81723640 minas demoproject en

http://support.automation.siemens.com/WW/view/en/81723640

Application description y 02/2014

PCS 7 in the mining industry(Demo Project)SIMATIC PCS 7, Minerals Automation Standard / CEMAT

Warranty and liability

PCS 7 Demo Project (Mining)Entry-ID: 81723640, V1.0, 02/2014 2

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Warranty and liability

Note The Application Examples are not binding and do not claim to be completeregarding the circuits shown, equipping and any eventuality. The ApplicationExamples do not represent customer-specific solutions. They are only intendedto provide support for typical applications. You are responsible for ensuring thatthe described products are used correctly. These application examples do notrelieve you of the responsibility to use safe practices in application, installation,operation and maintenance. When using these Application Examples, yourecognize that we cannot be made liable for any damage/claims beyond theliability clause described. We reserve the right to make changes to theseApplication Examples at any time without prior notice.If there are any deviations between the recommendations provided in theseapplication examples and other Siemens publications e.g. Catalogs thecontents of the other documents have priority.

We do not accept any liability for the information contained in this document.

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Table of contents


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Table of contentsWarranty and liability ............................................................................................... 21 Overview ......................................................................................................... 42 Minerals Automation Standard / CEMAT ....................................................... 5

2.1 MinAS philosophy .............................................................................. 52.2 The advantages of MinAS .................................................................. 62.3 The operating methodology of MinAS ................................................ 72.4 Main features of MinAS...................................................................... 82.5 MinAS blocks ................................................................................... 102.5.1 Drive functions ................................................................................. 102.5.2 Control/monitoring ........................................................................... 11

3 Mining demo project..................................................................................... 123.1 Overview ......................................................................................... 123.2 Process screens .............................................................................. 143.3 Plant area: Crushing ........................................................................ 173.3.1 Primary crusher ............................................................................... 183.3.2 Operator controls for groups, routes and maintenance ..................... 193.3.3 Conveyor belts ................................................................................ 203.3.4 Stockpile.......................................................................................... 203.4 Operator controls ............................................................................. 213.4.1 Faceplates ....................................................................................... 213.4.2 Object browser ................................................................................ 223.4.3 Integrated MinAS maintenance ........................................................ 233.4.4 Integrated MinAS trend .................................................................... 23

4 Installation and startup of the demo project ............................................... 24

4.1 Installing of MinAS ........................................................................... 244.2 Installing the demo project ............................................................... 254.3 Loading the AS program .................................................................. 254.4 Changing the computer name .......................................................... 264.5 Customizing the OS project ............................................................. 274.6 Launching the OS runtime ............................................................... 284.7 Initial state of the plant ..................................................................... 30

5 Operating the demo project ......................................................................... 33

5.1 Establishing the plant state using the object browser........................ 335.2 Performing fault diagnostics using "status call" and the object

list ................................................................................................... 365.3 Starting and stopping plant areas (groups) ....................................... 405.4 Faults in groups being started or already in operation ...................... 455.5 Integrated MinAS trend configuration ............................................... 495.6 Performing plant maintenance using the "maintenance list" .............. 515.7 MinAS alarm view with filter functions .............................................. 55

6 Further information ...................................................................................... 57

6.1 Application notes ............................................................................. 576.1.1 Process simulation .......................................................................... 576.1.2 Changing the operating mode .......................................................... 586.1.3 Storing notes on objects .................................................................. 596.2 Tips and tricks ................................................................................. 60

7 Sources and links ......................................................................................... 618 History .......................................................................................................... 61

1 Overview


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1 OverviewApplication objective

This document provides you with an overview of the functional scope of theMinerals Automation Standard (MinAS), as well as a description for the startupand functional properties of the demo project.

Core contents of the applicationThe following key aspects are covered in this application:x Minerals Automation Standard / CEMATx Installation and startup of the demo projectx Operation of the demo project based on the example of typical operating

scenarios

ValidityThe software requirements for operating the demo project are as follows:x SIMATIC PCS 7 V8.0 SP1 with a valid license or time-limited trial license.x Minerals Automation Standard / CEMAT V8.0 SP1 with a valid license or time-

limited demo mode.

You can find information about the product at:Minerals Automation Standard / CEMAT

[email protected]

2 Minerals Automation Standard / CEMAT


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2 Minerals Automation Standard / CEMATThe Siemens Industry Automation division developed the Minerals AutomationStandard / CEMAT V8.0 to meet the special demands of the mining industry.This standard uses the SIMATIC PCS 7 process control system, with its open,flexible and scalable system architecture, as a system platform that is expandedto include specific automation functions for mining applications.The Minerals Automation Standard / CEMAT V8.0 (hereinafter abbreviated as"MinAS") is a product for use in the mining and cement industry sectors.

Figure 2-1

2.1 MinAS philosophy

MinAS is more than just a library containing a few specific modules for the miningindustry. It also represents a complete philosophy:x How are devices such as conveyor belts, crushers and grinders, or even the

entire process configured?x How are processes in the mining industry operated?x How can diagnostics be performed quickly and simply in order to keep

unplanned plant downtime at a minimum in the event of a fault?

As an integrated solution, the Minerals Automation Standard focuses on:x Efficient engineering and qualityx Improved operation and monitoring



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2.2 The advantages of MinAS

ConfigurationMany advantages are available to the plant engineer during process configuration:x A tested and well-documented library of software modules for functions in the

mining industryx Technology-oriented configuration to achieve the highest software quality,

even without programming knowledgex Standard interface between the software modules to minimize faultsx Integrated simulation functions for engineering and factory acceptance tests

(FAT)x Bulk data processing

OperationMinAS enables users to handle the system simply and intuitively thanks to:x Easy-to-understand symbolsx Starting and stopping of entire process groups with a simple mouse clickx Easy route selectionx Efficient fault diagnostics



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2.3 The operating methodology of MinAS

The Minerals Automation Standard operating philosophy is, among other things,based on different operating modes:x "Automatic"x "Manual"x "Local"x "Out of service"

Advantages for operations management can be seen for example in typicalapplications such as system startup, troubleshooting (fault avoidance),maintenance and the exclusion of devices.The standardized and proven operating concepts result in reliable operation,reinforced by the opportunity for standardized training.

Automatic modeDuring normal operation, all drives in a technological plant area are started andstopped in "automatic mode." The start or stop command is then triggered by thestart/stop sequence or by the configured process conditions.

Manual modeIn "manual mode", the drives can be started and stopped individually at theoperating station. The "manual mode" can be specifically activated or deactivatedfor each individual drive or for groups.

Local modeIn this operating mode, interlocks are only active to a limited extent. The applicationareas for this operating mode are: startup, tests and maintenance work.

"Out of service" (maintenance)The "out of service" mode prevents the drive from starting and disables all controlfunctions by locking the control output. It also disables all messages.This operating mode is intended to be used with field devices that are defectiveor undergoing maintenance work.



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2.4 Main features of MinAS

MinAS provides an extensive collection of preconfigured, tested and welldocumented mining-specific library elements in order to offer support in variousdifferent areas of application in the minerals industry (mining and cement).To do this, it uses PCS 7 standard functions such as CFC configuration. For eachfunction block in the library, there is a block icon and accompanying faceplate witha consistent look and feel. The icon and faceplate are automatically generatedfor the graphical user interface and only arranged at the process screen incombination with static graphic elements. These library elements and templatesreduce engineering time and improve engineering quality.The essential functions are briefly described below:

Group controlGroup elements enable the representation of a plant area's operating state andprovide detailed fault diagnostics for all related objects.All drives, displays and measured value of a plant area are connected by a groupelement. This group provides summary information about faults and alarms andinterrupts or prevents the starting procedure in the case of a fault.

Global object browserThe object browser provides a status overview of the objects present in the system.Filter functions make it possible to search by operating mode, stored notes,maintenance state or bypassed interlocks.

Object listThe object list for a group shows the status of all related drives, measured valuesand process signals. In addition, drives can also display their measured valuesand process signals.

Information viewAdditional information (links, documents, drawings, videos) can be linked to eachobject. Information can be added during operation.

Integrated MinAS trendSimple configuration of a trend display by selecting analog values at the processscreen during operation. The trend display can be saved and linked to a processarea.

Integrated MinAS maintenanceFor drives and valves, additional information about maintenance and availabilitycan be configured. A maintenance view gives an overview of operating hours,starts, stops with faults, and downtime.



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Diagnostics viewList of all relevant block inputs and outputs with the corresponding status There isalso the option to change some of the block parameters directly in the diagnosticsview.

MinAS alarm viewUp to 10 customized filters can be created for process messages. Filter typesinclude: plant area, measuring point, message type, message text, date...In addition, "smart" filters make it possible to display alarms for active objects only.



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2.5 MinAS blocks

A detailed and complete description of the functions can be found in the productdescription. All of the blocks from the SIMATIC PCS 7 standard libraries can alsobe used.The blocks relevant for this demonstration are listed below.

2.5.1 Drive functions

C_DRV_1DThe C_DRV_1D block is used to control drives with one direction.

C_DRV_2DThe C_DRV_2D block is used to control drives with two directions.

C_VALVEThe C_VALVE block is used to control valves.

C_SIMOSThe C_SIMOS SIMCODE adapter block connects CEMAT drive blocks withSIMCODE.

C_ANNUN8At the C_ANNUN8 block, up to 7 binary process signals can be displayed. If oneof the process signals experiences a malfunction, then a fault or alarm messageis generated.

C_ANNUNCAt the C_ANNUNC block, one binary process signal can be displayed. If theprocess signal experiences a malfunction, then a fault or alarm message isgenerated.

C_MEASURThe C_MEASUR block can be used to read analog process data and monitor upto 8 limit values. It is possible to configure 4 of the limit values for the generationof fault/alarm messages. The other 4 limits are switching limits and do not generateany alarms.



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C_PROFBThe C_PROFB block can monitor binary or analog process feedback signals froma drive, such as rotational speed or pressures.If there is a fault in the process feedback, then the drive will be stopped viaa protective interlock.

2.5.2 Control/monitoring

C_GROUPThe C_GROUP block is a higher-level module used to switch technologicallyrelated devices on and off in automatic mode.The group block allows the visualization of operating states for a system sectionin the form of a status display and detailed fault diagnostics (status call).

C_ROUTEThe C_ROUTE block is a module for selecting transport routes within a group.

C_SELECTThe C_SELECT block can be used for every type of selection function. In contrastto the C_ROUTE block, it does not offer fault diagnostics.

3 Mining demo project


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3 Mining demo project3.1 Overview

The mining demo project illustrates the different process stages of a typical miningplant and its plant hierarchy in the form of an overview.In the process, the basic functionality and operation of MinAS are explained usingthe example of the "primary crushing" plant section.The MinAS demo project is divided into an AS section and an OS section.

AS sectionIn the "primary crushing" plant section of the AS program, the logic is configured fora crusher, conveyor belts and dust collectors. The program contains blocks for theacquisition of analog and digital data, blocks for controlling motors and valves, andthe blocks for route and group functions. If no process connection is available, thesignals and process data can be simulated with the help of a special test block.

Figure 3-1



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OS sectionThe demo project contains multiple process screens that are intended to clarify theproject using the example of a processing plant (e.g., for copper). In the "Crushing"area, the function of a crusher, including the removal of the raw materialby conveyor belts, has been visualized. This plant area is configured for thedemonstration of MinAS. The remaining screens are static and do not have anindividual function.

Figure 3-2



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3.2 Process screens

Using the plant hierarchy, you can navigate between the overview, crushing,grinding, rougher, cleaner, tailings and stockyard screens in the OS runtime.These screens are briefly described in the following table:

Table 3-1

Description Screen

Overview

Here, you are given an overview ofthe plant and can switch directly tothe desired plant section using thebuttons.

Crushing(can be operated by user)

This plant section providesa visualization of a crusher andthe belts that remove the material.After passing through the crusher,the mined ore is fed to the nextprocess via two conveyor belts: onefor coarse material and one for finematerial. When the crusher is ata standstill, ore can be fed tothe grinder from a stockpile.This screen contains thefunctionality of the demo project.It will be discussed in greater detailat a later point in this document.



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Description Screen

Grinding

The screen shows an example of anoverview for the grinding circuit.The ore is first ground in an SAGmill and is then ground in a ballmill in a second stage.

Rougher

This part of the plant shows the firststage of a flotation process,which consists of a line of roughersand an additional mill integrated inthe circuit.

Cleaner

Here, the second flotation stage,including a cleaning plant anda filter press, is visualized.



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Description Screen

Tailings

The "Tailings" area is an example ofa screen for the recovery of processwater and removal of residualstone.

Stockyard

This screen shows an example ofthe loading of a product at a port.The end product is deliveredby train, dumped into piles forintermediate storage, and thenloaded onto ships.



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3.3 Plant area: Crushing

This process picture contains the functionality of the demo project. Here, you canopen faceplates, change the status of objects, select routes, start and stop groups,etc. Detailed operation is explained in the chapter "5 Operating the demo project"using different scenarios.

Figure 3-3

(1) Primary crusher(2) Control elements for the group start/stop, route selection, maintenance list

and the object browser(3) Conveyor belt for feeding course ore to the secondary crusher(4) Conveyor belt for feeding fine or to the grinder(5) Stockpile

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3.3.1 Primary crusher

In the following partial image, you can see the crusher with the raw material hopperand the subsequent screening.

Figure 3-4

(1) Signaling installation for adding more raw material(2) Fill level of the raw material hopper(3) Drive for the crusher

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3.3.2 Operator controls for groups, routes and maintenance

Here, you can select routes and start or stop groups.

Figure 3-5

(1) Starts or stops the process of the selected route(2) Route selection crusher(3) Route selection stockpile(4) Control of the water injection system on conveyor 1(5) Control of the water injection system on conveyor 2(6) Opens the object browser(7) Opens the maintenance list(8) Opens the info dialog window

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3.3.3 Conveyor belts

Once crushing is complete, the coarse material is separated from the fine material.The coarse material is transported to the secondary crusher via the first conveyorbelt. The finer material is taken directly to the grinder on the second conveyor belt.

Figure 3-6

(1) Dust collector(2) Injection system(3) Conveyor belt drive(4) Safety switch for emergency stop and belt misalignment

3.3.4 Stockpile

Leftover material can be removed from the crusher and stored in a stockpile and,if necessary, fed back into the process. You can define the source of the materialfeed using the route selection.

Figure 3-7

(1) Signaling installation for filling from the stockpile(2) Fill level of the stockpile(3) Conveyor belt drive

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3.4 Operator controls

3.4.1 Faceplates

The plant is operated using block icons and the related faceplates.

Figure 3-8

The design and functionality of the icons and faceplates of MinAS are based onthe PCS 7 Advanced Process Library. By clicking on a block icon with the leftmouse button, you can open the related faceplate. Some icons, such as an analogvalue measuring point, feature special functions that can be displayed by clickingthe right mouse button. The following views are available for all faceplates:x Standardx Diagnosticsx Alarms and messagesx Informationx Presets for the PLC module (bits feature)

Additional views are available depending on the object, for example:x Object listx Curve view (trends)x Status call (groups and routes)



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3.4.2 Object browser

The object browser is a tool that can be used to apply filters for specific states ofthe system objects throughout the entire OS project. You can thus display all ofthe objects that have a particular status. You can select from the following options:x Interlock bypassx Message availablex Power management activex Rapid stopx Service necessaryx Object in "manual" modex Object in "local" modex Object in "out of service" modex Object in simulation

The displays for the objects with the "manual," "local," "out of service" and"simulation" modes can be combined.Figure 3-9



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3.4.3 Integrated MinAS maintenance

Additional information can be used to configure drives and valves for preventivemaintenance. Here, a maintenance view or the object faceplates will provideinsight into the operating hours, starts, stops, stops with faults, and downtime.

Figure 3-10

3.4.4 Integrated MinAS trend

Every analog value that is saved to the Tag Logging archive can added to a specialtrend display. Using the trend display, you can compare any number of desiredanalog values with one another. You can configure the trend display by clickingon the analog value icon item with the right mouse button. The trend groups canbe saved and reopened as desired.

Figure 3-11

4 Installation and startup of the demo project


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4 Installation and startup of the demoproject

4.1 Installing of MinAS

System requirements

Table 4-1

Hardware

AS PCS 7 CPU S7-414 or higherES/OS In compliance with the current PCS 7 specification

Table 4-2

Software

ES/OS SIMATIC PCS 7 V8.0 SP1ES/OS Minerals Automation Standard / CEMAT V8.0 SP1

InstallationInstallation of the MinAS required administrator rights. The target directory isalways"D:\CEMAT_CS". No other directory should be selected.During installation, you will be asked to enter a project code. Enter the code "001"for the Minerals Automation Standard. Additional project codes can be found inthe product's readme file.

Figure 4-1



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4.2 Installing the demo project

If you haven't done so already, download the "MinAS_Demo.zip" file from theIndustry Online Support Site and copy the file to your Engineering System.http://support.automation.siemens.com/WW/view/en/81723640

Table 4-3

No. Action

1. Open the SIMATIC Manager.2. De-archive the demo project.

x Select the menu command "File > Retrieve"x Navigate to the folder containing the "MinAS_Demo.zip" file and open the file.

3. Open the de-archived project.

4.3 Loading the AS program

The demo project is configured so that you can use PLCSIM as the automationsystem. If you would like to load the program in a real automation system, youmay need to make adjustments to the hardware configuration and the WinCCconnection configuration.

Table 4-4

No. Action

1. Start PLCSIMx Start PLCSIM by clicking the "Simulation on/off" button in the SIMATIC Manager

button bar.

x Select the connection "PLCSIM(TCP/IP)". This switches the PC/PG interface to"PLCSIM.TCPIP.1".

2. Load the configuration and the AS program in the simulator.3. Set the status of the simulated CPU to "RUN" or "RUN-P".



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4.4 Changing the computer name

When you open the OS project, you will receive a message indicating that theconfigured server is not available.In order to start the OS runtime, you need to make a one-time change to thecomputer name in the project. Proceed as follows:

Table 4-5

No. Action

1. Open the editor for the computer properties.2. In the "General" tab, click the "Use Local Computer Name" button.

3. To apply the new computer name, you must restart the OS project.Close and then reopen the OS project.



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4.5 Customizing the OS project

If you would like to change the resolution of the OS project to match the screenresolution of your monitor, you will need to follow a few steps. The PCS 7 standardscreens can be adjusted using the OS Project Editor. However, MinAS partiallyuses its own screens, which are overwritten using PCS 7 standard screens whenthe OS Project Editor is executed. In order to revert back to the typical MinAS userinterface, you will need to run the "CematProjectUpdate" tool.

Proceed as follows:Table 4-6

No. Action

1. If you have not done so yet, open the OS project.2. Open the OS Project Editor.

x Select the necessary screen resolution.x Click the "OK" button.



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No. Action

3. Launch the "CematProjectUpdate" tool. You can find the tool in the MinASinstallation folder. "D:\CEMAT_CS\CematProjectUpdate.exe"x Select the target project. By default, the OS project last opened by WinCC is

shown here.x Select the screen resolution identical to the one in the OS Project Editor and

confirm you selection by clicking the "Res" button.x Execute the OS project update by clicking the "Update OS Project" button.x Once the update has been successfully completed, you can close the tool.

4. Generate the header file for C scripts.x Open the "Global Script C" editor.x Execute the "Generate new header" menu command.

4.6 Launching the OS runtime

When you launch the runtime, you will be asked to authenticate yourself witha valid login.Here, you will enter the login "Operator" and the password "123456".

Figure 4-2



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Once you have successfully completed authentication, you can navigate betweenthe system sections using the area buttons.

Figure 4-3



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4.7 Initial state of the plant

Navigate to the "Crushing" plant area. This screen contains a concentratedgrouping of the demo project's functionalities.

Figure 4-4

When the AS program is restarted, the processing of material by the system isstopped. Simulation of the demo project is activated.In chapter "6 Further information", you can find more useful information foroperation.

The system objects are in the following state:

x Drives are off, and valves are closed and in both automatic mode andsimulation .

x The emergency stop and misalignment switches are not active and are insimulation .

x No route is selected.x The group has not been started.x The signaling installations for filling the primary crusher and the stockpile are

"red."



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The system objects have the following appearance:

Figure 4-5

(1) Motor stopped(2) Motor stopped with start interlock(3) Valve closed(4) Analog value display(5) Digital display (misalignment switch with warning and alarm signal)

On some objects, a message is already configured. This is indicated by the"memo" icon on the corresponding objects.

Figure 4-6

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In the control area for the group, the routes and the diagnostics, you will find thefollowing objects:x Group symbol for operating the plant sectionx Route symbol for selecting the material flow from the crusherx Route symbol for selecting the material flow from the stockpilex Symbol for the selection of the injection system on belt 1x Symbol for the selection of the injection system on belt 2

Figure 4-7

(1) The group is stopped and indicates that all connected objects are automaticmode .

(2) All routes are not deselected .

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5 Operating the demo project


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5 Operating the demo projectThe operation and functional properties of the demo project will be demonstratedwith the help of step-by-step instructions based on the following scenarios:x Establishing the system state using the object browserx Performing fault diagnostics before startup of the groups using "status call"

and the object list.x Starting and stopping plant areas (groups)x Faults in groups being started or already in operationx Integrated configuration of MinAS trendsx Performing plant maintenance using the "maintenance list"x MinAS alarm view with filter functions

5.1 Establishing the plant state using the object browser

ScenarioIn various situations, such as a shift change, it is necessary to quickly obtainan overview of the complete plant state. The MinAS global object browser isavailable as a powerful tool to help you achieve this. Filters allow you to quicklyachieve the desired information, for example: which objects had their statuschanged to "out of service", which objects are in maintenance mode, or whichobjects have a user note stored on them. From the list of results, you can quicklyswitch to the faceplate of the desired object, where you can view detailedinformation about the state of that particular object.

Conditions:The following conditions must be true for this scenario:x Some of the objects have an "out of service" status.

See chapter: "6.1.2 Changing the operating mode"x A note is already configured on some of the objects. By default, some of the

objects in the demo project already have notes.However, if the notes have been deleted, you will find information about howto restore them in chapter "6.1.3 Storing notes on objects".



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Operating stepsProceed as follows:

Table 5-1

No. Action

1. Navigate to the "Crusher" plant section.2. At the process screen, click on the "ObjectBrowser AS400" button to open the

dialog window.

3. Select the "Out of Service" option and confirm your selection by clicking theadjacent button with the green check mark.



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No. Action

4. The list of results then displays all objects whose status is "out of service".By double-clicking on a list entry, you can then open the faceplate of the desiredobject.

NoteThe entries are stored in the results list with a particular color. As can be seen inthe example, objects with the "out of service" status are highlighted in gray.Objects with a "simulation" status are shown with an orange background.

5. Click the "Memo active" button in the object browser. The list of results thendisplays all objects for which a note has been stored.

6. Open the faceplate of an object by double-clicking its entry in the results list.In the faceplate of the opened object, you can see in the status bar that there isa message for this object.



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No. Action

7. Switch to the "Memo" view. Here, you can view the stored message.

5.2 Performing fault diagnostics using "status call" andthe object list

ScenarioFor the troubleshooting of assigned objects, MinAS offers efficient tools todetermine the status according to the hierarchical structure of a plant section.In particular, these tools assist the user during the startup or stopping of plantsections.The "status call" is used for detailed fault diagnostics in order to display faults,alarms and interlocks of the assigned measuring points, drives and valves.This allows you to obtain a status from your system before starting it, even if theobjects have not yet triggered an alarm due to the fact that they are inactive.This additional function reduces the amount of time necessary for fault diagnosticsand makes it possible to directly switch to the particular objects affected from thelist of results.

Conditions:The following conditions must be true for this scenario:x The group is stopped (system standstill).x Some of the objects have an "out of service" status.

See chapter: "6.1.2 Changing the operating mode"x An emergency stop (rope switch) or a belt misalignment switch (misalignment

switch) has been triggered. See chapter: "6.1.1 Process simulation"



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Table 5-2

No. Action

1. You can already tell from the block icon that there is a fault in one of the groupobjects. However, because the system is not in operation, no alarm has been sentyet to the PCS 7 alarm logging system.

2. Open the faceplate for the route and switch to the "status call" view. Here, you cansee a preview of the message and react to the situation accordingly before startingup the conveyor belts and triggering a real alarm.



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No. Action

3. Switch to the "object list" view. Here, you will find all objects that belong to thegroup. Search for the objects that have an "out of service" status. These arehighlighted in gray.

4. By double-clicking one of the objects, you can open the related faceplate.Here, any notes that have been stored will indicate the reason for the status.



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No. Action

5. Change the status from "out of service" to "automatic" for all objects.



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5.3 Starting and stopping plant areas (groups)

ScenarioTechnological process stages, such as the transport of material via conveyor belts,flotation cells, or systems for grinding extracted ore, can be combined into groupswith MinAS. Operation and fault diagnostics are greatly simplified with the use ofgroups. Grouped drives and valves can be set to a particular status in a parallel orsequential manner with a simple mouse click. Fault conditions are displayed andanalyzed centrally in the group.

Conditions:The following conditions must be true for this scenario:x The objects are in automatic mode.

See chapter: "6.1.2 Changing the operating mode"x The group objects must be ready / there may not be any triggered alarms.

See chapter: "6.1.1 Process simulation"

Operating stepsProceed as follows:Table 5-3

No. Action

1. Select a route to start from within the group. To do this, open the faceplate for the"Feed from Crusher" route. Click the "Sel." button to select this route.



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No. Action

2. Open the faceplate for the group and start the group by clicking the "Start" button.

NoteThe startup of the group is indicated by the arrow in the group symbol.

3. The group startup passes through multiple phases.

Phase 1: "Time for startup warning":Length of time for the output of a signal indicating that the system is starting up.

Phase 2: "Waiting time":Length of time between the alarm signal and the system startup.

Phase 3: "Startup release time":The drives are started, valves are opened, etc. If any of the plant sections failto report operation once the startup time has expired, then a fault message isdisplayed and the group is stopped again.

Note:Operation of the group is indicated by the O in the group symbol.

12

3



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No. Action

4. In the plant process, the drives of the last conveyor belts are started first in order toavoid an accumulation of material. The last thing to be started is the drive for thecrusher. Once the crusher is up and running, the signaling installation for ore fillingswitches to green.

The block icon for the routes and the groups show the following status:x The "Start Feeding" is active.x The "Feed from Crusher" route is active.x The "Feed from Stockpile" route is deselected and locked (interlock).

5. To switch the route, open the faceplate for the "Feed from Stockpile" route and clickthe "Sel." button. In the block icon, the "P" indicates that this route has beenpreselected.



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No. Action

6. Deselect the currently active "Feed from Crusher" route. Open the faceplate andclick the "Desel." button. Because the route is currently still locked (interlock), onlythe color of the "S" icon changes from green to white. The "Feed from Crusher"route is still active.

7. Start the group again to apply the route change.



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No. Action

8. Once the startup sequence is complete, the process screen will show that thecrusher and the 1st conveyor belt were shut down and that the conveyor belt fromthe stockpile was activated instead. The signaling installation for the crusherindicates that no more material may be added.

9. To stop the system again, open the faceplate for the group and click the "Stop"button.

NoteThe shutdown of the group is indicated by the arrow in the group symbol.



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No. Action

10. Once the "shut down" process is complete, the system is once again in the originalstate.

5.4 Faults in groups being started or already in operation

ScenarioIf a fault occurs during operation of a system, the affected plant section is stopped.As a result, troubleshooting must be performed on the affected objects in order tosolve the problem. MinAS provides different functions that help the user keepdowntime as short as possible during troubleshooting.Together with the information view, the object list offers information about thestatus and process signals for all of the objects in a group.

Conditions:The following conditions must be true for this scenario:x The group is active or currently starting up.

See chapter: "5.3 Starting and stopping plant areas (groups)"x An emergency stop signal (e.g., RS_BC01_S4701) has been triggered.

See chapter: "6.1.1 Process simulation"

Figure 5-1



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Table 5-4

No. Action

1. An emergency stop was triggered in the area of the first conveyor belt, causing analarm to be triggered by the PCS 7 alarm logging system and to be displayed in thealarm line of the runtime interface. The block icons for the route and the group aremarked with an alarm icon. As a result of the alarm, the drive of the first conveyorbelt was stopped and locked to prevent a restart.

2. To determine the cause of the alarm, open the faceplate for the group and switchto the "object list" view. The red symbols in the list mark the object that triggeredthe system stop.



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No. Action

3. By double-clicking the list entry, you can open the related faceplate and use it toobtain detailed information.

4. Use the simulator block to reset the emergency stop signal again.See chapter: "6.1.1 Process simulation"

5. Before you can restart the faulty conveyor belt, you must acknowledge the currentfault and reset the conveyor belt drive again.You can acknowledge the fault using the acknowledgment button next to the PCS 7alarm line, in the PCS 7 alarm view or in the CEMAT alarm view.



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No. Action

6. The current fault on the drive can be reset in the faceplate. To do this, click the"Fault reset" button.

7. Start the group again by opening the faceplate and clicking the "Start" button.



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5.5 Integrated MinAS trend configuration

ScenarioWith the trend-configuration option integrated in MinAS, you can configurecustomized groups of trends and save them to be displayed again as desired.Trends provide the user with information about the operating state of the plantor the performance of individual components.You can easily active the trend configuration directly from the process screen byselecting the desire measuring values.

Conditions:No particular conditions are necessary for this scenario.


Table 5-5

No. Action

1. To access the trend group configuration dialog, click the unit of the desired analogvalue with the right mouse button. You can also add other values by right-clickingon the unit of the analog measuring point. The trend configuration dialog window willremain open during this step.Add the following analog values to the trend configuration:

(1) Material flow for conveyor belt 1(2) Material flow for conveyor belt 2(3) Raw material fill level

1

2

3



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No. Action

2. At the configuration dialog window for the trends, you can see the analog valuesselected, administer the groups and call the trend display.

(1) Selected analog values(2) Saved trend configurations(3) Button for calling the trend display

3. The trend display shows the tag values in different colors. The display can beswitched between current values and values from the archive.

(1) Online tags(2) Archived tags(3) Button for navigating through archived values(4) Button for displaying current values

1

2

3

1 2

3 4



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5.6 Performing plant maintenance using the "maintenancelist"

ScenarioFor drives and valves, MinAS offers additional information concerning preventivemaintenance and availability. Here, an MinAS maintenance view or the objectfaceplates will provide insight into the operating hours, starts, stops, stops withfaults, and downtime.The drives and valves can be configured using the following maintenance settings:x Fixed maintenance intervalx Maintenance after predetermined number of operating hoursx Maintenance after specific number of starts (motor) or openings and closings

(valve).This allows you to create statistics, e.g. for operating hours, stops or downtimedue to faults. In addition, the maintenance information can be used to derivemaintenance alarms or be made available to other external maintenance systemsin the block.

Conditions:No particular conditions are necessary for this scenario.




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Table 5-6

No. Action

1. Configure a service interval for a few motors and valves and start the maintenanceservice. To do this, open the faceplate for a motor or a valve and switch to the"maintenance" view. The button is located on the second level of the view buttons.This level can be activated by clicking the "..." button.

(1) Select the type of maintenance interval and configure the time or the numberof starts.

(2) Here, you can configure the time or the number of starts that will result inmaintenance being demanded.

(3) You can activate the maintenance function by clicking the "Start" button.

1

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No. Action

2. A maintenance demanded notification is indicated by the wrench icon . Detailedinformation can be found in the faceplate of the object requiring maintenance.

(1) Maintenance status of the object(2) Maintenance service status(3) Maintenance personnel status (manual maintenance)(4) Button for resetting the maintenance function

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2

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No. Action

3. You can obtain an overall status for all objects that have a configured maintenancefunction using the "CEMAT Maintenance List." You can open the overview in thedemo project by clicking the "Maintenance List" button.



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5.7 MinAS alarm view with filter functions

ScenarioThe messages and alarms in the system remain a crucial source of information fordetermining the system operating mode. The analysis of these alarms also enablesyou to draw conclusions about unexpected behavior from plant sections or theircomponents. For these tasks, MinAS offers the user an advanced alarm view withspecial functions that can be saved. The advanced alarm view is simple to handleand is used to provide selective information about the location and type of fault.

Conditions:At least one object has triggered an alarm in the PCS 7 alarm logging system.For this to be possible, the group must already be started when a fault occurs.See chapter: "6.1.1 Process simulation"


Table 5-7

No. Action

1. Click the button for the MinAS alarm view in the PCS 7 OS button menu.

2. Using the area buttons, you can show or hide the display for messages from thecorresponding plant area.



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No. Action

3. Additional filter settings are available if you switch the alarm view to the long-termarchive.

(1) Switch between the current and long-term archives; close the alarm view(2) Refresh the filter settings(3) Saving and loading filter settings(4) Additional filter settings for event, message tag, and message class

12 3 4

6 Further information


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6 Further information6.1 Application notes

6.1.1 Process simulation

In order to enable useful application despite a lack of connected hardware,a simulation was integrated. The simulator block allows the simulation of faultconditions, such as a misalignment of the belt, a triggered emergency stop, ora defective drive.You can activate or deactivate the simulation by clicking the "SimOn" button in the"Crushing" plant area. The hand icon opens the block for the simulated processsignals.

Figure 6-1



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At the opened faceplate, you can switch the binary signals on or off and adjustthe analog values for the fill levels and the material flow using the slider.To make it easier to locate the measuring point names, the following prefixes wereadded:x Drv: drivex Vlv: valvex RS: rope switch (emergency stop switch)x MS: misalignment switch

6.1.2 Changing the operating mode

To change the operating mode of a motor, a valve or a measuring point, proceedas follows:

Figure 6-2

(1) Open the faceplate for an object.(2) Click the button for changing the operating mode.(3) Select the new mode, e.g. "out of service."

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6.1.3 Storing notes on objects

You can store notes on the objects in the project. With the object browser, it is easyto find all of the objects that have a note. To add a note to an object, proceed asfollows:

Figure 6-3

(1) Open the faceplate for an object.(2) Switch to the "memo" view.(3) The "Note" tab contains a text field in which you can leave your message.(4) Save the text you have entered.

Once you have completed this, a note icon is displayed in the faceplate header.

1

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6.2 Tips and tricks

Trend groupsThere are different ways to operate the MinAS block icons for analog valueacquisition. The following possibilities are available to you:x Left mouse click:

The faceplate for the selected analog value is opened.x Right mouse click on the analog value:

A trend display is opened which shows the archived value with the limit valuesthat are currently set.

x Right mouse click on the unit of the analog value:The configuration dialog window is opened for the MinAS trend display.

Adjusting the OS screen resolutionThe standard PCS 7 tool for adjusting the screen resolution is the OS ProjectEditor. However, the Project Editor also replaces the special MinAS screens.To revert back to the normal MinAS interface after changing the resolution, youcan use the "CematProjectUpdate" tool.Perform the steps illustrated in chapter "4.5 Customizing the OS project."

Displaying the measuring point namesTo display the measuring point names at the process screen, you can use thefunction integrated in MinAS. To do this, click the following button:

Figure 6-4

7 Sources and links


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7 Sources and links

Table 7-1

Subject field Title\1\ Siemens Industry

Online Supporthttp://support.automation.siemens.com

\2\ Application page forthis entry

http://support.automation.siemens.com/WW/view/en/81723640

\3\ Minerals AutomationStandard

http://www.siemens.com/minas

\4\ Mining at IndustryOnline Support

http://support.automation.siemens.com/WW/view/en/63697570/136000

8 History

Table 8-1

Version Date Change

V1.0 11/2013 Publication

PCS 7 in the mining industry (Demo Project)Table of contentsWarranty and liability1 Overview2 Minerals Automation Standard / CEMAT2.1 MinAS philosophy2.2 The advantages of MinAS2.3 The operating methodology of MinAS2.4 Main features of MinAS2.5 MinAS blocks2.5.1 Drive functions2.5.2 Control/monitoring

3 Mining demo project3.1 Overview3.2 Process screens3.3 Plant area: Crushing3.3.1 Primary crusher3.3.2 Operator controls for groups, routes and maintenance3.3.3 Conveyor belts3.3.4 Stockpile

3.4 Operator controls3.4.1 Faceplates3.4.2 Object browser3.4.3 Integrated MinAS maintenance3.4.4 Integrated MinAS trend

4 Installation and startup of the demo project4.1 Installing of MinAS4.2 Installing the demo project4.3 Loading the AS program4.4 Changing the computer name4.5 Customizing the OS project4.6 Launching the OS runtime4.7 Initial state of the plant

5 Operating the demo project5.1 Establishing the plant state using the object browser5.2 Performing fault diagnostics using "status call" and the object list5.3 Starting and stopping plant areas (groups)5.4 Faults in groups being started or already in operation5.5 Integrated MinAS trend configuration5.6 Performing plant maintenance using the "maintenance list"5.7 MinAS alarm view with filter functions

6 Further information6.1 Application notes6.1.1 Process simulation6.1.2 Changing the operating mode6.1.3 Storing notes on objects

6.2 Tips and tricks

7 Sources and links8 History

81723640 minas demoproject en

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