tag
must be created for E51_BC1/F1.PV_Out#Value.
Acquisition cycle and Archiving/Display Cycle must be configured.
 As the archive name is different from 'ProcessValueArchive', the proper name must
be entered in the CFC, structure variable E51_BC1/F1.PV_Out.Value under
'Identifier'.
Archiving must not be selected in the CFC!!!!

Overview for Archiving Options:
Common Archive Common Archive Multiple Archives

(Automatically created) (Manually created) (manually created)
Name "SystemArchive" Name "ProcessValueArchive" Name "Crusher", "Raw Mill",
"Kiln", etc.
Select property 'Archiving' at Don't select property Don't select property
output Archiving' at output 'Archiving' at output
Tagname.PV_Out.Value Tagname.PV_Out.Value Tagname.PV_Out.Value
Archives are created during
OS Compile and Variable
@TagArchiveName is
created which contains the
Archive name
& &
- Create an Archive in the - Create multiple Archives in
WinCC Tag Logging the WinCC Tag Logging
- Create Archive Tags in - Create Archive Tags in
WinCC Tag Logging WinCC Tag Logging
- Connect to - Connect to
Tagname.PV_Out#Value Tagname.PV_Out#Value
&
- Enter Archive name
"Crusher", "Raw Mill" "Kiln",
etc. at output
Tagname.PV_Out.Value
under "Identifier"
- During OS Compile the
internal variable
Tagname.PV_Out
#Value#Shortcut is created.
Priorities for searching the Archive:
Prio1: Checking the entry in the internal variable measure.PV_Out#Value#Shortcut

Prio2: Entry in Variable @TagArchiveName (if existing)
Prio3: Default setting "ProcessValueArchive"

Exercise 5.5: Adding a measured value archive.
If using Option 1, open chart „E51_BC1‟, block 'F1', select output 'PV_Out.Value' and change the
property to "Archiving". Carry out a CFC compile and an OS Compile. Check the
Archiving/Display Cycle in the Tag Logging.
(If using Option 2, manually create the archive tag for E51_BC1/F1.PV_Out.Value in the Tag
Logging of WinCC. For Acquisition cycle and Archiving/Display Cycle, use '1 second'. OS
Compile is not necessary in this case.)
Test the function:
- In the runtime system, open the faceplate of the measured value and press 'Trends' in
order to see the archive.
- Use right mouse click on the block icon of the measured value in order to open the curve
directly (quick view function).
- Use control button together with right mouse click on the block icon of the measured
value in order to open the „APL Operator Trend Control'. In this window up to 8 values
can be grouped and displayed together
Add further values by Ctrl + right mouse click on the dimension of different measures.
Individual curves and the scales can be deselected.
The selection can be saved in order to memorize for the next time.

Summary: Block interfaces of C_MEASUR
Interfaces and parameters of C_MEASUR
ModuleTag
C_MEASUR MAIN_TAS
Measuring value 1/23
Enable fault message HH 1 BO PV_HH_En MV R Measured Value
Enable fault message H 1 BO PV_H_En PV_Out ST Process Value (Analog Output)
Enable fault message L 1 BO PV_L_En PV_Stat ST Analog Output Status + Unit
Enable fault message LL 1 BO PV_LL_En MV_Perc R Measured Value in % as Real
Enable fault message LZ 1 BO PV_LZ_En ScaleOut ST Range of process value (to driver)
Block measuring channel / bypass 0 BO PV_Bypas SubValDr R Substitute value (to driver)
1 = supervision enabled 1 BO SupOn PV_HH BO Oveshoot Limit HH
1 = switch to automatic mode 0 BO AutModOn PV_H BO Oveshoot Limit H
0 = force to Out of Service mode 1 BO OoSModOn PV_L BO Undershoot Limit L
Force MV output to scale low 0 BO FoScaLo PV_LL BO Undershoot Limit LL
1 = enable messages 1 BO MsgEn LZ BO Live Zero
1 = enable dynamic fault 1 BO DynFltEn DynFlt BO dynamic fault (not acknowledged)
Value HH Limit 100.0 R HH_Lim GradNegQ BO Gradient negative overshoot
Value H Limit 100.0 R H_Lim GradPosQ BO Gradient positive overshoot
Value L limit 0.0 R L_Lim BypaActQ BO Meas. channel blocked / bypassed
Value LL Limit 0.0 R LL_Lim FroValDe BO Frozen value detected
time delay Live Zero (s) 3 I LZDelTi PV_SHH BO Oveshoot switching limit HH
Time spike suppression delay (s) 3 I SpSupTi PV_SH BO Oveshoot switching limit H
Hysteresis (%) 0.0 R Hysteres PV_SL BO Undershoot switching limit L
Gradient Positive (%) 0.0 R GradPos PV_SLL BO Undershoot switching limit LL
Gradient Negative (%) 0.0 R GradNeg SubValOn BO Substitute value active (driver)
Gradient supervision delay (s) 0 I GradDTi SimActQ BO 1 = simulation activated
Time smoothing (s) 0 I SmooTi ErrorNum I Error Number
Frozen value tracing time (s) 60 I FroTraTi
Frozen value min. deviation (%) 2.0 R FroMiDev
Supervision delay time (s) 0 I SupOnTi
Value HH switching limit 100.0 R SHH_Lim
Value H switching limit 100.0 R SH_Lim
Value L switching limit 0.0 R SL_Lim
Value LL switching limit 0.0 R SLL_Lim
Substitute value from OS 0.0 R SubValOs
PV Simulation value from OS 0.0 R SimPV
PV - bar display limits for OS 100.0 ST PV_OpSca
UNIT % S UNIT
1 = bad process value 0 BO Bad
Process value 0.0 ST PV
1 = read card value 0 BO ReadCard
Read in value direct from the card 16#0 W MV_Card
Start value from the cards low bad range -692 I CaLZ_SCB
Start value of the cards nominal range 0 I Card_SCB
End value of the card nominal range 27648 I Card_SCE
Start value of the cards hig bad range 29377 I CaLZ_SCE

Route functions
Example 6: „Selection of the transport destination via route modules‟
A selection facility is needed in order to choose the transport direction for the transport group.
The following destinations are possible:
 to Concrete Silo E51-3S1

 to Concrete Silo E51-3S2
Belt Conveyor E51-BC2 has to be controlled to direction “X” for feeding into Silo E51-3S1 or
E51-3S2.
Direction “Y” is not used at the moment.
Use two route modules to make the selections. Make sure that only one selection can be given
at a time and that the group can only be started if a route was selected previously.
The application requires the following objects in addition:

Creating the route blocks and Property settings
In the Project Library 'Tng_Lib' in Hierarchy folder 'Templates_nnn', you find a template chart for
the route. Block 'R' is already configured with the correct Feature bit and OS Permission
settings.
For the example above, block type 'R' must be copied from template chart into the new chart for
the route blocks E51-101 and E51-102.
definition) must be entered. The block properties can be entered via the Properties dialog in the
CFC or via the Process object view.
In the plant hierarchy of AS1 in the Area 'E50 System Test ' subfolder „E51‟, create two
additional charts (one for each route) and name them as follows:
E51_101
E51_102
- Open the template chart ROUTE from 'Tng_Lib', Folder 'Templates_nnn'.

Permissions.
- Open chart E51_101 and E51_102.
- Copy block 'R' from the template chart ROUTE and insert it into chart E51_101 and
E51_102.
- Make sure that the blocks are inserted at the correct position in the runtime editor (routes
should be inserted between the drives and the group).

E51_101 00 to concrete silo E51-3S1 1
E51_102 00 to concrete silo E51-3S2 1

Group/Route link (essential)
supervision of a sequence. Operating modes, faults or warnings of the drives, annunciations and
measured values are shown as summarizing indications in the group block icon and faceplate.
The route blocks are kind of "filter" functions, in order to transmit only the operating mode, fault
of warning of the selected objects to the group. Also in the status call function, only the faults
and warnings of the selected objects are shown.
If routes are involved, instead of linking the drives directly to the group, the drives are linked to
the route block and the route block to the group.
In the example above the structure is as follows:

E51_101/00 to Concrete Silo E51-3S1
In the example E51 most of the equipment (except Concrete Silo E51-3S1 Level and
Temperature) belongs to both routes. The common equipment could as well be linked directly to
the group, but in this case, without route selection, the faults/warnings are not shown in the
group summarizing indication.
values) which are not linked to a group will go to "Out of Service" mode and do not work.
they must be linked to a superordinated group or route.

The link is carried out by connecting output G_LINK of the group to input G_LINK or the route.
Output R_LINK of the route is then connected to GR_LINK1 or GR_LINK2 of the drives.
Exercise 6.3: Link between Group, Route and drives
input G_LINK of both routes and output R_LINK of the route(s) to GR_LINK1 or GR_LINK2 of
the corresponding drive.
Changes only!)
Compile the OS.
- Try Related Objects function, Object list for group and route
- Simulate some faults and watch the behavior of Summarizing fault indication and Status
call for group and route
- Carry out a mode change for the complete group or for a complete route.

Group and Route connections for Automatic control
For Start and Stop in Automatic mode further connections are required. In this example it
depends on the route selection, which part of the drives is started or stopped.
Caution: The start and stop command is still carried out by the group, because the route block
! does not have a start-up-warning function.
The following connections are needed between group, route and drives/devices:
- In a group with routes the start command is given from the group to the routes and the
selected route forwards the start command to the drive(s). The stop command is given
from the group to the route and the selected route forwards the stop command to the
drive(s):
For the start in automatic mode group output CmdOn is connected input StartAut of the
routes and route output CmdOn is connected to input StartAut of the corresponding
drives.
For the stop in automatic mode group output PeCmdOff is connected to input StopAut of
the routes and route output CmdOff is connected to input StopAut of the corresponding
drives.
- For the feedback, the running signal RunSig or the position signal PosSig1 or PosSig2 of
the drives is connected to the Feedback of related objects FbObjOn and FbObjOff of the
route.
(A logic is needed to transmit the feedback on of all drives/devices)
The running signal RunSig of the routes is then connected to the Feedback of related
objects FbObjOn and FbObjOff of the group.
- Only the Quick Stop function is directly connected from the group to the drive(s), via
connection of group output QuicStpQ to drive input QuickStp.
- In order to inhibit the group start if no route is selected, the route selection output Select
must be used as start interlocking (input IntStart of the group).
- In order to permit only one route selection at a time the inverted route output Select must
be connected to route input IntOper of the second route (and vice versa).
Note: In this exercise automatic change-over is not foreseen. For direction change the
! feeding must be stopped.
drives/devices to the routes and from the routes to the group. This only depends on the
Group/Route link and no further connection in required.
empty) can be transmitted internally (via Group/Route Link) from the group to the route and from
the route to the drive and vice versa, if the corresponding function is enabled via Feature bits.
Note: By default the feature bits are set in order to transmit the information internally.
!

Connections between group and route(s):
Connections between route(s) and drive(s):

Exercise 6.4: Connections between group, routes and drives
Carry out all connections between the group and the two routes for starting/stopping and
feedback on/off.
Make sure that the group cannot be started without route selection.
The routes need to be mutually interlocked, so that only one route can be selected at a time.
Carry out the connections between the two routes and the corresponding drives for
starting/stopping and for feedback on/off.
For the automatic start/stop of the common drives you can either use the start/stop signals from
the route or from the group.
- Belt Conveyor E51-BC2 must always be controlled to direction “X” independent on the
destination silo. Direction “Y” is not used at the moment.
- Distribution Gate E51-MW1 must be open in order to feed into Concrete Silo E51-3S1
and closed in order to feed into Concrete Silo E51-3B2.
(Route E51-101.00 is used for control into E51-3B1, Route E51-102.00 is used for control
into E51-3B2)
The start sequence is programmed via interlocking condition (previous exercise).
Via process parameter StaDelTi of the drive, the 'Start command ON in automatic mode'
StartAut can be delayed.
Via Process parameter StpDelTi of the drive the 'Stop command OFF in automatic mode'
StopAut can be delayed.
OS Compilation is also required because of the modification in the last exercise (adding
structure interlock blocks).
- Select route E51-101 "to concrete silo E51-3S1"
- Stop the group and test the stop sequence.
- Deselect route "E51-101 "to concrete silo E51-3S1" and select route "E51-102 "to
concrete silo E51-3S2"
- Stop the group and test the stop sequence.

Uninterrupted route change-over
If the route change between destination Silo E51-3S1 and E51-3S2 has to be uninterrupted, this
requires a different programming.
- The operation interlock between the two routes must be removed.
- If one route is pre-selected and the pre-selection of another route is added, then the first
pre-selection must be reset.
 refer to PrSelOff and PSelOfEn
- In case of a route change without interrupt the group has to be started while it is
completely running (because the drives of the “old” route are still running).
To permit the group to give the start command again, the “group feedback On / route
feedback On“ must be “0”.
This is done through using the drive feedbacks together with the route pre-selection
PreSel for the route feedback ON.
 refer to FbObjOn
- The old route is deselected automatically once the newly started route runs completely.
 refer to SelOff
- The de-selection of the “old” route stops the drives that are no longer required.
 In this example this is not needed because the valve is the only element which
changes.
Pre-Selection and Selection of the route:
Selection R_
>=1
PrSelOn TRIGG
PreSel
RS_FF
Deselection BO S Q BO
>=1 BO R QN BO
PrSelOff
&
PSelOfEn
Select
RS_FF
IntStart & BO S Q BO
IntOper BO R QN BO
CmdOff &
FbObjOff
R_ >=1
SelOff TRIG

Connections between the two routes:
Exercise 6.5: Connections between routes
Adjust the connections between the two routes for the uninterrupted route change-over.
- Remove the operation interlock from the two groups
- Program the trigger for the „new selection‟ (PreSel & Select) and connect it to PrSelOff of
the other route.
- Program a trigger for „change-over completed‟ (Select & NOT ChangeOv) and connect it
to the SelOff of the other route.
- Include the preselection of the own route in the Route Feedback ON FbObjOn.
- Make sure that before start of E51-BC2 the Distribution gate is in the correct position
- Make sure that E51-BC2 remains running during route change-over.
- Test the function by starting the group and switching routes without stopping the
transport.

Summary: Block interfaces of C_ROUTE
ModuleTag
C_ROUTE MAIN_TAS
Route 1/23
1 = Start Interlock ok 1 ST IntStart CmdOn BO Command ON
1 = Operation Interlock ok 1 ST IntOper CmdOff BO Command OFF
1 = Manual interlock ok 1 ST IntManu PeCmdOn BO Permanent Command ON
Enable preselection OFF (with PrSelOff) 1 BO PSelOfEn RunSig ST Running Signal
Fb of related objects on 0 BO FbObjOn OffSig ST Output feedback OFF
Fb of related objects off 1 BO FbObjOff AutModOn BO 1 = Automatic mode ON
Fb of related object(s) in local 0 BO FbObjLoc ManModOn BO 1 = Manual mode ON
Fb of related object (s) in manual 0 BO FbObjMan LocModOn BO 1 = Local mode ON
Fb of related object(s) in out of Service 0 BO FbObjOoS PreSel ST Preselection ON
Preselection ON 0 BO PrSelOn Select ST Selected
Selection OFF 0 BO SelOff ChangeOv BO Route changeover flag
Preselection OFF (+PSelOfEn) 0 BO PrSelOff DynFlt BO dynamic fault (not ackn.)
1 = Start command ON in auto mode 0 BO StartAut Fault BO Fault
1 = Stop command OFF in auto mode 0 BO StopAut SimActQ BO 1 = simulation activated
Operator Permissions 1 ST OS_Pern R_LINK ST Link to routes/objects
Status of various features 1 ST Feature ErrorNum I Error Number
Link to the group Command 0 ST G_LINK

Annunciation block functions (Part II)
Example 7: 'Silo level annunciation'
The level switches for level max of the Concrete Silos E51-3S1 and E51-3S2 shall be indicated.
Level exceeded will give an alarm and switch off the transport.
The level switches are interlocks for the group (dependent on the selected routes) and no faults
and they should not lead to a summarizing fault indication in the group symbol.
In the following exercise we carry out the engineering of an annunciation blocks for „Silo level
max“.
If the group is not started and/or the corresponding Silo is not selected, the silo level indication
shows violet color (not ready) and no alarm message will be given.
Once the group is started the level switch of the selected Silo will be indicated in red color and it
produces an alarm message.
The Silo levels should never lead to a summarizing fault indication in the group, as the silo levels
are interlocking conditions and, not faults.

Depending on the functional descriptions the level switches can be used for a sequential group
stop (using the operating interlock IntOper) or for an immediate stop (using the Quick stop
function QuickStp).
Additional objects:
I/O list:

E51_3S1_L2 Concrete Silo Level switch Level max OK I 30.2
E51_3S2_L2 Concrete Silo Level switch Level max OK I 30.3

Creating CFC and blocks with proper Property settings
with different annunciation blocks C_ANNUNC. On the second sheet you find two examples for
process interlocks.
The block with name 'H' is preconfigured for 'warning mode', in order to create (yellow) warning
messages. The block with name 'HH' is preconfigured for fault mode in order to create (red) fault
messages.
definition) must be adjusted.
Exercise 7.1: Creating a new chart for the Silo, inserting the annunciation blocks and entering
block properties and message definitions
Area „E50 System Test', subfolder 'E51' already contains a chart E51_3S1 with two
measurements for concrete Silo E51-3S1. Additionally we need a chart for the second Silo which
must be named as follows:
E51_3S2
The annunciation block for the level switches must be inserted in the chart of the corresponding
silo.
For each level switch proceed as follows:

Permissions.
- Open charts E51_3S1 and E51_3S2.
- Copy block 'HH' from the template chart ANNUNC and insert it into chart E51_3S1 and
E51_3S2.
- Make sure that the new runtime group and blocks are inserted at the correct position in
the runtime editor (preferable before the damper).

E51_3S1 L2 Concrete Silo Level 1 Level max 1
E51_3S2 L2 Concrete Silo Level 2 Level max 1

- Enter the 'message text' for SIG1 and SIG2, e. g. "Level max".
The level switches are binary process signals which must be connected to input InSig or InSigB
of the C_ANNUNC block. As the signal is of format BOOL und the block input InSig is of format
STRUCTURE, the CFC Editor does not allow a direct connection to a binary input signal
Therefore use input InSigB.
Connect the signals to input InSigB of the corresponding Annunciation block.

Each silo level belongs to the corresponding route and must be linked to this route via link
interface.

E51_3S1/L2 Concrete Silo Level max
Carry out the link between the group and the annunciation blocks by connecting output G_LINK
of the group to input GR_LINK1 of both annunciations.

Beside the Route link, further connections are needed between group, route and annunciation
blocks, in order to interlock the group and in order to create messages only if the group is in
operation (active) and the route is selected.
If the process signal is only used as start interlock, the output OutSig (in case of fault
annunciation) or Warn (in case of warning annunciation) must be connected to the group start
interlock IntStart.
If output Warn is used, the signal must be inverted Warn has status "1" in case of a warning.
If the process signal is used as operation interlock, the output OutSig must be connected to
group operation interlock IntOper. This input enables starting and operation, which means the
additional connection to IntStart is not necessary.
If the process signal should cause a quick stop of the group, the output OutSig must be
connected to input QuickStp of the group. The output OutSig of all annunciation blocks used as
operation interlocking of the group must be connected to group input IntOper.
Any interlocking or stop condition must only be evaluated if the corresponding route is selected.
In order to create the messages only if the group is in operation, the group output Active
(together with the corresponding route selection) must be connected to input DynFltEn of the
annunciation blocks.
In order to exclude the annunciation blocks from the summarizing (warning / fault) indications of
the group, input GrFltLck if the annunciation block must be set to "1".
In the status call of the group the annunciation block will still be displayed.

faceplate:
description such as '+L' which is displayed in the faceplate.
Exercise 7.4: Connections between group and annunciation blocks and configuration of the
Carry out the connections between the transport group, the routes and the two annunciation
blocks.
Check the feature bit settings for both annunciation blocks.
status call).
Compile the OS.
- Simulate Silo level max for a non-selected silo and for a selected silo and check the
indications at the route and group:
Colors, summarizing indications, etc.
- Start the group and simulate Silo level max. A message should appear in the alarm line.
- If the Operation interlock was used, Silo level max should lead to a sequential stop.
- If the Quick Stop interface was used, Silo level max should lead to an immediate stop.
- If a group is stopped by interlocking it needs acknowledgement (normally carried out with

the acknowledgement of the alarm).

Example 8: 'Annunciation for group status call'
Sometimes it is useful to give the operator additional information in case of missing interlocking
conditions, e. g. in order to let him know why a group cannot be started.
For this purpose, you may create an annunciation block whose only purpose is to provide this
information in the group status call function. The annunciation block will be configured in order
not to give alarms at all.
For Group E51 an annunciation block is used in order to show that no route is selected and
therefore the group start is not possible.
It is not needed to show a block icon in the process picture, the information will only be available
for the group status call.
Additional objects:
Tag name Comment Block type

E51_100/00_IL Discharge E51-3B1 no route selected C_ANNUNC
The annunciation block only uses internal information and is not connected to any periphery
signal.
You can simulate the interlocking by deselection of both routes.

Creating an annunciation block for an existing group and Property settings
with different annunciation blocks C_ANNUNC. On the third sheet you find an example for group
status call annunciations.
The block with name 'StaInfo' is preconfigured in order not to create alarms and not to indicate
summarizing fault or warning in the group.
Exercise 8.1: Adding the annunciation blocks in chart E51_100 and entering block properties
and message definitions
Chart E51_100 already exists and contains group 00. Use the same chart for the status call
annunciation.
For inserting the new annunciation block proceed as follows:

Permissions.
- Open chart E51_100.
- Copy block 'StaInt' from the template chart ANNUNC and insert it into chart E51_100.
- Make sure that the blocks are inserted at the correct position in the runtime editor (in the
same runtime group as the group, preferable before the group block).

E51_100 00_IL Discharge E51-3B1 no route none
selected
- Open the properties dialog and enter the block name and the comment. Deselect the
option for block icon generation.
- Message definition is not needed because this block will never generate messages.

The new annunciation block belongs to group E51_100/00 and must be linked to this group via
Group link interface. In difference to the drives which have been linked to the routes, the
annunciation block for status call must be linked to the group directly.

E51_100/00_IL Discharge E51-3B1 no route selected
Carry out the link between the group and the annunciation block by connecting output G_LINK of
the group to input GR_LINK1 of the annunciation.

The start condition of the group is used as input for the annunciation block. The annunciation
block must be configured in order not to create alarms (DynFltEn = 0) and in order to not to be
included in the summarizing indications of the group (GrFltLck = 1).
Exercise 8.4: Connections between group and annunciation blocks and configuration of the
Carry out the connection between structure interlock and annunciation block.
Check the feature bit settings for the annunciation block.
Add a text via parameter InSig.Value, e. g. "Start Interlock". The string entered into InSig.Value
'Text 0' will be used for the status call. OutSig.Value is not needed for this kind of annunciation
blocks.
Compile the OS.
- Deselect both routes and carry out a status call for the group. Group summarizing
indication should only show and 'I' for 'Interlocked' and not 'F' for 'Fault'.

Bag Filter (Warning Motors)
Example 9: „Adding a bag filter to the existing group‟
The bag filter also belongs to group E51-100 but it is not an essential function (not necessary for
the production). For this reason the drives are so-called “Warning Motors”. In case of a drive
fault the blocks show warning (yellow) and not fault (red).
A warning during the start-up of the group will not cause any interrupt of the group start.
The bag filter and the rotary feeder get started by the group in the following sequence:
First E51-RF2, then E51-BF1 and after that E51-FN1.
E51-BC2 must be running before.
When stopping the group, the bag filter E51-BF1 and the fan E51-FN1 shall continue to run for
60 seconds (stop delay).

E51-BF1.C1 Bag Filter to E51-BC2 Frequency Converter C_DRV_1D W
E51-FN1.M1 Fan E51-BF1 C_DRV_1D W
E51-FN1.TU Fan E51-BF1 Temperature C_MEASUR ---
E51-RF2.M1 Rotary Feeder E51-BF1 C_DRV_1D W
E51-RF2.S1 Rotary Feeder E51-BF1 Speed Monitor C_PROFB W
I/O list:

E51_FN1_M1_U Fan Motor no local isolated I 10.0
E51_FN1_M1_S Fan Motor no local Stop I 10.1
E51_FN1_M1_G Fan Motor Local Start I 10.2
E51_FN1_M1_K Fan Motor Available I 44.0
E51_FN1_M1_T Fan Motor no thermal overload I 44.1
E51_FN1_M1_R Fan Motor Running I 44.2
E51_FN1_M1_D Fan Motor Switch ON Q 41.1
E51_FN1_TU Fan Temperature Actual value IW 1024
E51_RF2_M1_U Rotary Feeder Motor no local isolated I 11.0

E51_RF2_M1_S Rotary Feeder Motor no local Stop I 11.1
E51_RF2_M1_G Rotary Feeder Motor Local Start I 11.2
E51_RF2_S1 Rotary Feeder Speed Impulse Speed Pulse I 12.0
E51_RF2_M1_K Rotary Feeder Motor Available I 48.0
E51_RF2_M1_T Rotary Feeder Motor no thermal overload I 48.1
E51_RF2_M1_R Rotary Feeder Motor Running I 48.2
E51_RF2_M1_D Rotary Feeder Motor Switch ON Q 42.1
E51_BF1_C1_K Bag Filter Frequency converter Available I 42.0

E51_BF1_C1_R Bag Filter Frequency converter Running I 42.2
E51_BF1_C1_D Bag Filter Frequency converter Switch ON Q 40.3
Range and limits:
Tag name Range Unit (Phys) LL L H HH

E51_FN1_TU 0 – 200 °C 110 120

Creating CFC and blocks with proper Property settings
In the Project Library 'Tng_Lib' in Hierarchy folder 'Templates_nnn', you find the template charts
for block types C_DRV_1D, C_MEASUR and C_PROFB, which have already been used for the
previous exercises.
Use the corresponding blocks, according to the function.
definition) must be adjusted.

Exercise 9.1: Creating new charts, inserting the blocks and entering the block properties and
message definitions
In the plant hierarchy of AS1 in the Area 'E50 System Test‟, subfolder „E51‟, create 3 additional
charts and name it as follows:
E51_FN1
E51_RF2
E51_BF1
Insert the required blocks through copying form the template charts:
- For Fan E51-FN1, copy block „M‟ from template chart DRV_1D and block „X1‟ from
template chart MEASUR.
- For Rotary Feeder E51-RF2, copy block „M‟ from template chart DRV_1D and block „S1‟
from template chart PROFB.
- For Bag Filter E51-BF1 copy block „M‟ from template chart DRV_1D.

E51_BF1 C1 Bag Filter Frequency Converter 1
E51_FN1 M1 Fan 1
E51_FN1 TU Fan Temperature 1
E51_RF2 M1 Rotary Feeder 1
E51_RF2 S1 Rotary Feeder Speed Monitor 1
- For the Speed monitor, enter the 'message text' for SIG1 and SIG2, e. g. "Process
Feedback".
(MCC signals or Field signals).

The bag filter must work independent on the route selection and can either be linked to both
routes or directly to the group. In our example we will link the bag filter directly to the group.
In this case the group will show the following structure:

E51_RF2/S1 Rotary Feeder Speed Monitor
E51_BF1/C1 Bag Filter
E51_FN1/M1 Fan Motor
E51_FN1/TU Fan Temperature
E51_100/00_IL Discharge E51-3B1 no route selected
Carry out the link between the existing group and the new blocks.

The bag filter devices shall not interrupt the group start in case of malfunction, therefore the
drive blocks must be configured as warning devices. This is achieved via a feature bit setting
(Feature2.bit2 must be TRUE).
The same applies for the Speed Monitor belonging to E51-RF1, the warning mode at C_PROFB
must activated as well (Feature.bit29).
Caution: In order to stop the warning device by a fault (warning!) of the C_PROFB you have to
connect output Fault of the C_PROFB to the Protection interlock IntProtA of the drive.
In order to give (yellow) warning messages instead of (red) fault messages the message
configuration must be adapted as well.
As the bag filter belongs to both routes, the bag filter devices can be started/ stopped directly by
the group Start/Stop commands StartAut and StopAut.
During start-up of group „Transport out of bin E52-3B1‟ use the following start sequence:
- Belt Conveyor E51-BC2  Rotary feeder E51-RF2  Bag Filter E51-BF1

 Fan E51-FN1
During the shut-down of group „Transport out of bin E52-3B1‟, E51-BF1 and the fan E51-FN1
shall continue to run for 60 seconds (stop delay).
Exercise 9.4: Connections between group and the bag filter devices
and configuration of the process parameters and variable texts.
Carry out the connections between the group and the new devices:
- Consider the start command, stop command (including stop delay for E51-BF1 and E51-
FN1), quick stop command, group feedback on, group feedback off and the interlocking
conditions between the drives and/or process signals.
Adapt the feature bit settings for the Drive blocks and for the Process Feedback block in order to
activate the warning mode
- For the Drives, Feature2.bit2 must be changed to TRUE
- For the Process Feedback block, Feature.bit29 must be changed to TRUE
The message definition has already been adapted regarding texts in the previous exercise. But
for warning devices, in addition the message class for all alarms needs to be changed from
“Alarm – high” into “Warning – high”.
This is only necessary for the Drive blocks, the Annunciation block and Process Feedback block
already includes a warning message. The measured values will create warnings and faults.
Compile the OS.

In order to test the bag filter function:
- Start the group and check the start sequence: First E51-BC2, then E51-RF2, then E51-
BF1 and after that E51-FN1.
- Stop the group and check the stop sequence (including stop delay for E51-BF1 and E51-
FN1).
- Start the group and then generate a fault for one of the bag filter drives. A warning
message should appear in the alarm line.
- Carry out a status call for the group. The warning will be shown in yellow color.

Exercises in Area: 'Training'
The following exercises don‟t belong to the E50 System Test and will be carried out in Area
„Training‟.
Engineering examples „Group TG3‟ and „Group TG4‟
Group TG3-GR1 is used for the exercise „Pump Group‟ (Selection of one pump out of two) and
for the pressure supervision for the pumps.
Group TG4-GR1 is used in order to explain the Positioning function of the damper, the Setpoint
function of the drives and the Analog value selector.

List of Motors and Instruments:
Location
HAC Equipment (who) Device (what) Block Type F/W
(where)
TG3-PU1 Pump 1 C_DRV_1D F
TG3-PU1.P1 Pump 1 Pressure C_PROFB F
TG4-FA1 Fan C_DRV_1D F

TG4-FA1.J1 Fan Power C_MEASUR
TG4-FA1.TA Fan Bearing Temperature A C_MEASUR
TG4-FA1.TB Fan Bearing Temperature B C_MEASUR
TG4-FA1.TU Fan Winding Temperature U C_MEASUR
TG4-FA1.TV Fan Winding Temperature V C_MEASUR
TG4-FA1.TW Fan Winding Temperature W C_MEASUR
TG4-DA1 Damper C_DAMPER F
TG4-DA1.Z1 Damper Position C_DAMPER
Groups and Selections:
Location
(where)
TG3-GR1.G1 Pump Group C_GROUP
TG3-PU1.SEL Selection Pump 1 C_SELECT
Fan/Damper
TG4-GR1.G1 C_GROUP
Group
The signals for the above listed equipment are already assigned to I/O addresses and entered in
the symbols file. In each exercise you find a list of inputs and outputs to be used.
A hardware configuration for the I/O periphery exists as well.
Simulation and test:
For the test of the exercise „Pump Group‟ some inputs can be simulated via buttons on the
screen (as there is no real periphery available).
Via this buttons simulation flags are set/reset. In an already prepared simulation program
SIM_TRAINING (FC1399), which must be called before the other applications, the status of the
flags is transferred to the inputs.

Selection functions
Example 10: 'Pump in Stand-by mode'
In the following exercise, two selection blocks are used in order choose one pump out of two.
The second pump is stand-by. If the selected pump trips the other pump automatically gets
selected and started.
In this example, one selection block automatically deselects the other selection block in order to
select only one pump at a time.
The group can only be started if at least one pump is selected (Start Interlock).
The selection is changed in case of a dynamic fault of the pump.
TG3-GR1.G1 Pump Group C_GROUP

Each drive/device is connected to Periphery signals which are simulated in this example via
Buttons in the Process Picture, or in some cases directly in the program.
I/O list:

TG3_PU1_M1_R Pump Contactor Feedback on Simulation
TG3_PU1_M1_K Pump Available M 1025.0
TG3_PU1_M1_D Pump Contactor ON Simulation
TG3_PU2_M1_R Pump Contactor Feedback on Simulation

TG3_PU2_M1_K Pump Available M 1026.0
TG3_PU2_M1_D Pump Contactor ON Simulation
Contactor feedback and Position feedback are not simulated by buttons because these signals
depend on the Contactor ON command and are therefore difficult to switch "in time". The
simulation will be carried out in the CFC of the drive function.

Creating CFCs and blocks with proper Property settings
for drives, group and selection, which are needed for the example. The blocks in these template
charts already have the correct settings regarding mode change and local switch (Feature bits
and OS Permissions).
definition) must be entered for each object. The block properties can be entered via the
Properties dialog in the CFC or via the Process object view.
For repeating functions it may be useful to create one instance (first Pump), enter the properties
and copy this block after that.
In the plant hierarchy of AS1 in the Area 'Training' you find a subfolder '001_Pumps'. This
subfolder will be used for the third group (Pump group).
TG3_PU1
TG3_PU2
TG3_GR1
Each chart will be used for one pump + selection block and one additional chart for the group. In
the Runtime Editor, automatically a runtime group is created with the same name. Make sure
that the Runtime groups are inserted between OB1_START and OB1_END.
It is recommended to insert the drives before the group.
- Open the template chart DRV_1D from 'Tng_Lib', Folder 'Templates_nnn'.

- Open chart TG3_PU1, copy block C_DRV_1D from the template chart and insert it into
the chart of the drive.
- Open the template chart SELECT from 'Tng_Lib', Folder 'Templates_nnn'.

- Open chart TG3_PU1, copy block C_SELECT from the template chart and insert it into
the chart of the drive.
- Repeat this step for the second drive and for the group, using the block from the
corresponding template chart.


TG3_GR1 G1 Pump group 1
TG3_PU1 SEL Selection Pump 1 1
TG3_PU1 M1 Pump 1 1
TG3_PU2 SEL Selection Pump 2 1
TG3_PU2 M1 Pump 2 1
Connection to the I/Os – Standard Signals of the drives
(MCC signals or Field signals). If a signal does not exist, the block input carries the default value
which is the "healthy" condition.
Contactor feedback for C_DRV_1D and C_DRV_2D must always be connected, as well as
Position feedback of C_DAMPER and C_VALVE.
Contactor feedback for C_DAMPER and C_VALVE is normally not needed. Supervision is
possible if the function is enabled via the corresponding feature bit.
Exercise 10.2: Connecting the standard signals according to the I/O list to the blocks
Connect the signals to the corresponding block.
Inputs which don't exist remain without connection. They will automatically have the default
status.
Contactor feedback of C_DRV_1D must be simulated; otherwise the block generates a fault.
- Contactor feedback of the drives can be simulated by connecting output ContOn to input
FbkRun.

The selection blocks have no link to the group and do not show up in the group instance list. In
this example the drives must be linked directly to the group.
TG3_GR1/G1 Pump Group

TG3_PU1/M1 Pump 1
TG3_PU2/M1 Pump 2
values) which are not linked to a group automatically go to "Out of Service" mode and will not
work.
they must be linked to a superordinated group or route.
GR_LINK1 (or GR_LINK2) of each drive.
Changes only!)
Compile the OS.
You may now test the drive functions in manual mode.

Selection Change
Selection is carried out via HMI and only one pump can be selected at a time.
The following screen shot shows the two selection blocks and how they are interconnected:
The selection of Pump 1 automatically switches off the selection of Pump 2 (and vice versa). A
trigger must be used (rising edge) in order to switch off the selection only once.
The selection is used as interlocking condition for the corresponding pump.
The dynamic fault of a pump (motor tripped) automatically selects the standby pump.

Group connections for Automatic control
For Start and Stop in Automatic mode further connections are required:
The drive start is carried out via the group start command CmdOn or in case of fault recognition
of the opposite direction (edge). This is only possible if the group was started before (if
PeCmdOn = 1-Signal).
The drive stop is carried out via the group stop command CmdOff or PeCmdOff.
In order to create alarm messages even if the pump is not running the drive may be switched
into Standby mode via interface StaByEn. Connect group output PeCmdOn to StaByEn of the
drive.
For immediate stop connect group output QuicStpQ to drive input QuickStp.

Group interlocks and feedback:
In order to inhibit the group start if no pump is selected, the selection output Select must be used
as start interlocking (input IntStart of the group).
For the feedback ON, the running signal RunSig of the drives together with the respective
selection must be connected to the Run Feedback FbObjOn of the group.
For the feedback OFF, the inverted signal RunSig of the drives must be connected to the Off
Feedback FbObjOff of the group.
drives/devices to the group. This only depends on the Group link and no further connection in
required.
empty) can be transmitted internally (via Group Link) from the group to the drive and vice versa,
if the corresponding function is enabled via Feature bits.
!

Exercise 10.4: Connections between group, selections and drives
Adjust the process parameters for Warning time WarnTi, Waiting time WaitTi, Start up command
release time CoURelTi and Shut down supervision time CoDRelTi.
Carry out the connections between the selection blocks (trigger must be programmed in the
same OB!!!!) and program the interlocking condition for the drives.
Program the start and stop command for the pumps, as well as Quick stop.
Enable the standby mode of the drives via the Permanent ON command from the group.
Make sure that the group can only be started if one of the pumps is selected.
Forward the information "All drives running" and "All drives off" to the group.
OS Compilation is also required because adding structure interlock blocks.
Test the selection function:
- One selection must reset the other selection.
- Select Pump 1 and start the group.
- Create a fault for Pump 1 (Remove Signal ElAvail). Alarm must be created and selection
must be switched to the second pump.
- Correct the fault and try the other direction.
Summary: Block interfaces of C_SELECT
Interfaces and parameters of C_SELECT
ModuleTag
C_SELECT MAIN_TAS
Selection 1/23
1 = Selection Interlock ok 1 ST IntStart Select ST Selected
1 = Deselection Interlock ok 1 ST IntSwOff NonInter BO non interlocked
Selection ON 0 BO SelOn ErrorNum I Error Number
Selection OFF 0 BO SelOff
1 = Switch to automatic mode 0 BO AutModOn

Using Process feedback blocks for pressure supervision
Example 11: Pressure supervision
The example 'Pump group' will be extended by two process feedback blocks for the pressure
supervision for pump TG3-PU1.M1 and pump TG3-PU2.M1.
Additional objects:
Each process feedback block is connected to a Periphery signal which is simulated in this
example via Buttons in the Process Picture.
I/O list:

TG3_PU1_P1 Pump 1 Pressure M 1025.1

Creating a process feedback block for an existing drive and Property settings
with different process feedback blocks C_PROFB. The block with name 'P' is configured for
pressure supervision.
- Block 'P' can be used for a binary process feedback which, once the equipment is
running provides a continuous 1-Signal. The block is configured for supervision in ON
direction only (the pressure signal may remain '1' even if the pump is stopped).
Block type 'P' must be copied from template chart PROFB into the existing charts TG3_PU1 and
TG3_PU2.
definition) must be entered.
object view.

Exercise 11.1: Adding the process feedback blocks in chart TG3_PU1 and TG3_PU2 and
entering block properties and message definitions
Charts TG3_PU1 and TG3_PU2 already exist and each chart contain a motor M1. The pressure
switches belong to the pump and must be inserted in the same chart.
For each pressure signal one process feedback block must be inserted. Proceed as follows:
- Open the template chart PROFB from 'Tng_Lib', Folder 'Templates_nnn'.

The description beside the blocks shows the function and the settings of Feature bits and
OS Permissions.
- Open chart TG3_PU1 and chart TG3_PU2.
- Copy block 'P' from the template chart PROFB and insert it into charts TG3_PU1 and
TG3_PU2.
1. Process Feedback block with O_LINK connection to the drive

TG3_PU1 P1 Pump 1 Pressure 1
- Enter the 'message text' for SIG1 and SIG2, e. g. "Pressure low".

In case of a binary process feedback signal, the symbol must be connected to input InSig or
InSigB of the C_PROFB block.
Symbols file.
In case of an analog process feedback signal, the symbol must be connected to input PV of the
C_PROFB block. The values for Startup OK limit StUpLim and Shutdown OK limit ShDoLim
must be adjusted.
Exercise 11.2: Connecting the process feedback signal according to the I/O list to the block
On page 132 you find the I/O list for the block. The symbol already exists in the Symbols file.
(A memory is used instead of an input because of simulation via HMI).
Connect the signal to input InSigB of the Process feedback block.

As the process feedback blocks always belong to a drive and the drives must be linked to a
group or route, the process feedback block does not have a GR_LINK1 or GR_LINK2 interfaces.
In this case output O_LINKQ of the drive must be connected to input O_LINK of the process
feedback block.
In the Object list of the group, the process feedback blocks are displayed one level below:
TG3_GR1/G1 Pump group

TG3_PU1/M1 Pump 1
TG3_PU1/P1 Pump 1 Pressure
TG3_PU2/M1 Pump 2
TG3_PU2/P1 Pump 2 Pressure
Exercise 11.3: Link between group, drive and process feedback block
Carry out the link between the drive and process feedback block by connecting output O_LINKQ
of the drive to input O_LINK of the process feedback block.

Output ProFB of the process feedback block must be connected to input ProFB of the drive
block.
During the startup of the drive the supervision starts after the 'on delay time for monitoring'
PFOnDTi has elapsed.
Off delay monitoring must be disabled (via Feature.bit30) because the pressure signal may
remain "1" even if the pump is stopped.
Input Message Enable MsgEn must be connected with the signal for power supply supervision!
faceplate:
faceplate of the C_PROFB block. Text 0 is additionally used for status call function and
description such as '+P' which is displayed in the block icon and in the faceplate.

Exercise 11.4: Connections between drive and process feedback block and configuration of the
Carry out the connections between the drive and the process feedback block.
Check the feature bit settings for the process feedback block.
Adjust the process parameters for 'On delay for monitoring start' PFOnDTi.
status call).
Compile the OS.
- Start the drive and check the process feedback supervision function via simulation of P1.

Using Annunciation blocks for pressure supervision (optional exercise)
Example 12: 'Pressure supervision'
The example 'Pump group' will be extended by two annunciation blocks for the pressure
supervision for pump PU1/M1 and pump TG3_PU2/M1.
Additional objects:
TG3-PU1.P1 Pump 1 Pressure C_ANNUNC F
TG3-PU2.P1 Pump 2 Pressure C_ANNUNC F
I/O list:


Creating annunciation blocks for an existing drive and Property settings
with different annunciation blocks C_ANNUNC. On page four you find a block with name 'P',
which is prepared for pressure signals. Feature bits and OS Permissions are configured for
motor protections.
For the example above, one block of type 'P' must be copied from template chart ANNUNC into
the charts for each pump.

Exercise 12.1: Adding the annunciation blocks in chart TG2_PU1 and TG2_PU2 and entering
block properties and message definitions
Charts TG3_PU1 and TG3_PU2 already exist and each chart contain a motor M1. The pressure
switches belong to the pump and must be inserted in the same chart.
For each pressure signal one annunciation block must be inserted. Proceed as follows:

Permissions.
- Open chart TG3_PU1 and chart TG3_PU2.
- Copy block 'P' from the template chart ANNUNC and insert it into charts TG3_PU1 and
TG3_PU2.
1. All Annunciation blocks which are linked via O_LINK to the drive

- Enter the 'message text' for SIG1 and SIG2, e. g. "Pressure low".

The pressure switches are binary process signals which must be connected to input InSig or
InSigB of the C_ANNUNC block. As the signal is of format BOOL und the block input InSig is of
format STRUCTURE, the CFC Editor does not allow a direct connection to a binary input signal
Therefore use input InSigB (like in the previous examples).
In order to show the status of the pressure in the block icon (green color for pressure available),
the same information must be linked to input ProcSig of the annunciation block.
Connect the signals to input InSigB and ProcSig of the corresponding Annunciation blocks.

In case of annunciation blocks belonging to a drive, the drive is already linked to the group via
GR_LINK1 or GR_LINK2 (or via a C_MUX block). Instead of linking the annunciation block to
the group, it may be linked to the drive via Object link. Therefore output O_LINKQ of the drive
must be connected to input O_LINK of the annunciation block.
The result is that in the Object list of the group, the Annunciations are displayed one level below:
GR1/G1 Pump group

PU1/M1 Pump 1
PU1/P1 Pump 1 Pressure
PU2/M1 Pump 2
PU2/P1 Pump 2 Pressure
Carry out the link between the drives and annunciation blocks by connecting output O_LINKQ of
the drive to input O_LINK of the corresponding annunciation blocks.

annunciation block, in order to stop the drive in case of a pressure fault.
The pressure signal is a general protection (effective in all modes) and must therefore be
connected to the protection interlock IntProtG of the pump drive.
In order to memorize the trip change parameter MemTrip to 1-Signal
Via connection of the running signal RunSig of the drive to supervision enable SupOn of the
annunciation block, the supervision is disabled as long as the drive is not running. The
supervision function is additionally delayed via parameter SupOnTi.
Supervision enable can be achieved via input SubOn, or internally via O_LINK (if Feature.bit18 is
set). If Feature.bit18 = TRUE, the input SupOn does not need to be connected.
Message trigger is not needed because the supervision is only enabled if the motor is running.

faceplate:
description such as '+P' which is displayed in the block icon and in the faceplate.
Exercise 12.4: Connections between drive and annunciation blocks and configuration of the
Carry out the connections between the pumps and the annunciation blocks for pressure
supervision.
Check the feature bit settings for both annunciation blocks.
Adjust the process parameters for 'Supervision delay time' SupOnTi.
Memorize the trip via input MemTrip.
status call).
Compile the OS.
- Stop the group. Check the pressure supervision while the pumps are not running.
- Select a pump and start the group. Check the pressure supervision.

Positioning function of C_DAMPER
Example 13: 'Fan and Damper'
Big fans can only be started if the damper is closed. It is therefore advisable to already close the
damper when the group is stopped.
Before the start of the fan it must be taken care that the damper is in closed position. As soon as
the fan is running the positioning mode is enabled and the damper can be controlled via operator
faceplate to the desired position.
In this exercise a new group is programmed, which only consists of a fan and a damper and a
measurement for the damper position:
Location
(where)
Fan/Damper
TG4-GR1.G1 C_GROUP
Group
TG4-FA1 Fan C_DRV_1D F
TG4-DA1 Damper C_DAMPER F
TG4-DA1.Z1 Damper Position C_DAMPER
This example does not use any periphery signals and therefore you find no simulation Buttons in
the Process picture.
Contactor feedback and Position feedback are not simulated. The simulation will be carried out
in the CFC of the drive function.

Creating CFCs and blocks with proper Property settings
which are needed for the example.
Template DAMPER_POSI contains a damper block and a measured value for the damper
position.
At the damper block the additional block parameters needed for the positioner function are
already made visible and the positioning mode is enabled. Feature bits and OS Permissions are
already configured correctly.
Template DAMPER_POSI_SIM cannot be used for real applications and was made for the
training only. It contains a damper block and a measured value for the damper position and
already includes the simulation block C_SIMDMP for the simulation of the limit positions and the
position value.
At the damper block the additional block parameters needed for the positioner function are
already made visible and the positioning mode is enabled. Feature bits and OS Permissions are
already configured correctly.
Additional block parameters for positioning function of C_DAMPER:
ModuleTag
C_DAMPER MAIN_TAS
Damper 1/23
SP_LoLim R Setpoint Low limit Out
Enable Inching 1 BO InchEn SP_HiLim R Setpoint High limit Out
1 = Enable positioner mode 1 BO PsMoEn SP_Out ST Setpoint Output
1 = Setpoint tracking On 1 BO SP_TrkEn PosOn BO Positioner ON
Setpoint Low limit 0.0 R SP_LoLim
Setpoint High limit 100.0 R SP_HiLim
1 = Enable external Setpoint 0 BO SP_ExEn
External Setpoing ST SP_Ex
SP - Bar display limits for OS 100.0 ST SP_OpSca
Unit Set point %' SN UNIT
Position input value (0-100) ST PosVal
Position value live zero 0 BO PosValLZ
Minimum pulse length time 0.5 R MiPulTi
Actuator runtime from pos1 to pos2 60 R MovActTi
Switch on of the dead zone high 1.0 R DeadZoH
Switch on of the dead zone low 1.0 R DeadZoL

In the template chart DAMPER_POSI_SIM you find the following links between damper block,
measured value block and simulation block already made:
Inching mode and positioning mode are enabled and the parameters MovActTi in C_DAMPER
and MovActTi in C_SIMDMP are consistent.
definition) must be entered for each object. The block properties can be entered via the
Properties dialog in the CFC or via the Process object view.

In the plant hierarchy of AS1 in the Area '001_Training' you find a subfolder '001_FanDamper'.
This subfolder will be used for the Fan Damper group.
TG4_FA1
TG4_DA1
TG4_GR1
One chart will be used for each drive/device and one additional chart for the group. In the
Runtime Editor, automatically a runtime group is created with the same name. Make sure that
the Runtime groups are inserted between OB1_START and OB1_END.
It is recommended to insert the drives in the start order and then the group.
- For the fan, open the template chart DRV_1D from 'Tng_Lib', Folder 'Templates_nnn'
and copy block C_DRV_1D into chart TG4_FA1.
- For the damper, open the template chart DAMPER_POSI_SIM from 'Tng_Lib', Folder
'Templates_nnn' and copy the blocks C_DAMPER, the C_MEASUR and the C_SIMDMP
together into chart TG4_DA1.
- For the group, open template chart GROUP rom 'Tng_Lib', Folder 'Templates_nnn' and
copy the blocks into chart TG4_GR1.

TG4_GR1 G1 Fan Damper Group 1
TG4_FA1 M1 Fan 1
TG4_DA1 M1 Damper 1
Z1 Damper Position 1
M1_SIM Damper Simulation ---

Simulation of the I/Os for Contactor feedback and Limit Position
Inputs and outputs for connection to the periphery (MCC signals or Field signals) don't exist for
this example. The block input will carry the default value which is the "healthy" condition.
Contactor feedback for C_DRV_1D must always be connected, as well as Position feedback of
C_DAMPER and C_VALVE.
Contactor feedback for C_DAMPER is not needed in this example.
Exercise 13.2: Simulation of contactor feedback and damper position
Contactor feedback of C_DRV_1D as well as Limit Positions of C_DAMPER must be simulated;

otherwise the block generates a fault.
- Contactor feedback of the drives can be simulated by connecting output ContOn to input
FbkRun.
- The limit positions of the damper and the position value are already simulated via
C_SIMDMP (connecting the contactor outputs ContOn1 and ContOn2 of the damper to
the corresponding inputs of the simulation block and the limit position outputs FbkPos1
and FbkPos2 of the simulation block to the corresponding inputs of the damper; the
position value QPosVal of the simulation block must be connected to the input PV of the
measurement).
Both drive blocks must be linked to the group. The measured value for the damper position
belongs to the damper and can be linked to the C_DAMPER block via O_LINK.
TG4_GR1/G1 Fan/Damper group

TG4_DA1/M1 Damper
TG4_DA1/M1 Damper Position
TG4_FA1/M1 Fan
Exercise 13.3: Link between Group, Route and drives
GR_LINK1 (or GR_LINK2) of the drives/devices.
Carry out the link between the damper and the measurement by connecting output O_LINKQ of
the damper to input O_LINK of the measured value.

Drive interlocks and Group connections for Automatic control
Interlocks and start/stop commands for the fan:
- The fan can only be started of the damper is closed. Output PosSig1 of the damper must
therefore be used as Start interlock IntStart of the fan.
- The fan will be started and stopped via normal group on and off commands CmdOn and
PeCmdOff. Quick stop function can be used for immediate stop
For the damper block a special logic is needed:
- During startup of the group the damper must be controlled to the close position (in order
to make the fan 'ready to start'. If the fan stops the damper may be closed automatically.
 See logic for StrtAut1
Caution: Interface StrtAut1 (or StrtAut2) must never be connected with a continuous 1-
! Signal. Signal must go to '0' in case of a trip in order to enable acknowledgement.
- After the fan is running, the damper must be enabled for the positioning mode (interface
InchEn and PosMoEn must get 1-Signal).

Feedback to the group:
- The group is completely running if the fan is running.
- The group is completely stopped if the fan is stopped and the damper is closed.
drives/devices to the routes and from the routes to the group. This only depends on the
Group/Route link and no further connection in required.
empty) can be transmitted internally (via Group/Route Link) from the group to the route and from
the route to the drive and vice versa, if the corresponding function is enabled via Feature bits.
!
Adjust the process parameters for Warning time WarnTi, Waiting time WaitTi, Start up command
release time CoURelTi and Shut down supervision time CoDRelTi.
Carry out the connections for interlocking conditions between the drives.
Carry out the connections between the group and the drives for starting/stopping and feedback
on/off.
Compile the OS.
- Start the group. First the fan must be started. Once the fan is running, the damper can be
positioned.
- After the positioning mode is enabled, change the setpoint for the damper and check the
function.
- During the positioning you can switch to 'Inching mode' from the diagnosis window. In the
inching mode you can trigger the outputs with the little arrows in the damper faceplate.
- Stop the group. The damper must be closed.

SIMOCODE Adapter function
Example 14: 'C_DRV_1D with SIMOCODE'
If SIMOCODE is used instead of conventional MCC, a communication to the PROFIBUS device

is needed. The CEMAT drive blocks do not have this communication interface itself, but the
SIMOCODE Adapter block C_SIMOS can be used in order to establish a connection between
the CEMAT drive block and the SIMOCODE.
The SIMOCODE Adapter block C_SIMOS can be used for C_DRV_1D, C_DRV_2D, C_VALVE
and C_DAMPER. The block is open (no KNOW_HOW_PROTECT) and can be adapted by the
CEMAT Users depending on the functionality.
Basic settings in the C_SIMOS block:
- SIMOCODE basic type (parameter BasicTyp)

Type 2: with current value (4 bytes read and 4 bytes write)
Type 1: with current and power value (12 bytes read and 4 bytes write)
- Input/Output start address (Parameter IO_Addr)
The basic information which is exchanged between drive block and adapter block is as follows:
- The Contactor on command ContOn from the drive must be connected to ContOn1 (or
ContOn2) of the C_SIMOS block.
- The Contactor feedback FbkRun1 (or FbkRun2) of the C_SIMOS block must be
connected to the Contactor feedback FbkRun on the drive.
- In order to disable the alarming in local mode, the information 'Drive in local mode' must
be transmitted to the C_SIMOS block (via connection of output LocalAct of the drive
block to input LocalAct of the C_SIMOS block).
- The status information from the SIMOCODE is transmitted to the drive via Structure
interface SimoStat.
- In order to change the drive to local mode and to disable the supervision functions the
output MonOnly from the C_SIMOS must be connected to input MonOnly of the drive
block.
Further information may be transmitted to the drive according to availability and function.
(This may differ from plant to plant):
- The output I_Perc from the C_SIMOS block can be transmitted to the drive input
AV_Perc.
- The output Overload from the C_SIMOS block may be connected to drive input Overload.
- The output Input4Q from the C_SIMOS block may be connected to drive input ElAvail.

SIMOCODE example
Example for the connections between C_SIMOS block and C_DRV_1D block:
You will find this example in the training project under 001_Example  001_Simocode in Group
EG7_GR1.
In the Runtime system, go to Area 001_Examples to see the function.

Summary: Block interfaces of C_SIMOS
Interfaces and parameters of C_SIMOS
ModuleTag
C_SIMOS MAIN_TAS
Rotary Feeder 1/23
Basic Type (2= Standard, 1= with POWER) 2 I BasicTyp I_Perc I Current value in %
Input/Output start address (process image) 0 I IO_Addr Power R Power kW (basic type 1 only)
Time for General fault/warning delay 0 I GFWDelTi Ready BO Communication OK SIMOCODE ready
Contactor ON direction 1 0 BO ContOn1 SC_Fault BO General fault SIMOCODE
Contactor ON direction 2 0 BO ContOn2 EarthFlt BO Earth fault
reset SIMOCODE from external 0 BO Reset Overload BO Overload fault
Enable messages 1 BO MsgEn Unbalanc BO Unbalance
1 = drive in local mode 0 BO LocalAct StallFlt BO Motor stalled fault
SC_Warn BO General warning SIMOCODE
OverlWa BO Overload warning
CurrFlow BO Drive current flow
SimoStat ST Status from SIMOCODE
Input1Q BO Basic input 1 of SIMOCODE
Input4Q BO Basic input 4 of SIMOCODE (el. Ready)
FbkRun1 BO Contactor Feedback ON direction 1
FbkRun2 BO Contactor Feedback ON direction 2
MonOnly BO Monitor only, controlled by local box
ErrorNum I Error Number

Variable Speed Drives
Example 15: SINAMICS, ROBICON and other VSD drives
Multiple drive functions like SINAMICS, ROBICON or VSD drives from other suppliers may exist
in a plant. As the interface and functionality is different from drive to drive, no 'ready-made'
function block is available in the Minerals CEMAT Library.
Instead of this, the CEMAT drive function C_DRV_1D will be used together with Adapter blocks.
The Adapter blocks are open (no KNOW_HOW_PROTECT) and can be modified according to
the plant requirements.
The link to the group, the start/stop command, the interlocking conditions and the mode change
is carried out via the CEMAT drive block C_DRV_1D. Similar to the SIMOCODE example the
CEMAT drive block C_DRV_1D forwards the contactor on command to the adapter block and
receives the contactor feedback. The adapter block is kind of a Subcontrol for the CEMAT drive.
Input SubCFlt of the drive block C_DRV_1D must be set in case of a fault in the Subcontrol
function. The fault will lead to a message and will be displayed in the diagnosis window.
Input SubCFp of the drive block must be connected with any output of the Subcontrol function.
In case of using SINAMICS or ROBOCON, input MonOnly of the drive block must be connected
with output MonOnly SINAMICS Adapter block C_SINA or ROBICON Adapter block C_ROBI in
order to change the drive to local mode and to bypass the supervision functions.
The setpoint can directly be entered via the faceplates of C_DRV_1D or via external Setpoint by
the program and will be forwarded to the Adapter block.
The Setpoint function must be enabled via Feature.bit29.
Additional Block interfaces in C_DRV_1D for setpoint function
ModuleTag
C_DRV_1D MAIN_TAS
Unidirectional Drive 1/23
Enalble External Setpoint 0 BO SP_ExEn Sp_Out ST Setpoint output

Tracking Setpoint SP_Out to SP_OS 0 BO SP_TrkEn
External Setpoint 0.0 ST SP_Ex
Setpoint High Limit 0.0 R SP_HiLim
Setpoint Low Limit 0.0 R SP_LoLim
Process value input (for setpoint function) 0.0 ST PV

Exercise 15.1: Enabling the setpoint function
Enable the setpoint function for Fan TG4_FA1/M1 via Feature.bit29.
Configure the setpoint limits to 0-100%
- SP_HiLim and SP_LoLim must be adapted.
- Identifier of PV.Value and Unit of SP_Os and SP_Out.Value must be changed from "rpm"
to "%"
For Simulation purpose, connect Setpoint Output SP_Out to Process value input PV.
Compile the OS.
- Test the Setpoint indication in the runtime system.
Example for the connections to SINAMICS Adapter block C_SINA:

Adapter to non-CEMAT blocks
Example 16: 'Connecting non CEMAT blocks directly to the group (or route)'
Via the Adapter function C_ADAPT a non CEMAT block can directly be assigned to a group. The
summarizing fault/warning of this block will be indicated in the group block icon and also in the
group status call. The status of the function (running, off, faulty) will be displayed in the group
instance list.
The adapter block C_ADAPT has no block icon in the process picture and no faceplate exists.
Only the block icon of the non CEMAT block will be displayed.
Required block connections in the CFC
In the training project under 001_Examples  001_Adapter a PCS 7 motor block of type
'MOTOR' is connected to a CEMAT group. If you look at the CFC you will see the required
connections:
The start/stop command of the group is directly connected to the non CEMAT block (PeCmdOn
is connected to AUTO_ON of the MOTOR) and the running signal QRUN of this block is
connected to the FbObjOn and FbObjOff of the group.
In order to transmit the status of the non CEMAT block to the group/route an adapter block
C_ADAPT must be used.
- The Summarizing fault of the non CEMAT block is transmitted to the C_ADAPT via input
Fault.
- The dynamic (unacknowledged) fault of the non CEMAT block is transmitted to the
C_ADAPT via input DynFlt.
- The Summarizing warning of the non CEMAT block is transmitted to the C_ADAPT via
input Warning.

- The dynamic (unacknowledged) warning of the non CEMAT block is transmitted to the
C_ADAPT via input DynWarn.
- Via a link from the Group/Route to the link interfaces GR_LINK1 or GR_LINK2 of
C_ADAPT the fault/warning status is transmitted to the group.
Exercise 16.1: Checking the function in the Runtime system
In the Runtime system, go to Area 001_Examples search for the 'Adapter Example'.
Switch Motor EG1_WF1/M1 to automatic mode and start group EG1_GR1/G1.
Motor EG1_WF1/M1 motor will trip with 'Runtime Error'.
Open the object list of the group:

 It will show a line for the motor, but without status indication
Carry out a status call for the group:

 A grey line will appear with a missing fault text. Under "Fault Text" you find the name of the
cfg-file which is missing under D:\CEMAT_CS\Config

Required status information from the non CEMAT block
The non CEMAT block must provide the following information in one status word (WORD or
DWORD format).
Information about Running or faulty [Run]:

- Motor running
- Summarizing fault
- Summarizing warning
Information about the fault type [Fault], e. g.:

- Available
- Protection
-…
In case of block type MOTOR the status word VSTATUS contains the following information:
7 6 5 4 3 2 1 0
QMON_ERR QMSS_ST QMAN_AUT BA_EN OCCUPIED
15 14 13 12 11 10 9 8
OOS QMSG_SUP QSTOP QRUN LOCK
23 22 21 20 19 18 17 16
USTATUS_07 USTATUS_06 USTATUS_05 USTATUS_04 USTATUS_03 USTATUS_02 USTATUS_01 USTATUS_00
31 30 29 28 27 26 25 24
USTATUS_15 USTATUS_14 USTATUS_13 USTATUS_12 USTATUS_11 USTATUS_10 USTATUS_09 USTATUS_08
VSTATUS, Bit 5: QMSS_ST Motor Protection fault

VSTATUS, Bit 7: QMON_ERR Contactor feedback fault
VSTATUS, Bit 9: QRUN Motor running
The information for summarizing fault is not available but can be created via an additional logic
in the CFC, where the information QGR_ERR is transmitted to USTATUS.
VSTATUS, Bit 16: QGR_ERR summarizing fault

Creating a configuration file for the non CEMAT block
For the group object list and for the status call function the CEMAT group needs a configuration
file with a definition, where to find the information.
The configuration file must have a fix structure and must be located under
D:\CEMAT_CS\Config. The name must be identical to the block type of the non CEMAT
function.
An example you find in file SIM_ADAP3_009.cfg:
;This is an example file for an SIMATIC block of a subcontractor

;to show this object in the CEMAT Group/Route-Status
[Control]
;The name of the variable, which is an equivalent
;to the CEMAT Status variable
StatusVariableName=STA_MAR
[Run]
;This section is only for the Group Instance List (GRINZ)
;Bit (1-32) from StatusVariableName for Status Run
RunBit=25
;Bit (1-32) from StatusVariableName for Status Fault
FaultBit=26
;Bit (1-32) from StatusVariableName for Status Warning
WarningBit=28
[Fault]
;Visible, Attribut,Comment,Bit,Fault Class,Warning
1,FT1,Fault 1,17,P,F
1,WA1,Warning 1,21,P,W
;end of list (do not delete this line)

Exercise 16.2: Creating the config file and checking the function again
Create the config-file MOTOR_009.cfg with the following structure. (You can use the template
file SIM_ADAP3_009.cfg as default and save it as MOTOR_009.cfg):
; This is an example file for a SIMATIC block of a subcontractor to show this object in the
CEMAT Group/Route-Status
[Control]
; The name of the variable, which is an equivalent
; to the CEMAT Status variable
StatusVariableName=VSTATUS (Block specific output parameter)
[Run]
; This section is only for the Group Instance List (GRINZ)
; Bit (1-32) from StatusVariableName for Status Run
RunBit=10
; Bit (1-32) from StatusVariableName for Status Fault
FaultBit=17
;Bit (1-32) from StatusVariableName for Status Warning
WarningBit=18
[Fault]
;Visible, Attribut,Comment,Bit,Fault Class
1,FT1,Protection,6,P,F (Bit5 Motor Protective Switch)
1,FT2,Feedback,8,E,F (Bit7 Monitoring Error)
;end of list (do not delete this line)
After saving the Config file the Object list and Status call should give the correct information. Try
it again!
Summary: Block interfaces of C_ADAPT
Interfaces and parameters of C_ADAPT
ModuleTag
C_ADAPT MAIN_TAS
Adapter 1/23
Fault P Fault INST_DB I Instance DB for test
Dynamic fault (not acknowledged) 0 BO DynFlt HIGHLIGH BO Hightlight (mark) symbol
Warning P Warning ErrorNum I Error Number
Dynamic warning (not acknowledged) 0 BO DynWarn

Analog value selector
Example 17: 'Connecting multiple measurements to a drive'
In the exercise 'Display of the measured value in the drive faceplate' we already connected a
measurement to a drive via drive inputs AV and AV_Stat. In the following example multiple
measured values shall be linked. In this case an analog value selector must be used.
In the following exercise 6 measurements will be added to fan TG4_FA1 (from the positioner
example).
TG4_FA1/J1 Motor Power

TG4_FA1/TU Winding Temperature U
TG4_FA1/TV Winding Temperature V
TG4_FA1/TW Winding Temperature W
TG4_FA1/TA Bearing Temperature A
TG4_FA1/TB Bearing Temperature B
The selected measurement can be displayed in the faceplate of the motor.
Creating an analog value selector and connecting it to the drive
The 6 measurements belong to Fan TG4_FA1 and must therefore be inserted in the same chart.
Additionally a C_ANASEL block must be added and connected to measurements and the drive
as follows:

Exercise 17.1: Adding the measurements and the C_ANASEL block in chart TG4_FA1 and
linking it to the drive
In order not to start from scratch I have prepared a template chart with the 6 measurements.
You will find it in the Project Library 'Tng_Lib' in Hierarchy folder 'Templates_nnn'.
Chart TG4_FA1 already exists and contains motor M1. The six measurements and the
C_ANASEL block will be inserted in the same chart. Proceed as follows:
- Open the template chart MEASUR_SET from 'Tng_Lib', Folder 'Templates_nnn'.
- Open chart TG4_FA1.
- Copy all blocks from the template chart MEASUR_SET and insert it into chart TG4_FA1.
- Open template chart ANASEL and copy the one with 8 visible inputs into chart TG4_FA1.
- Add the O_LINK connection between measurements and the drive
- Connect the running signal RunSig of the drive to the simulation for Motor Power.
- Add the necessary connections between measurements, C_ANASEL block and drive.
Compile the OS.
- Observe the function in the Runtime system.

Summary: Block interfaces of C_ANASEL
Interfaces and parameters of C_ANASEL
ModuleTag
C_ANASEL MAIN_TAS
Analog value selection 1/23
Input 1 0.0 ST In01 Out_Val ST Output
Input 1 Status % ST In01Stat Out_Stat ST Output Status
Input 2 0.0 ST In02 CL_HH ST Collective limit HH over all inputs
Input 2 Status % ST In02Stat CL_H ST Collective limit H over all inputs
Input 3 0.0 ST In03 CL_L ST Collective limit L over all inputs
Input 3 Status % ST In03Stat CL_LL ST Collective limit LL over all inputs
Input 4 0.0 ST In04
Input 4 Status % ST In04Stat
Input 5 0.0 ST In05
Input 6 0.0 ST In06
Input 7 0.0 ST In07
Input 8 0.0 ST In08
Input 9 0.0 ST In09
Input 10 0.0 ST In10
Selection via Operator 1 I SelExt
Selection via AS Input 1 I SelExt
Call User Faceplate ST SelSP1
Output Tag empty S Out_Tag

CEMAT SETTINGS IN THE PCS 7 PROJECT
For considerations at the beginning of the engineering refer to Engineering Manual, chapter
02_Preparations.
For all settings for CEMAT required in the PCS 7 Project follow the Engineering Manual, chapter
03_PCS7_Project.
Exercise:
At this step a new PCS 7 Project for CEMAT is created. The project consists of one AS, one OS
(Single Station) and a Project Library.
Further Engineering Manuals exist; each of it describes a certain Engineering Step:
04_Assignments gives an overview of the block resources
05_Engineering_Examples basic programming rules for CEMAT
06_AS_Engineering Engineering rules for CFC programming
07_AS-AS_Coupling Engineering rules for the communication between AS
08_OS_Engineering Engineering rules for Picture design
09_Engineering_Tools Engineering Tools (Excel Macros)
10_Check_list Check list for configuration and programming
11_Project_Administration Save and restore functions
13_Graphic_Templates Available bitmaps for Process pictures
14_Tips_Tricks Tips and Tricks
15_Update_Information How to upgrade the project from an older CEMAT Version
Note: Please consider chapters 06, 08, 10 and 13 have an Appendix for LafargeHolcim
Projects which must be considered in case of MinAS Projects with Option 4.

CEMAT V9 Project Standards
The following Project Standards exist. Through configuration of the blocks, the Project version
001 Minerals can be adapted to the functionality of Standard 000, 004, 006, 007, 023, 024, 025,
026 and 028.
Functionality of Standard 027 (Lafarge) cannot 100% be achieved at the moment.
Code Standard
000 Normal Standard
001 Minerals Standard
004 Holcim Standard
006 Dyckerhoff
007 Heidelberg Cement
023 Vigier
024 Bushehr
025 Caima
026 Alsen
027 Lafarge
028 Rossi
Options for the Customization of Project Standard 001:
For LafargeHolcim plants Minerals Standard needs some customization. This can be achieved
via Options:
Code OPTION Standard

001 1 Minerals Standard without customization
001 4 Minerals Standard with customization for LafargeHolcim Plants
001 7 Minerals Standard with customization for Heidelberg Cement Plants

CONFIGURATION OF THE CEMAT BLOCKS AND FACEPLATES
General settings in the System Chart SYSPLCxx
During the creation of the PCS 7 Project the System Chart SYSPLC00_Option4 has been
copied from the Project Library into the Chart folder of the AS. SYSPLC00_Option4 already has
the correct settings for LafargeHolcim plants and must be renamed according to the PLC
Number:
SYSPLC01 for AS1

SYSPLC02 for AS2
SYSPLC03 for AS3
….
Note: The System Chart must be installed in the Plant Hierarchy, which is assigned to an OS
Project; otherwise no Tags from System Chart are created in the Tag Management.
Renaming the System Chart different than SYSPLCxx is not permitted and will not work.
Make sure that the blocks from system chart are installed at the correct position in the Runtime
sequence, which should be as follows:
The CEMAT blocks need to be installed in OB1, between Runtime group OB1_START and
OB1_END.
The System Chart contains a lot of general settings for AS Program, definitions which are valid
for all CEMAT blocks. These are e. g.:
- The Acknowledgement mode
- The Option for adaptations to customized Text display in the OS
- The Warning mode
- The PLC number
- The Sequence Test Mode
- Text definitions for “still faulty” message
- The Feature master blocks

Acknowledgement modes
Beside the message in the alarm line, the CEMAT block as well needs acknowledgement, in
order to reset the dynamic fault.
The messages in the alarm line can only be acknowledged one by one,
- either via the acknowledge button in the alarm line
(only the visible alarms will be acknowledged)
- or via the acknowledge button in the Object Faceplate.
- or via the acknowledge error button in the button line

(all alarms of the selected Picture will be acknowledged)
For the fault acknowledgement in the AS (dynamic fault of the CEMAT blocks) different
options exist. It may be carried out
- together with the acknowledgement of the alarm line or the acknowledge button in the
button line (for the selected area) or via acknowledgement button in the object faceplate.
- for the complete AS, group-wise or for the individual object.
- via HMI or by program
The general configuration of the fault acknowledgement from HMI is configured in the System
chart SYSPLCxx at block C_FB_PLC, interfaces ACK_GR and ACK_OB. The settings are valid
for the complete PLC and the default setting is “AS-wide acknowledgement”.
AS-wide acknowledgement (default):

With the acknowledgement of the message in the alarm line, an acknowledgement command is
sent to the AS which produced the message, and all blocks within this AS are acknowledged at
the same time.
Via the acknowledgement button of any CEMAT Object Faceplate an acknowledgement
command is sent to the corresponding AS, and all blocks within this AS are acknowledged at the
same time.
Parameter Setting on C_FB_PLC
ACK_GR =0
ACK_OB =0

Group-wise acknowledgement
The acknowledgement of the message in the alarm line is independent of the fault
acknowledgement in the block.
For fault acknowledgement in the AS the Operator must press the Acknowledgement button in
the group faceplate. The acknowledgement command is sent only to the group. From the group
it is transmitted to all connected objects. (Programming required!)
The connection can be done via O_LINK and corresponding feature bit settings or via linking the
output AckGr of the Group module with input Ack of the Objects.
Acknowledgement of individual Objects via its faceplate is possible as well.
If annunciations, process feedbacks or measurements are linked to the drive via O_LINK, the
acknowledgement of the drive leads to the acknowledgement of annunciations and
measurements at the same time.
ACK_GR =1
ACK_OB =0
Object-wise acknowledgement
The acknowledgement of the message in the alarm line leads to the acknowledgement of the
block which generated the alarm.
In this mode the acknowledgement of individual Objects via its faceplate is possible as well.
ACK_GR =0
ACK_OB =1
Caution: In case of protection interlock of a drive, the message is not created by the drive
itself, but by an annunciation block or measure. In this case the acknowledgement of the alarm
line does not acknowledge the drive fault. The drive faceplate must be opened and
Acknowledge button must be pressed there.
Fault acknowledgement by AS Program

All CEMAT Objects have an interface Ack for individual fault acknowledgement by AS program.
This interface is used in case of group-wise acknowledgement, but in can also be used wherever
acknowledgement by AS program is needed.
Interface Ack works parallel to the acknowledgement command from HMI.
Irrelevant
Note: If there is a requirement for “acknowledgement only by program” (e. g. via a field signal)
it is possible to disable the Acknowledgement from HMI with Feature.bit19 (for Module types
C_ANNUNC, C_ANNUN8, C_MEASUR, C_PROFB) or Feature2.bit27 (for Module types
C_DRV_1D, C_DRV_2D, C_DAMPER, C_VALVE) and to connect interface Ack with the
external Signal.

Additional Fault Reset via Object Facplate (optional)

For all Objects types for drives, annunciation blocks and measurements, there is an option to
memorize the trip until an additional “Fault Reset” button in the object faceplate is pressed.
Resetting the fault on object level forces the operator to look at the equipment to be reset.
Only dynamic faults are memorized, static faults don‟t require additional Fault Reset.
The Fault Reset can only be carried out after the fault is cleared (after the fault is acknowledged
and gone).
The Fault Reset Function is enabled via feature bit and OS Permission at the individual objects:
For C_DRV_1D, C_DRV_2D, C_DAMPER and C_VALVE the Fault Reset function is enabled via
Feature2.bit19 and OS_Perm.bit19.
BitNr. Function/Features Default value

19 enable module function "Fault reset" FALSE
BitNr. Function/OS Permission Default value

19 1 = enable module function "Fault reset" FALSE
For C_ANNUNC, C_ANNUN8, C_PROFB, C_PROFBx and C_MEASUR the Fault Reset
function is enabled via Feature.bit12 and OS_Perm.bit12.

12 enable module function "Fault reset" FALSE
BitNr. Function/OS Permission Default value

12 1 = enable module function "Fault reset" FALSE
Caution: If Fault reset is enabled at the C_PROFB block or C_PROFBx block or if Fault reset is
enabled at the C_DRV_1D/C_DRV_2D block, Feature.bit14 of C_PROFB must be FALSE!

Warning mode
In the system chart SYSPLCnn at block C_FB_PLC the reaction of the Group in case of a
warning during start-up can be configured.
If Parameter REL_WSTP = 1 the (dynamic) warnings interrupt the group start
If Parameter REL_WSTP = 0 the (dynamic) warnings don‟t interrupt, the group start will
continue.
In LafargeHolcim Projects Parameter REL_WSTP of block C_FB_PLC must be set to 0-Signal,
which is anyway the default setting in Minerals Automation Library Minerals_Cemat.
Note: (Dynamic) faults in any object of the group always interrupt the group start!
PLC Number °
Parameter PLC_NO of block C_FB_PLC is only needed in case of object links to a group in a
different AS (see object description of C_GROUP).
In this case parameter PLC_NO must be set to the same number as the System chart:
Example:
In the chart SYSPLC01 set a "1" on PLC_NO.
etc.

Sequence-Test
The sequence test mode can be used for program test without the periphery being available.
This is very useful for general function tests, for the Factory Acceptance Test or for Operator
Training.
The sequence test mode always applies to the complete PLC and must be enabled via System
chart SYSPLCxx, block C_FB_PLC at input SEQ_TEST.
In order to enable the sequence test mode, the string „TEST‟ on parameter SEQ_TEST has to
be entered and the AS has to be restarted.
In the sequence test mode the output for contactor on commands are never set and the
contactor feedback signals and process feedback signals of the drives are simulated internally.
The signal status of the binary inputs can be simulated via diagnosis view of the faceplates,
where the status indications are converted into simulation buttons which allow “switching” of the
inputs.
The process values can directly be entered in the faceplates and replace the real Process value.
- After the Sequence Test mode is enabled, by default all inputs are in healthy condition and
the simulation buttons appear. The status can be changed by toggle function.
- Contactor feedback signals and process feedback signals can only be forced to an unhealthy
condition, the same applies to the Analog process signals of ProFB blocks.
- For the blocks C_ANNUNC, C_ANNUN8, C_PROFB, C_PROFBx, C_MEASUR and for the
Process value of C_DAMPER the Sequence test mode can be disabled, for example for
cases where the program includes a calculation or an internal simulation.
The sequence test mode includes a function for saving, restoring or interrupting the simulation.
This can be carried out via block C_FB_PLC, inputs SimSave, SimLoad and SimPause in
System chart SYSPLCxx.
- With 1-Signal at input SimPause the Sequence test can be interrupted at any time. The PLC
is running in kind of an idle mode, no action any more.
- With a positive edge at input SimSave the test situation can be saved (e. g. at the end of a
day, or in order to repeat the same step several times)
- With a positive edge at input SimLoad the previously test situation can be reloaded in order
to proceed with the same step.
In order to leave the sequence test mode, enter the string „NO‟ at the parameter SEQ_TEST and
restart the AS. By this the sequence test mode of all blocks is reset.

Option for customizing texts

For the Text display in the HMI Faceplates the block parameter names of the Minerals
Automation Standard are used, mostly complemented by a comment or description.
For LafargeHolcim Projects adjustments are needed for text definitions in order to follow the
HAC, this applies to button descriptions, I/O names or fault types.
- Button descriptions can be defined individually per instance, directly at the CFC
parameters. Under “Customizing CEMAT Faceplates via text variables” you find a list of
text variables in the CEMAT blocks.
- For general text adaptations which are valid for the complete system, DataSets exist in
the OS. More information about this you will find in chapter OS Engineering under
“DataSets for Project Adjustments”.
Three Variants of DataSets already exist, which can be selected via Parameter Option at block
C_FB_PLC in the system chart:
OPTION Adaptations
In the basic version the block parameter names and descriptions from Minerals
1
Automation Standard 001 are used.
With customized texts for former Project Standard 004 (adaptations to ACS or
4
HAC)
With customized texts for former Project Standard 007 (adaptations to Heidelberg
7
Standard)
For LafargeHolcim Projects Parameter OPTION of block C_FB_PLC must be set to “4” in order
to adapt the text display in the HMI Faceplates to the ACS (LafargeHolcim Asset Codification
System) or HAC (Holcim Asset Code).
This is automatically correct if System Chart SYSPLC00_Option4 has been copied.

Supplement for „Still faulty‟ message

For LafargeHolcim Projects the messages for the drive blocks need to be customized according
to the ACS or HAC. For this reason the supplement for the „Still faulty‟ message must be
adapted as well. This is done in the System Chart at block C_FB_PLC and automatically correct
if Chart SYSPLC00_Option4 has be copied.
General functions
It is not very likely that conventional pushbuttons for Fault Acknowledgement, Horn
Acknowldedgement, Release or Lamptest are used in a modern plant. But block C_PUSHB still
exists and has inputs for centralized functions (affecting all blocks within the AS).
The block also has a HORN output which will be triggered in case of a fault or warning and
which can be connected a physical output in order to give an alarm. The sound is limited by
timer THUP.

Settings for Feature bits and OS Permissions

Via Feature bits certain functions of the Cemat block can be enabled and disabled and thus the
behaviour of the block can be configured.
Via OS Permissions operator actions can be enabled or disabled.
A detailed description of the individual Feature bits and OS Permissions can be found can be
found in the object descriptions.
Note: LafargeHolcim Projects require a specific configuration of the Feature bits and OS
Permissions. This can be found in the Engineering Manual, Chapter 06_AS_Engineering.
Due to safety reasons it is not possible to change the status of the Feature bits and OS
Permissions of the Cemat blocks online. The blocks work with an internal memory which is only
refreshed in configuration state.
- if it is called for the first time in the program or
- during restart of the AS or
- if the block is in Out of Service mode or
- in sequence test mode (PIN protected)
Online change of Feature bits and OS Permissions in Sequence test mode

During Sytem Test of FAT it modifications in Feature bits and OS Permissions may be required
more frequently and thus we want to allow online changes.
If the block is in Sequence Test mode and Paremter SYSTEST has value „9999‟ the feature bits
and OS Permissions can be changed online.

Adaptation of the blocks regarding Operating mode and Periphery
Settings for Local switch and MCC
The Minerals Automation Standard can be adjusted to any kind of Local switch or MCC via
Feature bit settings. The following tables show the suitable settings for Local Switch and MCC
Signals in LafargeHolcim Projects.
Feature bit settings for local switch:

3 Local start active in Automatic / Manual FALSE
4 Local stop active in Automatic / Manual TRUE
5 Local start only inching FALSE
6 Start-up warning in Local mode FALSE
7 No stop after switching from Local to Automatic / Manual FALSE
8 AutModLo is used as position switch FALSE
9 Local switch matrix KXK0 FALSE
10 Local switch matrix CAIMA FALSE
11 AutModLo = 0 forces drive to Local mode FALSE
12 Local switch matrix LOC_010 FALSE
Contactor feedback supervision and evaluation of the limit switches for C_DAMPER:

27 Contactor feedback supervision TRUE
29 Limit switch D1: 1 = normal open; 0 = normal closed TRUE
30 Limit switch D2: 1 = normal open; 0 = normal closed TRUE
Contactor feedback supervision and "active direction" for C_VALVE:

17 Contactor feedback supervision FALSE
29 Normally open valve (direction 1 active) FALSE

Operation mode change
The Minerals Automation Standard also allows adjustments regarding operation mode change,
dependent on the philosophy of the customer.
In order to comply with the LafargeHolcim mode operation philosophy, the Feature bit settings
and OS Permissions must be configured as follows:
Feature bit settings for mode change:

21 Automatic mode exists TRUE
13 Manual mode exists TRUE
16 Manual mode Non Interlocked (only IntProtG active) FALSE
17 Manual mode Only Protection Interlocks (IntProtG and IntProtA active) FALSE
Manual mode Reduced Interlocks (IntProtG, IntProtA, IntStaE and IntOpE
18 FALSE
active)
0 Local mode exists TRUE
19 StartAut switches drive to Automatic mode TRUE
23 QuickStp active in all operating modes TRUE
27 RunSig also in Manual with Reduced Interlocks FALSE
OS Permissions for mode change:
BitNr. Function/OS Permissions Default value

2 1 = Operator can change to Automatic mode TRUE
0 1 = Operator can change to Local mode TRUE
1 1 = Operator can change to Manual mode Interlocked FALSE
5 1 = Operator can change to Manual mode Non Interlocked FALSE
6 1 = Operator can change to Manual mode Reduced Interlocks TRUE
7 1 = Operator can change to Manual mode Only Protection Interlocks FALSE

Operator authorization levels
Operator commands are restricted by the following criteria:
- Feature bit settings

 Complete function can be enabled/disabled
- OS PermissionLog
 Decides if an operator action is allowed or not allowed,
dependent on OS Permission & Status
- Operator authorization in WinCC

 Operator authorization levels in WinCC User Administrator
- Instance specific Operator authorization levels

 Operator authorization level can be modified via block parameter in the CFC
Operator authorization levels for C_DRV_1D
OS_Per-
Feature Op_ Block
OS Commands mission
Bit Level Parameter
Log
Switch to automatic mode 21 2 5 AutModOn
Switch to Out of Service mode 23 OoSModOn
Rapid stop 30 30 5 AutModOn
Switch to local mode 0 0 5 LocModOn
Mode Change
Switch to manual mode 13 1 5 ManModOn
Manual mode: non interlocked 16 5 23 COMMAND
Manual mode: only protection 17 7 23 COMMAND
Manual mode: reduced interlocks 18 6 23 COMMAND
Start 10 5 ManModOn
Start/Stop/Select Stop 11 5 ManModOn
Enable Power Management 4 5 PMinvol
Acknowledge Fault Reset FW2-19 19 5 AutModOn
Setpoint 29 28 5 SP_Os
Setpoint Setpoint low limit 20 19 SP_LoLim
Setpoint high limit 20 19 SP_HiLim
Start delay time 31 22 StaDelTi
Stop delay time 31 22 StpDelTi
Process Parameter Time for feedback monitoring 31 22 FbkMonTi
Time for feedback off monitoring 31 22 FbkOffTi
Time for startup warning 31 22 WarnTi
Reset statistic values 29 23 RelTimOS
Maintenance
Start Maintenance 16 29 MaiInt
User command User Pulse 29 29 5 UserPulse

Feature bit setting for “Switch to manual mode”
OS_Permission for “Switch to manual mode”

Operator authorization levels in WinCC
Instance Specific Operator authorization levels

Feature Master Concept
Feature Master blocks
Features and OS Permissions related to the operating or programming philosophy must be

consistent in all instances of the block. In order to ensure this, the relevant Feature bits and OS
Permission bits can be selected and defined once per block type via the corresponding Feature
Master block located in the system chart. These settings can be applied to all instances of the
block type.
Note: The feature master settings in SYSPLC00_Option4 are already configured for
LafargeHolcim Plants. Don‟t modify without approval from LafargeHolcim Headquarter.
Example for Feature Master block C_M_DRV_1D for CEMAT block type C_DRV_1D:
Structure bit settings:
Via Structure Feature of the Feature Master block the default values for the Feature bits are
defined:
Via Structure input Feat_Copy of the Feature Master block it can be decided whether the default
value from Structure Feature is transferred to the block instances or not.
With Feat_Copy.bitxx = 1-Signal, the status of the Feature.bitxx is transferred to all instances of
the corresponding CEMAT block.

Each object description shows the default values for Feature bits and OS Permissions, which
can be adjusted according to the plant requirements.
The Copy bits by default are set to "0" (value is not copied) and need to be adjusted as well.
Example for Feature bits and copy information:
BitNr. Function/Features Value Copy

0 Local mode exists 1 0
1 Local ON via program possible 1 1
2 Local OFF via program possible 1 1
3 Local start active in Automatic / Manual 0 1
Value = 0: Function is set to FALSE

Value = 1: Function is set to TRUE
Copy = 0: Value is not copied to the instance (0 = no) and can be configured
individually per instance of the CEMAT block
Copy = 1: Value is copied to all instances of the block (1 = yes) and cannot be
modified at the instance itself.
(In the Runtime System, Features and OS Permissions which cannot be
modified individually are marked in grey colour.)
Example:

Feature Master blocks exist for the following block types:

C_M_DRV_1D for C_DRV_1D
C_M_DRV_2D for C_DRV_2D
C_M_DAMPER for C_DAMPER
C_M_VALVE for C_VALVE
C_M_MEASUR for C_MEASUR
C_M_ANNUNC for C_ANNUNC
C_M_ANNUN8 for C_ANNUN8
C_M_PROFB for C_PROFB
C_M_PROFBx for C_PROFBx
C_M_GROUP for C_GROUP
C_M_ROUTE for C_ROUTE

Configuration mode and Consistency check

Feature bits and OS Permissions must always be consistent and can therefore not be modified
for running (or active) devices.
Therefore, all CEMAT blocks with Feature master work with an Internal Memory, which is not
getting updated during normal operation of the block.
The internal Memory is only updated in Configuration mode
- If the block is called for the first time in the program
- During the restart of the AS
- If the block is in Out of Service mode
- In Sequence test mode (PIN protected)
The HMI always shows the status of the internal memory!
In order to allow the transfer of Features and OS Permissions from the Feature Master block to
the CEMAT Module, block parameter FeatMast of the CEMAT Module must have 1-Singal.
Update of the internal memory:

The Feature bit settings of the Feature Master blocks are checked for consistence. Only if the
setting is consistent (block output ErrorNum = 0) and if the CEMAT block is in configuration
state, the setting of the Feature Master is transferred to the instance of the CEMAT module.
A wrong configuration in the Feature Master block leads to an Engineering Error:
 no transfer to the internal Memory
If the block instance is in configuration mode, a wrong Feature configuration leads to an

Engineering error:
 no transfer to the internal Memory
The Internal Memory always contains consistent Feature bit settings!

Error numbers
The CEMAT blocks also check if the Feature bits and OS Permissions have plausible settings. In
case of a configuration error an Error code is displayed. The list of Error codes you find in the
corresponding Object description
Example for the Error codes of block type C_DRV_1D:
Error number Fault description

1 No operation mode enabled
O_LINK of the drive is connected to a block different than C_SEND_G
2
 Only connection to C_SEND_G is allowed!
The drive is not linked (GR_LINK1, GR_LINK2, MUX_LINK, O_LINK)
3
 Check GR_LINK1, GR_LINK2, MUX_LINK, O_LINK connections
Block (including Signal objects) cannot be added to O_LINK buffer.
4
 The O_LINK buffer is limited to 20 objects!
5
"Local start always active (also in auto and manual)" must be FALSE if
6 AutModLo is used as position switch (Feature.bit8 = TRUE).
 Check Feature.bit3!
"Local start always active (also in auto and manual)" must be FALSE for
7 Matrix KXKO or LOC_011 (Feature.bit9 or Feature.bit12 = TRUE)
'No stop after switching from local to auto' must be FALSE if AutModLo is
8 a position switch (Feature.bit8 = TRUE)
'No stop after switching from local to auto' must be FALSE for Matrix
9 KXKO or LOC_011 (Feature.bit9 or Feature.bit12 = TRUE)
"Local stop active in auto/manual mode" must be FALSE if the local start
10 is an inching mode (Feature.bit.5)
'Local Switch Signal AutModLo = "0" forces drive to local mode' is only
11 possible if AutModLo is a position switch (Featurebit.8 = TRUE)
Only one out of these options can be selected:
"AutModLo" is used as position switch" or "Local Switch Matrix KXK0" or
12
"Local Switch Matrix LOC_010" or "Local Switch Matrix Caima"
 Check Feature.bit8, 9, 10 and 12!
'Local start only inching' is not allowed for Local Switch Matrix "KXK0" or
13 "LOC_010" or Local Switch Matrix "Caima" (Feature.bit9, 10 and 12)
'"StartAut" switches drive to Automatic mode' must be FALSE if
14 AutModLo is a position switch (Feature.bit8 = TRUE)
'"StartAut" switches drive to Automatic mode' must be FALSE for Matrix
15 KXKO or LOC_011 (Feature.bit9 or Feature.bit12 = TRUE)
Caution: Only one error number can be indicated at a time!

!

Considerations regarding Feature bit settings

It must be distinguished between Features and OS Permissions which define the general
operation or programming philosophy of a plant and Features and OS Permissions which enable
instance specific functions.
Features and OS Permissions which define the general plant philosophy should be identical in all
instances of the block and must therefore be selected at the Feature Master block.
The Feature bits and OS Permission bits which need to be configured individually per instance
must not be selected to be copied from the Feature Master block.
The following pages will help you to choose proper feature bit settings. (For details refer also to
the corresponding object description).
Caution: Please keep in mind that not all combinations are permitted. Invalid settings will lead
! to an engineering error.
Feature bit settings for control functions (C_GROUP, C_ROUTE, C_SELECT):
Type Function Feature bits

Operating
Which operating modes exist? Feature bit 0, 13, 21
mode
OP Station Local authorization active (OPStation available)? Feature bit 24
'Interlock bypass' exists for GROUP? Feature bit 14
GROUP not empty reset' exists? Feature bit 15
'Immediate Stop' exists for GROUP? Feature bit 16
Operation GROUP Acknowledgement mode? Feature bit 19
Each GROUP-start retriggers start-up-warning? Feature bit 29
GROUP automatic start must be enabled by
Feature bit 17
operator action?
CFC Using GR_LINK interfaces for mode signal
Feature bit 25
Program transfer?
Evaluation of ST_Worst? Feature bit 22
Display Enable operation messages? Feature bit 26, 27
Display last stop reason for GROUP or ROUTE? Feature bit 11
Via OS Permissions it can be decided which operator action is permitted.
Each Operator action is linked to an authorization level. The authorization level can be adjusted
at the block interfaces in the CFC directly. (See Instance specific Authorizations)

Feature bit settings for drive functions (C_DRV_1D, C_DRV_2D, C_DAMPER, C_VALVE):

Which operating modes exist? Feature bit 0, 13, 21
Feature bit 16, 17, 18, 27
Interlocking level for the manual mode?
Operating Feature2 bit3
mode Interlocking level for the local mode? Feature2 bit 1, 4
Mode change possible via interface or only via
Feature bit 1, 2, 14, 15
Operator Station?
LOCAL mode characteristics:
- Selector Switch/Repair switch Feature bit 8
- only inching Feature bit 5
- LOCAL switch matrix for Signal evaluation Feature bit 9, 10, 12
Local
- LOCAL start/stop command always active Feature bit 3, 4
switch
- with/without start-up-warning Feature bit 6
- with/without interrupt when switching to AUTO Feature bit 7
- Forcing to LOCAL via field switch signal Feature bit 11
- Force to AUTO via command “automatic start” Feature bit 19
Contactor feedback supervision for DAMPER? Feature bit 27
MCC/Field
Limit switches for DAMPER NO/NC? Feature bit 29, 30
signals
Contactor feedback supervision for VALVE? Feature bit 17
Additional fault reset button? Feature2 bit 19
Quick Stop active in all operating modes Feature bit 23
Rapid stop exists? Feature bit 30 (DAMPER: 17)
Operation VALVE has simulation function for limit positions Feature bit 31
and/or “Retain last command” function? Feature2 bit 12
DAMPER has simulation function for limit
Feature2 bit 12
positions
CFC Using GR_LINK interfaces for mode change, drive
Feature bit 25, 26, 28
Program feedback or feedback 'not empty'?
Evaluation of ST_Worst? Feature bit 22
Display Operating messages for Local start/stop Feature2 bit 0
Display last stop reason? Feature2 bit 11
Warning device? Feature2 bit 2
Setpoint exists (VSD drive)? Feature bit 29
Individual Use calibrated position value for DAMPER? Feature bit 31
settings Regain lost limit position for DAMPER Feature2 bit 13
Normally open VALVE? Feature bit 29
User Output (pulse)? Feature2 bit 29
at the block interfaces. (See Instance specific Authorizations).

Feature bit settings for annunciation and measures (C_ANNUNC, C_ANNUN8, C_PROFB and
C_PROFBx):

MCC/Field Process feedback signal delivers pulses? Feature bit 27
signals Process feedback signal is an analog value? Feature bit 15
Process feedback monitoring also during start-up
Feature bit 31
(PFOnDTi)
Process feedback monitoring in all operation
Feature bit 13
modes
Operation Memorize process feedback fault up to new
Feature bit 14
startup of drive?
Acknowledgement only via interface Ack for
Feature bit 19
C_ANNUNC and C_ANNUN8?
Additional fault reset button? Feature bit 12
Using GR_LINK interfaces for mode feedback Feature bit 26
Using O_LINK for Message trigger in C_ANNUNC
Feature bit 16
or C_ANNUN8?
Using O_LINK for Warning activation in
Feature bit 17
C_ANNUNC?
CFC
Program Using O_LINK for Supervision enable in
Feature bit 18
C_ANNUNC or C_ANNUN8?
Using O_LINK for or Message enable in
Feature bit 16
C_PROFB?
Using O_LINK for Maintenance counter
Feature bit 20
activation?
Display Evaluation of ST_Worst? Feature bit 22
Shut-down monitoring for C_PROFB Feature bit 30
Feature bit 2, 5, 8, 11, 27,
Shut-down monitoring for C_PROFBx
28
Individual
settings Simulation value for C_ANNUNC and
Feature bit 28
C_ANNUN8?
Feature bit 29 (ANNUN8: 0-
Warning mode for C_ANNUNC and C_ANNUN8?
6)
Each operator action is linked to an authorization level. The authorization level can be adjusted

Feature bit settings for measures (C_MEASUR):

Signal Reaction in case of Live Zero? Feature bit 9
evaluation Calibration of Card value possible? OS Permission bit 19
Output ProFB = 1 if process feedback
Feature bit 31
signal = 1?
Memorize process feedback fault up to new
Operating Feature bit 14
startup of drive?
mode
Acknowledgement only via interface Ack for
Feature bit 19
C_ANNUNC and C_ANNUN8?
Additional fault reset button? Feature bit 12
Using GR_LINK interfaces for mode feedback Feature bit 26
CFC
Program Using O_LINK for Maintenance counter
Feature bit 20
activation?
Force outputs of C_MEASUR to '0' if supervision
Feature bit 17
enable = '0'?
C_MEASUR has bypass / service function? Feature bit 0
C_MEASUR has gradient supervision? Feature bit 1
C_MEASUR with root extraction function? Feature bit 2
Individual C_MEASUR with smoothing function? Feature bit 3
settings
C_MEASUR with spike suppression? Feature bit 4
C_MEASUR with square function? Feature bit 5
C_MEASUR used for suction measurement? Feature bit 7
Tracking actual value to Simulation value? Feature bit 10
C_MEASUR with frozen value detection? Feature bit 11
Each operator action is linked to an authorization level. The authorization level can be adjusted

Feature bit settings for storage function (C_STORAG):

CFC
Using GR_LINK interfaces for mode feedback? Feature bit 26
Program
Individual
Enable storage locked? Feature bit 0
settings
Master Library – Templates
A master library with template charts according to the plant requirements is not a must but it is
highly recommended.
Via Feature Master the Feature bits and OS Permissions for all general definitions can be
configured, such as Operating mode and Operating Philosophy, Local switch, MCC and Field
signal availability.
Via Template charts CFC Programming rules and settings for certain applications can be
defined. This may be for a single block, as we have used it for the training or for more complex
functions, e. g. Belt conveyor with rope switches, drift switches and measurement.

Feature bits and OS Permissions
Feature bits of C_DRV_1D

1 Local ON via program possible TRUE
2 Local OFF via program possible TRUE
3 Local start active in Automatic / Manual FALSE
4 Local stop active in Automatic / Manual TRUE
5 Local start only inching FALSE
6 Start-up warning in Local mode FALSE
8 AutModLo is used as position switch FALSE
9 Local switch matrix KXK0 FALSE
10 Local switch matrix CAIMA FALSE
11 AutModLo = 0 forces drive to Local mode FALSE
12 Local switch matrix LOC_010 FALSE
14 Manual ON via program possible FALSE
15 Manual OFF via program possible TRUE
Manual mode Only Protection Interlocks (IntProtG and IntProtA
17 FALSE
active)
Manual mode Reduced Interlocks (IntProtG, IntProtA, IntStaE and
18 FALSE
IntOpE active)
20 FALSE
22 Write quality code ST_Worst to module output FALSE
23 QuickStp active in all operating modes TRUE
24 Local authorization active (OP Station perm. needed) FALSE
25 GR_LINK interface used for mode change to drive TRUE
26 GR_LINK interface used for mode feedback from drive TRUE
28 GR_LINK interface used for Not Empty from drive TRUE
29 Enable setpoint FALSE
30 Rapid stop exists TRUE
31 FALSE
Special Requirements for LafargeHolcim projects:

Feature.bit7 No stop after switching from Local to Automatic / Manual  FALSE
Feature.bit14 Manual ON via program possible  FALSE
Feature.bit23 QuickStp active in all operating modes  TRUE
Feature.bit28 GR_LINK interface used for Not Empty from drive  TRUE
Feature.bit30 Rapid stop exists  TRUE

Feature2 bits of C_DRV_1D

0 Local start and stop operation messages TRUE
1 Local operation without essential interlock FALSE
2 Warning mode active FALSE
3 Stop interlock in Manual mode FALSE
4 IntProtA in local mode (bypass via StartLoc) TRUE
5 FALSE
6 Start-up warning in Automatic mode FALSE
7 FALSE
8 FALSE
9 FALSE
10 FALSE
11 Last stop reason TRUE
12 FALSE
13 FALSE
14 FALSE
15 FALSE
16 FALSE
17 FALSE
18 FALSE
19 Additional Fault reset function FALSE
20 FALSE
21 FALSE
22 FALSE
23 FALSE
24 FALSE
25 FALSE
26 FALSE
27 Only Interface Ack for acknowledgement active FALSE
28 FALSE
29 User output (pulse) FALSE
30 FALSE
31 FALSE

Feature.bit0 Local start and stop operation messages  TRUE
Feature.bit4 IntProtA in local mode (bypass via StartLoc)  TRUE
Please consider that the Feature bit settings can only be changed in configuration state. For a
running plant this means that the block has to be in Out of Service mode.
If the block is in configuration state and the feature bit settings are consistent (ErrorNum = 0),
the Feature Master block settings and the status of Feature word Feature/Feature2 are
transferred into the internal memory of the module.
Note: Do not connect any logic to input Feature and Feature2.

OS Permissions of C_DRV_1D
BitNr. Function/OS Permissions Default value

0 1 = Operator can change to Local mode TRUE
1 1 = Operator can change to Manual mode Interlocked FALSE
2 1 = Operator can change to Automatic mode TRUE
3 FALSE
4 1 = Operator can enable Power management FALSE
5 1 = Operator can change to Manual mode Non Interlocked FALSE
6 1 = Operator can change to Manual mode Reduced Interlocks TRUE
7 1 = Operator can change to Manual mode Only Protection Interlocks FALSE
8 1 = Enable Single Step Operation TRUE
9 FALSE
10 1 = Operator can start TRUE
11 1 = Operator can Stop TRUE
12 FALSE
13 FALSE
14 FALSE
15 FALSE
16 1 = Operator can start the Maintenance function TRUE
17 FALSE
18 1 = Enable Single step mode change TRUE
19 1 = Enable Fault reset FALSE
20 1 = Operator can enter SPHiLim TRUE
21 1 = Operator can enter SPLoLim TRUE
22 FALSE
23 FALSE
24 FALSE
25 FALSE
26 FALSE
27 1 = Setpoint change with direct input TRUE
28 1 = Operator can modify setpoints TRUE
29 1 = Enable User button FALSE
30 1 = Enable Rapid stop TRUE
31 1 = Operator can modify process parameters TRUE

OS_Perm.bit1 1 = Operator can change to Manual mode Interlocked  FALSE
OS_Perm.bit6 1 = Operator can change to Manual mode Reduced Interlocks  TRUE
OS_Perm.bit27 1 = Setpoint change with direct input  TRUE
OS_Perm.bit30 1 = Enable Rapid stop  TRUE
Please consider that the OS Permission settings can only be changed in configuration state. For
a running plant this means that the block has to be in Out of Service mode.
If the block is in configuration state the Feature Master block settings and the status of
OS_Perm are transferred into the internal memory of the module.
Note: Do not connect any logic to input OS_Perm.

Template Example
A template can be a simple block (just a C_DRV_1D) or a complex function like a belt conveyor
(e. g. consisting of a motor, a process feedback supervision, belt drift switches, pull rope
switches, and current measurement).
This is the template C_DRV_1D from the Project Library of the Training Project:

Using group link for mode change and feedback
Feature bit settings in C_DRV_1D

1 Local ON via program possible TRUE
2 Local OFF via program possible TRUE
14 Manual ON via program possible FALSE *)
15 Manual OFF via program possible TRUE
17 Manual mode Only Protection Interlocks (IntProtG and IntProtA active) FALSE
Manual mode Reduced Interlocks (IntProtG, IntProtA, IntStaE and IntOpE
18 FALSE
active)
25 GR_LINK Interface used for mode change TRUE
26 GR_LINK Interface used for mode feedback from drive TRUE
*) Feature.bit14 is set to “FALSE” because according to LafargeHolcim Philosophy, group-wise

change to Manual mode should not be permitted.
Feature bit settings in C_GROUP

13 Manual mode exists FALSE *)
26 GR_LINK Interface used for mode Signal transfer TRUE
*) Feature.bit13 is set to “FALSE” in order not to permit the group-wise change to Manual mode.
It is still possible to switch the individual objects to Manual mode with reduced interlocks
(OS_Perm.bit6 for the drives = TRUE)

Individual connections for mode change and feedback
Mode change and feedback derived from Group link
More details you find in the object descriptions of group and drive objects.

Definition of Variable texts
Many faceplates have variable texts which can be adapted instance-specific.
Example: Variable texts in the faceplate of C_DRV_1D
The texts can be configured in the CFC, in the properties of some block parameters. Each block
type has different text variables. You find a complete list in the Engineering manual, chapter
06_AS_Engineering.

Block parameters for text configuration for C_DRV_1D, C_DRV_2D, C_DAMPER and
C_VALVE:
C_DAMPER
C_DRV_1D
C_DRV_2D
C_VALVE
Property in Default
OS Function Variable name CFC OS Variable value
Current or Power
x x AV_Perc.Value Identifier S7_Shortcut J=
indication
Unit for Position Value x PosVal.Value Identifier S7_Shortcut %
Unit for Input Signal x PV.Value Identifier S7_Shortcut rpm

Unit for Setpoint from
x SP_Os Unit S7_Unit rpm
OS
Unit for Setpoint
x SP_Out.Value Unit S7_Unit rpm
output
Button text for Text 0 S7_string_0 Off
x x ManModOn
start/stop buttons Text 1 S7_string_1 On
Button text for Text 0 S7_string_0 X
x x ManModOn
start/stop buttons Text 1 S7_string_1 Y
Button text for stop x x AutModOn Text 0 S7_string_0 Off
Subcontrol Button OS
ToolTipText in x x SubCFp additional OS_Text
Standard Faceplate Text
User Function Button OS
ToolTipText in x x x x SelFp1 additional OS_Text
Standard Faceplate Text
User button for pulse
x x x x UserPulse Text 1 Pulse
output
Status display for user
x x x x UserFbk Text 1 On
feedback

Configuration of the HMI functions
If you do the Engineering for a LafargeHolcim Project you have to make the following settings in
addition to the general setting.
For the general Screen design refer to the LafargeHolcim Documents "HMI Screen Design
Guideline" and "HMI Screen Design Guideline ANNEX 1:"
R-CMS-ECT-08-1442-E_HMI_Design_Spec_Guideline_MainDoc_V1-2.pdf
R-CMS-ECT-08-1442-E_HMI_Design_Spec_Guideline_Annex1_V1-0.pdf
For HMI Structure and Picture names see document:

Holcim_HMI_PDL_Struktur_CEMAT_1208.xls
An Overview of bitmaps, designed according the LafargeHolcim Specification you find in file
Holcim_Symbols.xls
Generation of Process Pictures
All process pictures for direct access from Overview Window (picture tree) have to be created in
the process object view or plant view of the SIMATIC Manager.
Pictures which are not included in the picture tree (because they are called from other pictures)
may be created in the component view of the SIMATIC Manager or directly in the GraCS Folder
of WinCC.
In LafargeHolcim Projects there is a rule the naming of Process pictures, depending on the plant
section. Additionally to this, Picture windows must be created which contain navigation buttons.
For HMI Structure and Picture names please refer to

D:\CEMAT_CS\Docu\Engineering\Holcim_HMI_PDL_Struktur_CEMAT_1208.xls
Default Pictures with the correct naming you find under

D:\CEMAT_CS\AddOn\Project_Picture_Templates\WinCC\GraCS
You can use the template picture “501_PO.pdl” as an example for Process Pictures.
Note: Please keep in mind that the size of the example process pictures is 1280x825 and
! needs to be adapted according to your screen resolution!

Picture Navigation
In PCS 7 the Navigation between Process Pictures is defined via the OS Project Editor, based
on the Area definition in the plant view. In the Runtime System the picture tree is shown in the
Overview range (upper part of the Screen). The main picture of each Area (Overview) can
directly be accessed via buttons in the Overview Area. If detail pictures exist, the arrow beside
the Area button opens an additional dialog for the navigation to the levels below.
The number of Area buttons depends on the plant size and the number of Areas. Example for a
picture tree with 5 by 5 AREA buttons:
For LafargeHolcim Projects Picture Windows must be added with buttons for the Navigation
within an AREA in order to have fast access. The Navigation Windows are inserted at the bottom
of the Screen and need to be adapted according to the Plant Configuration.
Note: Please consider the additional space which is needed for the picture windows. The
! available range in the process picture will be reduced by 30 Pixel.
A detailed description you find in the document

R-CMS-ECT-08-1442-E_HMI_Design_Spec_Guideline_Annex1_V1-0.pdf
Default Picture Windows with the correct naming you find under
D:\CEMAT_CS\AddOn\Project_Picture_Templates\WinCC\GraCS
The following files need to be copied into the GraCS Folder of your OS project in order to get the
3 additional navigation buttons in @Buttons11.PDL:
@Buttons11.PDL with buttons PO, PS and PT

HOL_PO.PDL
HOL_PS0.Pdl
HOL_PT0.Pdl
The rest of the pdls in this folder are templates for the additional navigation window (above the
button line):
You can use the template picture “501_DN.pdl” as an example for Navigation window.

For Button text and Picture name definition, open “501_DN.pdl” and modify in “Open Picture”
the shown red text below.
Further templates are
- “501_TO.pdl” for Section Trend Overview

- “501_T1.pdl” for Section Trend
- “501_SO.pdl” for Section Silo
- “501_RO.pdl” for Section Recipe
Name definitions
Picture Names: For Picture names see file Holcim_HMI_PDL_Struktur_CEMAT_1208.xls
Object names: The object names are created in the Engineering of the CFC. In the OS only
selection of existing objects is possible.

Block icon definition
For LafargeHolcim Projects in addition to template picture C_@PCS7Typicals_CemV9_001.PDL

the LafargeHolcim template picture C_@PCS7Typicals_CemV9_001_004.PDL must be used.
This contains all block icons with adaptations to LafargeHolcim Standard.

LafargeHolcim Symbols Library
In addition to the block icon the equipment (motors, actuators, valves, etc. must be animated, in
order to show
Grey color if the device is not running (or closed)
Green color if the device is running (or not closed)
The symbols for the equipment are standardized according to LafargeHolcim Specifications and
a selection of symbols (emf-files) can be found the Subfolders of directory
D:\CEMAT_CS\AddOn\Holcim Symbols\WinCC\GraCS
Most of the symbols are available in grey and green color in order to show "running" or "not
running".
Status Display for Equipment
In order to show how the symbols must be linked to the STATUS2 bits of the device a template
picture exists under D:\CEMAT_CS\WINCC\GRACS.
The name of the Template picture is C_Holcim_Symbols.PDL and it contains a number of

examples for Status displays of C_DRV_1D, C_DRV_2D, C_DAMPER and C_VALVE.

You may copy one of those status displays to your Process Picture, open Object Properties and
add the tagname to the Dynamic of Attribute "Status1".
The easiest way to create a new status display is copying an existing one and using the
Configuration Dialog in order to assign new pictures (e. g. emf from
D:\CEMAT_CS\AddOn\Holcim Symbols\WinCC\GraCS).
The width and height of each symbol is shown in file Holcim_Symbols.xls, together with the
name of the emf-file. In this proportion the values must be entered under Property "Geometry".

ENGINEERING TOOLS
The following Engineering Tools exist:
- Info Data Generation „C_INFO.xls‟

 can be used for all Project versions
- CFC Generation „CEMAT_ENGINEERING.xls and Libraries‟

 available for all classic Project versions
 not available for 001 Minerals!
- New Check Tool V9 „CEMATCheckTool.exe‟

 can be used for Project versions 000, 001, 004, 006 and 007
 Multiple PLCs can be checked at a time
- Migration tools
 CFC Migration of CEMAT V2, V3, V4 to CEMAT V9
 no migration tool for existing project versions to 001 Minerals
All Excel tools can be saved as XLSM (Excel 2010)
Generation of Data for Info Dialog
Operating principle for the Generation of User Archive data C_INFO:
For details see Engineering Manual, chapter 09_Engineering_Tools.

New check Tool „CEMATCheckTool.exe‟
The information which is needed has to be exported from the PCS 7 project as follows:
If multiple projects shall be checked at the same time, the following steps have to be repeated
for each user project.
The file names are standardized and spelling must be exact (case sensitive!)
For Chart Reference data use name MyProject_R.csv

For Export I/Os use name MyProject_PS.csv
For Export all blocks use name MyProject_B.csv
For the Symbol Table use name MyProject_Symbols.sdf
MyProject hast to be replaced by the name of the AS.
For details see Engineering Manual, chapter 09_Engineering_Tools.

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CEMAT Objects CEMAT V9 MinAS Option4

THE CEMAT V9 MINERALS LIBRARY 5

CEMAT OBJECT FUNCTIONS 11

Exercises in Area „E50 System Test‟ 12

Group and drive functions 15

Annunciation block functions (Part I) 51

Process Feedback block functions 70

Measuring value functions 79

Copyright  Siemens AG. All Rights Reserved. 1

Example 5: 'Belt Conveyor Flow measurement' 79

Annunciation block functions (Part II) 102

Bag Filter (Warning Motors) 113

Exercises in Area: 'Training' 120

Selection functions 122

Using Process feedback blocks for pressure supervision 131

Using Annunciation blocks for pressure supervision (optional exercise) 138

2 Copyright  Siemens AG. All Rights Reserved.

Positioning function of C_DAMPER 145

SIMOCODE Adapter function 152

Variable Speed Drives 155

Adapter to non-CEMAT blocks 157

Analog value selector 162

CEMAT SETTINGS IN THE PCS 7 PROJECT 165

CEMAT V9 Project Standards 166

CONFIGURATION OF THE CEMAT BLOCKS AND FACEPLATES 167

General settings in the System Chart SYSPLCxx 167

Adaptation of the blocks regarding Operating mode and Periphery 176

Copyright  Siemens AG. All Rights Reserved. 3

Operator authorization levels 178

Feature Master Concept 181

Master Library – Templates 191

Feature bits and OS Permissions 192

Configuration of the HMI functions 200

ENGINEERING TOOLS 206

4 Copyright  Siemens AG. All Rights Reserved.

THE CEMAT V9 MINERALS LIBRARY

The CEMAT V9 Minerals library Minerals_Cemat_V9000 contains three S7-Program folders:

Copyright  Siemens AG. All Rights Reserved. 5

CEMAT Blocks for General Functions (System Chart)

Block name Description

6 Copyright  Siemens AG. All Rights Reserved.

Block name Description

C_INTLK2 Interlock with 2 inputs

C_ADAPT Adapter Module

C_TIS_B Bool Variable for TIS

Copyright  Siemens AG. All Rights Reserved. 7

Block name Description

8 Copyright  Siemens AG. All Rights Reserved.

Exercise 0.1: Preparations

Copyright  Siemens AG. All Rights Reserved. 9

General Module Structure

Periphery signals Annunciations (invisible)

From the operator station

Group/ route link

10 Copyright  Siemens AG. All Rights Reserved.

CEMAT OBJECT FUNCTIONS

Different Areas are defined:

11 Copyright  Siemens AG. All Rights Reserved.

Exercises in Area „E50 System Test‟

Engineering example „Group E51‟:

12 Copyright  Siemens AG. All Rights Reserved.

List of Motors and Instruments:

Groups and Routes: