DOCU MinAS PCS7 V82 en

Application example 09/2016
PCS 7 in the mining

industry (demo project)
SIMATIC PCS 7, Minerals Automation Standard / CEMAT
https://support.industry.siemens.com/cs/ww/en/view/81723640
Warranty and liability
Warranty and liability
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PCS 7 Demo project (mining)

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Table of contents
Table of contents
Warranty and liability................................................................................................... 2
1 Overview ............................................................................................................. 5
2 Minerals Automation Standard / CEMAT ......................................................... 6
2.1 The MinAS philosophy ......................................................................... 6
2.2 The advantages of MinAS .................................................................... 7
2.3 The MinAS operating methodology ...................................................... 8
2.4 Main features of the MinAS .................................................................. 9
2.5 MinAS blocks ...................................................................................... 10
2.5.1 Drive functions .................................................................................... 10
2.5.2 Control/monitoring .............................................................................. 11
2.5.3 Scalable production control ................................................................ 11
3 Mining demo project ........................................................................................ 13
3.1 General overview ............................................................................... 13
3.2 Process pictures ................................................................................. 15
3.3 "Crushing" system area ...................................................................... 18
3.3.1 Primary crusher .................................................................................. 19
3.3.2 Operator controls for groups, routes and maintenance ..................... 20
3.3.3 Conveyor belts ................................................................................... 21
3.3.4 Stockpile ............................................................................................. 21
3.4 Operator controls ................................................................................ 22
3.4.1 Faceplates .......................................................................................... 22

3.4.2 Object browser ................................................................................... 23
3.4.3 Integrated MinAS maintenance .......................................................... 24
3.4.4 Integrated MinAS trend ...................................................................... 24
4 Installation and commissioning of the demo project .................................. 25
4.1 Installing the MinAS............................................................................ 25
4.2 Installing the demo project ................................................................. 26
4.3 Loading the AS program .................................................................... 26
4.4 Adapting the computer name ............................................................. 27
4.5 Customizing the OS project................................................................ 28
4.6 Launching the OS runtime.................................................................. 29
4.7 Initial state of the system .................................................................... 30
5 Operating the demo project ............................................................................ 34
5.1 Establishing the plant state using the object browser ........................ 34
5.2 Performing error diagnostics using "Status call" and the object
list ....................................................................................................... 39
5.3 Starting and stopping system areas (groups) .................................... 43
5.4 Faults in groups being started or already in operation ....................... 49
5.5 Integrated MinAS trend configuration ................................................. 53
5.6 Performing system maintenance using the "Maintenance list" .......... 55
5.7 MinAS alarm view with filter functions ................................................ 58
5.8 MinAS recipe management ................................................................ 60
6 Further information ......................................................................................... 82
6.1 Application notes ................................................................................ 82
6.1.1 Process simulation ............................................................................. 82
6.1.2 Changing the operating mode ............................................................ 83
6.1.3 Storing messages on objects ............................................................. 84
6.2 Tips and tricks .................................................................................... 84
7 References ....................................................................................................... 86

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Table of contents
8 History............................................................................................................... 86

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1 Overview
1 Overview
Application objective
This document provides you with an overview of the functional scope of the
Minerals Automation Standard (MinAS), as well as a description for commissioning
and functional properties of the demo project.
Core contents of the application

The following key aspects are covered in this application:
Minerals Automation Standard / CEMAT
Installation and commissioning of the demo project
Operation of the demo project based on the example of typical operating
scenarios
Validity
The software requirements for running the demo project are as follows:
SIMATIC PCS 7 V8.2 with a valid license or time-limited trial license
Minerals Automation Standard / CEMAT V8.2 with a valid license or time-
limited demo mode
Note You can find information about the product at:

Minerals Automation Standard / CEMAT
Contact: cemat.industry@siemens.com

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2 Minerals Automation Standard / CEMAT
2.1 The MinAS philosophy

The Siemens Industry Automation division developed the Minerals Automation
Standard / CEMAT V8.2 to meet the special requirements 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 expanded
to include specific automation functions for mining applications.
The Minerals Automation Standard / CEMAT V8.2 (hereinafter abbreviated as
"MinAS") is a product for use in the mining and cement industry sectors.
2.1 The MinAS philosophy

MinAS is more than just a library containing a few specific modules for the mining
industry. It also represents a complete philosophy:
How are devices such as conveyor belts, crushers and grinders, or even the
entire process configured?
How are processes in the mining industry operated?
How can diagnostics be performed quickly and simply in order to keep
unplanned plant downtime at a minimum in case of error?
As an integrated solution, the Minerals Automation Standard focuses on:
Efficient engineering and quality
Improved operation and monitoring

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2.2 The advantages of MinAS
2.2 The advantages of MinAS

Configuration
The plant engineer can benefit from many advantages during process
configuration:
A tested and well-documented library of software modules for functions in
the mining industry
Technology-oriented configuration to achieve the highest software quality,
even without programming knowledge
Standard interface between the software modules to minimize faults
Integrated simulation functions for engineering and factory acceptance
tests (FAT)
Bulk data processing
Operation
MinAS enables users to handle the system simply and intuitively thanks to:
Easy-to-understand symbols
Starting and stopping of entire process groups with a simple mouse click
Easy route selection
Efficient fault diagnostics

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2.3 The MinAS operating methodology
2.3 The MinAS operating methodology

Among other things, the Minerals Automation Standard operating philosophy
is also based on different operating modes:
"Automatic"
"Manual"
"Local"
"Out of service"
Advantages for operations management can be seen, for instance, in typical

applications 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 mode
During normal operation, all drives in a technological system area are started and
stopped in "Automatic mode." The start or stop command is then triggered by the
start/stop sequence or by the configured process conditions.
Manual mode
In "Manual mode", the drives can be started and stopped individually at the
operating station. The "Manual mode" can be specifically activated or deactivated
for each individual drive or for groups.
Local mode
In this operating mode, interlocks are only active to a limited extent. The application
areas for this operating mode are: commissioning, tests and maintenance work.
Out of service (maintenance)

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

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2.4 Main features of the MinAS
2.4 Main features of the MinAS

MinAS provides an extensive collection of preconfigured, tested and well
documented mining-specific library elements in order to offer support in various
different areas of application in the minerals industry (mining and cement).
To do this, it uses PCS 7 standard functions such as CFC configuration.
For each function block in the library, there is a block icon and corresponding
faceplate with a consistent look and feel. The icon and faceplate are automatically
generated for the graphical user interface and only arranged at the process
screen in combination with statistical graphic elements. These library elements
and templates reduce engineering time and improve engineering quality.
The essential functions are briefly described below:
Group control
Group elements enable the representation of a system area's operating state and
provide detailed error diagnostics for all related objects.
All drives, displays and measured value of a system area are connected by a group
element. This group provides summarized notes about faults and alarms and
interrupts or prevents the starting procedure in case of error.
Global object browser

The 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 list
The object list for a group shows the status of all related drives, measured values
and process signals. In addition, drives can also display measured values and
process signals assigned to them.
Information view
Additional information (links, documents, drawings, videos) can be linked to each
object. Information can be added during operation.
Integrated MinAS trend

Simple configuration of a trend display by selecting analog values at the process
screen during operation. The trend display can be saved and linked to a process
area.

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2.5 MinAS blocks
Integrated MinAS maintenance

For drives and valves, additional information about maintenance and availability
can be configured. A maintenance view gives an overview of operating hours,
starts, stops with faults, and downtime.
Diagnostics view
List of all relevant block inputs and outputs with the corresponding status. There is
also the option to change some of the block parameters directly in the diagnostics
view.
MinAS alarm view

Up to 10 customized filters can be created for process messages. Filter types
include: system area, measuring point, message type, message text, date, ...
In addition, "Smart" filters make it possible to display alarms for active objects only.
2.5 MinAS blocks

A detailed and complete description of the functions can be found in the product
description. All of the blocks from the SIMATIC PCS 7 standard libraries can also
be used.
The blocks relevant for this demonstration are listed below.
2.5.1 Drive functions
C_DRV_1D
The C_DRV_1D block is used to control drives with one direction.
C_DRV_2D
The C_DRV_2D block is used to control drives with two directions.
C_VALVE
The C_VALVE block is used to control valves.
C_SIMOS
The C_SIMOS SIMCODE adapter block connects
CEMAT drive blocks with SIMCODE.
C_ANNUN8
At the C_ANNUN8 block, up to 7 binary process signals can be displayed. If one
of the process signals experiences a malfunction, then a fault or alarm message
is generated.
C_ANNUNC
At the C_ANNUNC block, one binary process signal can be displayed. If the
process signal experiences a malfunction, then a fault or alarm message is
generated.

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2.5 MinAS blocks
C_MEASUR
The C_MEASUR block can be used to read analog process data and monitor up
to 8 limit values. It is possible to configure 4 of the limit values for the generation
of fault/alarm messages. The other 4 limits are switching limits and do not generate
any alarms.
C_PROFB
The C_PROFB block can monitor binary or analog process feedback signals from
a drive, such as rotational speed or pressures.
If there is a fault in the process feedback, the drive will be stopped via a protective
interlock.
2.5.2 Control/monitoring
C_GROUP
The C_GROUP block is a higher-level module used to switch technologically
related devices on and off in automatic mode.
The group block allows the visualization of operating states for a plant unit in
the form of a status display and detailed fault diagnostics (status call).
C_ROUTE
The C_ROUTE block is a module for selecting transport routes within a group.
C_SELECT
The C_SELECT block can be used for every type of selection function. In contrast
to the C_ROUTE block, it does not offer fault diagnostics.
2.5.3 Scalable production control
C_P_MAT
The C_P_MAT block is an element for CEMAT MinAS Scalable Production Control.
This block can manage up to 24 storage locations for products or raw materials.
The operator can assign materials to the storage locations at execution time.
C_P_MGR
The C_P_MGR block is the central element of the CEMAT MinAS Scalable
Production Control. This block can manage 25 recipes plus an additional recipe
so called "Final recipe" (FR, recipe 99).
C_PD_AR
The C_PD_AR (Absolute, REAL) block is the data distributer of the CEMAT MinAS
Scalable Production Control for the C_PM_AR recipe module. The block has the
setpoint outputs for the recipe module of the active recipe.
C_PD_RTR
The block C_PD_RTR (Relative, Totalizing, REAL) is the data distributor of the
CEMAT MinAS Scalable Production Control for the recipe module C_PM_RTR.
The block has setpoint outputs for the recipe module of the active recipe.

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2.5 MinAS blocks
C_PM_AR
The block C_PM_AR (Absolute, REAL) is a recipe module of the CEMAT MinAS
Scalable Production Control. The module has up to predefined 8 setpoints as
absolute values (for instance, as revolutions per minute for a speed setpoint).
All values are of the REAL type.
C_PM_RTR
The block C_PM_RTR (Relative, Totalizing, REAL) is a recipe module for the
CEMAT MinAS Scalable Production Control. The module has up to 8 setpoints
of a reference size (RV) given in percent. The first setpoint cannot be changed
by the operator and is always the difference between 100% and the sum of
setpoints 2 to 7. All values are of the REAL type.

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3 Mining demo project
3.1 General overview

The mining demo project illustrates the different process stages of a typical mining
system and its plant hierarchy in the form of an overview.
In the process, the basic functionality and operation of MinAS are explained using
the example of the "Primary crushing" plant unit.
The MinAS demo project is divided into an AS section and an OS section.
AS section
In the "Primary crushing" plant unit of the AS program, the logic is configured for
a crusher, conveyor belts and dust collectors. The program contains blocks for the
acquisition of analog and digital data, blocks for controlling motors and valves, and
the blocks for route and group functions. If no process connection is available, the
signals and process data can be simulated with the help of a special test block.

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OS section
The demo project contains multiple process screens that are intended to clarify the
project using the example of a processing plant (e.g., for copper). The function of
a crusher, including the removal of the raw material by conveyor belts is visualized
in the "Crushing" system area, and the basic elements of the recipe for a cement
grinding with SPC are realized by way of example.
These system areas are configured for the demonstration of MinAS.
The remaining screens are static and do not have an individual function.

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3.2 Process pictures

Using the plant hierarchy, you can navigate between the overview, crushing,
grinding, rougher, cleaner, tailings and SPC example screens in the OS runtime.
These screens are briefly described in the following table:
Description Screen
Process pictures
Here, you are given an overview of

the system and can switch directly
to the desired plant unit using the
buttons.
Crushing
(can be operated by user)
This plant unit provides

a visualization of a crusher and
the belts that remove the material.
After passing through the crusher,
the mined ore is fed to the next
process via two conveyor belts:
one for coarse material and one
for fine material. When the crusher
is at a standstill, ore can be fed
to the grinder from a stockpile.
This screen contains the
functionality of the demo project.
It will be discussed in greater detail
at a later point in this document.

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Description Screen
Grinding
The screen shows an example of

an overview for the grinding circuit.
The ore is first ground in an SAG
mill and is then ground in a ball mill
in a second stage.
Rougher
This part of the system shows the

first stage of a flotation process,
which consists of a line of roughers
and an additional mill integrated in
the circuit.
Cleaner
Here, the second flotation stage is

visualized together with a cleaning
system and a filter press.

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Description Screen
Tailings
The "Tailings" area is an example

of a screen for the recovery of
process water and removal of
residual stone.
SPC example
(can be operated by user)
This picture shows an example of

the recipe management with three
recipes for three types of cement.
The SPC material manager

enables flexible assignment of
materials to storage locations.

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3.3 "Crushing" system area

This process screen contains the functionality of the demo project. Here, you can
open faceplates, change the status of objects, select routes, start and stop groups,
etc. Detailed operation is explained in chapter "5 Operating the demo project" by
means of different scenarios.
2
1
4
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 ore 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 hopper
and the subsequent screening.
3
1. Signaling installation for adding more raw material

2. Fill level of raw material
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.
6
1
7
2
8
3
5
1. Starts or stops the process of the selected route

2. Route selection crusher
3. Route selection stockpile
4. Control of the injection system on belt 1
5. Control of the injection system on belt 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 conveyor
belt. The finer material is taken directly to the grinder on the second conveyor belt.
1 2
4
1. Dust filter
2. Injection system
3. Belt conveyor 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 material
feed using the route selection.
1. Signaling installation for filling from the stockpile

2. Fill level of the stockpile
3. Belt conveyor drive

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3.4 Operator controls

3.4.1 Faceplates
The system is operated using block icons and the related faceplates.
The design and functionality of the icons and faceplates of MinAS are based on
the PCS 7 Advanced Process Library. By clicking on a block icon with the left
mouse button, you can open the related faceplate. Some icons, such as an analog
value measuring point, feature special functions that can be displayed by clicking
the right mouse button. The following views are available for all faceplates:
Standard
Diagnostics
Alarms and messages
Information
Presets for the PLC module (bits feature)
Additional views are available depending on the object, for instance:

Object list
Curve view (trends)
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 of
the system objects throughout the entire OS project. You can thus display all of
the objects that have a particular status. You can select from the following options:
Objects independent from the Master feature
Interlock bypass
Message available
Power management active
Rapid stop
Service necessary
Object in "Manual" operating mode
Object in "Local" operating mode
Object in "Out of service" operating mode
Object in simulation
The displays for the objects with the "Manual," "Local," "Out of service" and
"Simulation" operating modes can be combined.

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3.4.3 Integrated MinAS maintenance
Additional information can be used to configure drives and valves for preventive
maintenance. Here, a maintenance view or the object faceplates will provide
insight into the operating hours, starts, stops, stops with faults, and downtime.
3.4.4 Integrated MinAS trend

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

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4 Installation and commissioning of the demo project
4.1 Installing the MinAS
4 Installation and commissioning of

the demo project
4.1 Installing the MinAS
System requirements
Hardware
AS PCS 7 CPU 410-5H
ES/OS In compliance with the current PCS 7 specification
Table 4-1
Software
ES/OS SIMATIC PCS 7 V8.2
ES/OS Minerals Automation Standard / CEMAT V8.2
Installation
To install MinAS, you require administrator rights. The target directory is always
"D:\CEMAT_CS". No other directory should be selected.
During installation, you will be asked to select a project code. Select "CEMAT
AS OS 001 Minerals" for the Minerals Automation Standard. Additional project
codes can be found in the product's readme file.

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4.2 Installing the demo project
4.2 Installing the demo project

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

2. Retrieve the Demo Project.
Select the menu command "File > Retrieve...".
Navigate to the storage path containing the "MinAS_demo.zip" file and
open the file.
3. Open the retrieved project.
4.3 Loading the AS program

The demo project is configured so that you can use PLCSIM as the automation
system. If you would like to load the program in a real automation system, you
may need to make adjustments to the hardware configuration and the WinCC
connection configuration.
1. Start PLCSIM
Start PLCSIM by clicking the "Simulation on/off" button in the SIMATIC

Manager button bar.
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 Adapting the computer name
4.4 Adapting the computer name

When opening the OS project, you will receive a note indicating that the configured
server is not available.
In order to start the OS runtime, you need to make a one-time change to the
computer name in the project. Proceed as follows:
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
4.5 Customizing the OS project

If you would like to change the resolution of the OS project to match the screen
resolution of your monitor, you will need to follow a few steps. The PCS 7 standard
screens can be adjusted using the OS Project Editor. However, MinAS partially
uses its own screens, which are overwritten using PCS 7 standard screens when
the OS Project Editor is executed. In order to revert back to the typical MinAS user
interface, you will need to run the "CematProjectUpdate" tool.
Proceed as follows:
1. If you have not done so yet, open the OS project.
2. Open the OS Project Editor.
Select the necessary screen resolution.
Click the "Apply" button.

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4.6 Launching the OS runtime
3. Start the "CematProjectUpdate" tool. You can find the tool in the MinAS
installation folder. "D:\CEMAT_CS\CematProjectUpdate.exe"
Select the target project. The OS project last opened by WinCC is shown
here by default.
Select the screen resolution identical to the one in the OS Project Editor
and confirm your selection by clicking the "Res" button.
Start the OS project update by clicking the "Update OS Project" button.
Once the update has been successfully completed, you can close the tool.
4. Generate the header file for C scripts.

Open the "Global Script C" editor.

Execute the "Generate new header" menu command.
4.6 Launching the OS runtime

When you start the runtime, you will be asked to connect with a valid login name.
Enter the login name "Operator" and password "123456".

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4.7 Initial state of the system
Once you have successfully completed authentication, you can navigate between
the plant units using the section buttons.

Navigate to the "Crushing" system area. This screen focuses on the demo project's
functionalities.

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When the AS program is restarted, the processing of material by the system

is stopped. Simulation of the demo project is activated.
In chapter "6 Further information", you can find more useful information for
operation.
The system objects are in the following state:

Drives are off, and valves are closed and in Automatic mode .
The emergency stop and misalignment switches are not active and are in
Stop mode.
No route is selected.
The group has not been started.
The signaling installations for filling the primary crusher and the stockpile are
"red."
The system objects have the following appearance:
2
3
4
1. Motor stopped
2. Valve closed
3. Analog value display
4. Digital display (misalignment switch with warning and alarm signal)

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On some objects, a message is already configured. This is indicated by the

"Memo" icon on the corresponding objects.

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In the control area for the group, the routes and the diagnostics, you will find the
following objects:
Group symbol for operating the plant unit
Route symbol for selecting the material flow from the crusher
Route symbol for selecting the material flow from the stockpile
Symbol for the selection of the injection system on belt 1
Symbol for the selection of the injection system on belt 2
2
1. The group is stopped and indicates that all connected objects are in Automatic
mode .
2. All routes are deselected .

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5 Operating the demo project
5.1 Establishing the plant state using the object browser

The operation and functional properties of the demo project will be demonstrated
by means of step-by-step instructions based on the following scenarios:
Establishing the plant state using the object browser
Performing error diagnostics before startup of the groups using "Status call"
and the object list.
Starting and stopping system areas (groups)
Faults in groups being started or already in operation
Integrated configuration of MinAS trends
Performing system maintenance using the "Maintenance list"
MinAS alarm view with filter functions
MinAS recipe management

Scenario
In various situations, such as a shift change, it is necessary to quickly obtain an
overview of the complete plant state. The MinAS global object browser is available
as a powerful tool to help you achieve this. Filters allow you to quickly achieve the
desired information, for instance: which objects had their status changed to "Out
of service", which objects are in service mode, or which objects have a user note
stored on them. From the list of results, you can quickly switch to the faceplate of
the desired object, where you can view detailed information about the state of that
particular object.
Requirement
The following conditions must be met for this scenario:
Some of the objects have an "Out of service" status.
See Chapter: "6.1.2 Changing the operating mode"
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 how
to restore them in chapter:
"6.1.3 Storing messages on objects".

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Operation steps
Proceed as follows:
1. Navigate to the "Crusher" plant unit.
2. At the process screen, click on the "ObjectBrowser AS401" button to open
the dialog window.
3. Select the "Out of Service" option and confirm your selection by clicking the
adjacent button with the green check mark.

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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
desired object.
Note The entries are stored in the results list with a particular color. As can be seen
in the example, objects with the "Out of Service" status are highlighted in gray.
Objects with a "Simulation" status are shown with an orange background.

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5. Click the "Memo active" button in the object browser. The list of results then
displays 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
is a message for this object.

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

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5.2 Performing error diagnostics using "Status call" and the object list
5.2 Performing error diagnostics using "Status call" and

the object list
Scenario
For the troubleshooting of assigned objects, MinAS offers efficient tools to
determine the status according to the hierarchical structure of a plant unit. In
particular, these tools assist the user during the startup or stopping of plant units.
The "Status call" is used for detailed error 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
the objects 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 diagnostics
and makes it possible to directly switch to the particular objects affected from
the list of results.
Requirement
The group is stopped (system standstill).
Some of the objects have an "Out of Service" status.
An emergency stop (rope switch) or a belt misalignment switch (misalignment

switch) has been triggered. See Chapter: "6.1.2 Changing the operating
mode".

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Operation steps
Proceed as follows:
1. You can already tell from the block icon that there is a fault in one of the group
objects. However, because the system is not in operation, no alarm has been
sent yet to the PCS 7 alarm logging system.

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2. Open the faceplate for the route and switch to the "Status call" view. Here, you
can see a preview of the message and react to the situation accordingly before
commissioning the conveyor belts and triggering a real alarm.
3. Switch to the "Object list" view. Here, you will find all objects that belong to the
group. Search for the objects that have an "Out of Service" status. These are
highlighted in gray.

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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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5.3 Starting and stopping system areas (groups)
5. Change the status from "Out of Service" to "Automatic" for all objects.

Scenario
Technological process stages, such as the transport of material via conveyor belts,
flotation cells, or systems for grinding extracted ore, can be combined into groups
with MinAS. Operation and error diagnostics are greatly simplified with the use of
groups. Grouped drives and valves can be set to a particular status in a parallel or
sequential manner with a simple mouse click. Fault conditions are displayed and
analyzed centrally in the group.
Requirements
The objects are in Automatic mode.
The group objects must be ready / there may not be any triggered alarms.
See Chapter: "6.1.1 Process simulation"

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Operation steps
Proceed as follows:
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.
2. Open the faceplate for the group and start the group by clicking the "Start"
button.
Note The startup of the group is indicated by the arrow in the group symbol.

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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 units fail to report
operation once the startup time has expired, then a fault message is displayed and
the group is stopped again.
Note Operation of the group is indicated by the O in the group symbol.


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4. In the system process, the drives of the last conveyor belts are started first
in order to avoid an accumulation of material. The last thing to be started is
the drive for the crusher. Once the crusher is up and running, the signaling
installation for ore filling switches to green.
The block icon for the routes and the groups show the following status:
The "Start/Stop Feeding" group is active.
The "Feed from Crusher" route is active.
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
click the "Sel." button. In the block icon, the "P" indicates that this route has
been preselected.

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6. Deselect the currently active "Feed from Crusher" route. Open the faceplate
and click the "Desel." button. Since the route is currently still locked (interlock),
only the color of the "S" icon changes from green to white. The "Feed from
Crusher" route is still active.
7. Restart the group to apply the route change.

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8. Once the startup sequence is complete, the process screen will show that the
crusher and the 1st conveyor belt were shut down and that the conveyor belt
from the storage silo was activated instead. The signaling installation for the
crusher indicates that no more material may be added.
9. To stop the system again, open the faceplate for the group and click the "Stop"
button.
Note The shutdown of the system is indicated by the arrow in the group symbol.

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5.4 Faults in groups being started or already in operation
10. Once the "shut down" process is complete, the system is once again in the
original state.

Scenario
If a fault occurs during operation of a system, the affected plant unit is stopped.
As a result, troubleshooting must be performed on the affected objects in order
to solve the problem. MinAS provides different functions that help the user keep
downtime as short as possible during troubleshooting.
Together with the information view, the object list offers information about the
status and process signals for all of the objects in a group.

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Requirement
The group is active or currently starting up.
See Chapter: "5.3 Starting and stopping system areas (groups)"
An emergency stop signal (e.g., RS_BC01_S4701) has been triggered.
See Chapter: "6.1.1 Process simulation".
Operation steps
Proceed as follows:
1. An emergency stop was triggered in the area of the first conveyor belt, causing
an alarm to be triggered by the PCS 7 alarm logging system and to be
displayed in the alarm line of the runtime interface. The block icons for the
route and the group are marked with an alarm icon. As a result of the alarm,
the drive of the first conveyor belt was stopped and locked to prevent a restart.

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2. To determine the cause of the alarm, open the faceplate for the group and
switch to the "Object list" view. The red symbols in the list mark the object
that triggered the system stop.
3. By double-clicking the list entry, you can open the related faceplate and use it
to obtain detailed information.

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4. Use the simulator block to reset the emergency stop signal again.
5. Before you can put the faulty conveyor belt back into operation, you must
acknowledge the current fault and reset the belt conveyor drive again.
You can acknowledge the fault using the acknowledgment button next to the
PCS 7 alarm line, in the PCS 7 alarm view or in the CEMAT alarm view.
6. Start the group again by opening the faceplate and clicking the "Start" button.

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5.5 Integrated MinAS trend configuration

Scenario
With the trend-configuration option integrated in MinAS, you can configure
customized groups of trends and save them to be displayed again as desired.
Trends provide the user with information about the operating state of the system
or the performance of individual components.
You can easily activate the trend configuration directly from the process screen
by selecting the desired measured values.
Requirement
There are no particular requirements for this scenario.
Operation steps
Proceed as follows:
1. To access the trend group configuration dialog window, click the unit of the
desired analog value with the right mouse button. You can also add other
values by right-clicking on the unit of the analog measuring point. The trend
configuration dialog window will remain open during this step.
Add the following analog values to the trend configuration:
(1) Conveyor belt 1 material flow

(2) Conveyor belt 2 material flow
(3) Raw material fill Level

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2. At the configuration dialog window for the trends, you can see the analog
values selected, administer the groups and call the trend display.
1 3
2
(1) Selected analog values

(2) Saved trend configurations
(3) Button for starting the trend display
3. The trend display shows the tag values in different colors. The display can be
switched between current values and values from the archive.
1 2
4
3

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5.6 Performing system maintenance using the "Maintenance list"
(1) Online tags

(2) Archive tags
(3) Button for navigating through archived values
(4) Button for displaying current values
5.6 Performing system maintenance using the

"Maintenance list"
Scenario
For drives and valves, MinAS offers additional information concerning preventive
maintenance and availability. Here, a MinAS maintenance view or the object
faceplates will provide insight into the operating hours, starts, stops, stops with
faults, and downtime.
The drives and valves can be configured using the following maintenance settings:
Fixed maintenance interval
Maintenance after predetermined number of operating hours
Maintenance after specific number of starts (motor) or openings and closings
(valve).
This enables the creation of statistics, e.g. for operating hours, stops or downtime
due to faults. In addition, the maintenance information can be used to derive
maintenance alarms or be made available to other external maintenance systems

in the block.
Requirement

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Operation steps
Proceed as follows:
1. Configure a service interval for a few motors and valves and start the
maintenance service. 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.
2
(1) Select the type of maintenance interval and configure the time or the number
of starts.
(2) Here, you can configure the time or the number of starts that will result in
maintenance being demanded.
(3) You can activate the maintenance function by clicking the "Start" button.

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2. A maintenance demanded notification is indicated by the spanner icon .

Detailed information can be found in the faceplate of the object requiring
maintenance.
2
3
4
(1) Maintenance status of the object

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

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5.7 MinAS alarm view with filter functions
3. You can obtain an overall status for all objects that have a configured
maintenance function using the "CEMAT Maintenance List." You can open
the overview in the demo project by clicking the "Maintenance List" button.

Scenario
The messages and alarms in the system remain a crucial source of information for
determining the system operating mode. The analysis of these alarms also enables
you to draw conclusions about unexpected behavior from plant units or their
components. For these tasks, MinAS offers the user an advanced alarm view with
special functions that can be saved. The advanced alarm view is simple to handle
and is used to provide selective information about the location and type of fault.
Requirement
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.
Operation steps
Proceed as follows:
1. Click the button for the MinAS alarm view in the PCS 7 OS key area.

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2. Using the area buttons, you can show or hide the display for messages from
the corresponding system area.
3. Additional filter settings are available if you switch the alarm view to the long-
term archive.
2 3 4
(1) Switch between the current and long-term archives; close the alarm view
(2) Refresh the filter settings
(3) Save and load filter settings
(4) Additional filter settings for event, message tag, and message class

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5.8 MinAS recipe management

Scenario
The main part of cement production is the grinding process, where the clinker base
material is ground according to different recipes together with additives such as fly
ash, gypsum and lime.
The SPC blocks in CEMAT MinAs V8.2 enable a recipe-controlled production
process for manufacturing various types of cement.
The following example shows the basic functionalities for the recipe management
of a cement grinding plant using SPC.
Recipe management with 3 recipes (for 3 cement types)

2 recipe modules for assignment of setpoint parameters (one "Absolute REAL"
and one "Relative Totalizing REAL")
Materials management for feed hoppers 1 to 3 (clinker, gypsum and fly ash)
Requirement

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Operation steps
Proceed as follows:
1. Navigate to the plant unit "SPC Example".
2. Click on the blue "Recipe Management" button in the process picture to open
the SPC Recipe Manager dialog window.
3. Here you can modify recipes and assign parameters for delay time. The active
recipe is marked with a green color.

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4. Click on the recipe name "CEM IV 52,5 R" and confirm your choice with "OK".
No delay time is configured in the example for this recipe change.

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5. The recipe "CEM IV 52,5 R" is now active and marked with a green
background color.

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6. Switch back to the recipe "CEM I 32,5 R" and confirm your selection with OK.
Since there is a predefined delay time for the recipe "CEM I 32,5 R", the recipe
change is only completed after the delay time elapses. The operator can skip
this change-over delay by clicking the Skip button.

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7. You can see all the modules of all recipes by clicking the "Object list".

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8. In "Object list" you can see all the modules and you can double-click an entry
to access the desired module. Double-click on the module "C_PM_RTR".
This module contains the desired quantity of fresh material and the distribution
(in percent) of the individual components: clinker, gypsum and fly ash.

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9. In this dialog window, you can change the setpoints for gypsum or fly ash,
whereby the clinker quantity is adjusted automatically.
Enter 5 % for gypsum and press the "Enter" button.
Note Note: The setpoints are entered in C_PM_RTR as a percentage of a reference

size (fresh material, in this case).

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10. Then click "OK" to confirm your entry.


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11. Now, click on the "Diagnostics" button.

12. In this dialog window, you to change the setpoint limits.

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13. Close the C_PM_RTR dialog window and double-click on the C_PM_AR
module. This module includes all setpoints for rotational speeds and positions
for units required for cement grinding.
14. Navigate to the "Diagnostics" view to change sample setpoints.

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15. The setpoints changed by the operator are marked with a blue font color and
must be additionally confirmed because there is no other way for multiple
changes to be applied concurrently.
For instance, the setpoint 80 for the separator and press the "Enter" button.
16. To confirm your setpoint change, click OK.


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17. As a result, you will see that the new setpoint is accepted by the module.
18. Navigate to the "SPC Example" plant unit and click on the blue "Feeding
hoppers" button in the process picture to open the SPC Material Manager
dialog window.

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19. In this example, this SPC Material Manager is for materials management
of feed hoppers 1 to 3 (clinker, gypsum and fly ash)
The setpoint value specifications for the material scales are supplied by
the Material Manager because the assignment (feed hopper to material)
can change and therefore the right scale is always addressed.
The operator can assign materials to the storage locations during execution
time.

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20. Switch to "Diagnostics" view. Here you can assign materials to the various
storage locations as long as the actual value on the scale
(= conveyed material) is zero, i.e., the storage location is not used.

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21. Here you can see the assignment of material to the storage locations.
The selection keys are not released for as long as material is being conveyed.

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22. Switch the scale WF_H02 to the manual operating mode. Please note that at
the current point in time, the setpoint for fly ash (=1.2 t/h) is issued to the scale
of Bunker 2 and the setpoint for gypsum (=2.8 t/h) is issued to the scale of
Bunker 3.

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23. Stop the motor.
24. Also set the scale WF_H03 to the manual operating mode and stop the motor.

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25. Then you can change the material assignment of these two storage locations.

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26. Assign the gypsum material to storage location Fresh_Feed_H02 (=Bunker 02)
and the fly ash material to Fresh_Feed_H03 (=Bunker 03) and confirm your
selection with OK.

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27. Click the "On" button to start the motor.

28. Switch to Automatic mode.
Also start the WF_H03 motor and switch to Automatic mode.

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29. Now you can see that the setpoints for gypsum and fly ash are supplied in
reverse order (i.e., the right way) to the scale.
The materials management for cement silos 1 to 5 is only for display purposes
in the process picture and has no further function in the example project.

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6 Further information
6.1 Application notes
6.1.1 Process simulation
In order to allow you test a project properly even without connected hardware,
CEMAT has an internal simulation that is only active during the sequence test.
For the purpose of this demo project, the sequence Test Mode has already been
activated in the system chart SYSPLC01.
The following functions can be executed in Sequence Test Mode:
Save
Load
Pause (or Hold)
The hold function serves for freezing the state of all CEMAT objects.
The current state of all CEMAT blocks is saved by clicking the Save button.
Load is used for loading the last saved state.
The Diagnostics view of the CEMAT object faceplates enables you to influence
the hardware-related block inputs.

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6.1.2 Changing the operating mode
To change the operating mode of a motor, a valve or a measuring point, proceed

as follows:
1. Open the faceplate of an object.

2. Select the "Out of Service" mode.

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6.2 Tips and tricks
6.1.3 Storing messages on objects
You can store messages on the objects in the project. With the object browser, it is
easy to find all of the objects that have a message. To add a message to an object,
proceed as follows:
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 message icon is displayed in the faceplate
header.
6.2 Tips and tricks

Trend groups
There are different ways of operating the MinAS block icons for analog value
acquisition. You have the following options:
Left mouse click:
The faceplate for the selected analog value is opened.
Right mouse click on the analog value:
A trend display is opened which shows the archived value with the limit values
that are currently set.
Right mouse click on the unit of the analog value:
The configuration dialog window is opened for the MinAS trend display.

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6.2 Tips and tricks
Adjusting the OS image resolution

The standard PCS 7 tool for adjusting the image resolution is the OS Project
Editor. However, the Project Editor also replaces the special MinAS screens.
To revert back to the normal MinAS interface after changing the resolution,
you can use the "CematProjectUpdate" tool.
Perform the steps illustrated in chapter "4.5 Customizing the OS project".
Displaying the measuring point names

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

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7 References
7 References
Table 7-1
Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Download page of this entry
https://support.industry.siemens.com/cs/ww/en/view/81723640
\3\ Minerals Automation Standard

http://www.siemens.com/minas
\4\ Mining industry in the Industry Online Support

https://support.industry.siemens.com/cs/ww/en/ps/21155/ae
8 History
Table 8-1
Version Date Change

V1.0 Feb. 2014 First edition
V2.0 Sept 2016 Updating to PCS 7 V8.2 and MinAS / CEMAT V8.2

Entry ID: 81723640, V2.0, 09/2016 86

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Application example 09/2016

PCS 7 in the mining

Warranty and liability

PCS 7 Demo project (mining)

3.4.1 Faceplates .......................................................................................... 22

PCS 7 Demo project (mining)

PCS 7 Demo project (mining)

Core contents of the application

Note You can find information about the product at:

PCS 7 Demo project (mining)

2 Minerals Automation Standard / CEMAT

2.1 The MinAS philosophy

PCS 7 Demo project (mining)

2.2 The advantages of MinAS

Efficient fault diagnostics

PCS 7 Demo project (mining)

2.3 The MinAS operating methodology

Advantages for operations management can be seen, for instance, in typical

Out of service (maintenance)

PCS 7 Demo project (mining)

2.4 Main features of the MinAS

Global object browser

Integrated MinAS trend

PCS 7 Demo project (mining)

Integrated MinAS maintenance

MinAS alarm view

2.5 MinAS blocks

2.5.1 Drive functions

PCS 7 Demo project (mining)

2.5.3 Scalable production control

PCS 7 Demo project (mining)

PCS 7 Demo project (mining)

3 Mining demo project

PCS 7 Demo project (mining)

PCS 7 Demo project (mining)

3.2 Process pictures

Here, you are given an overview of

This plant unit provides

PCS 7 Demo project (mining)

The screen shows an example of

This part of the system shows the

Here, the second flotation stage is

PCS 7 Demo project (mining)

The "Tailings" area is an example

This picture shows an example of

The SPC material manager

PCS 7 Demo project (mining)

3.3 "Crushing" system area

PCS 7 Demo project (mining)

3.3.1 Primary crusher

1. Signaling installation for adding more raw material

PCS 7 Demo project (mining)

3.3.2 Operator controls for groups, routes and maintenance

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

1. Starts or stops the process of the selected route

PCS 7 Demo project (mining)

3.3.3 Conveyor belts

4. Safety switch for emergency stop and belt misalignment

1. Signaling installation for filling from the stockpile

PCS 7 Demo project (mining)

3.4 Operator controls

Additional views are available depending on the object, for instance: