Manual

Beijing High Light Automation Engineering Co. Ltd.
北京海莱德自动化工程有限公司
DCS System
For Bolivia San

Buenaventura Factory
System Manual
(Version 1.2)
Beijing High Light Automation Engineering Ltd
Beijing High Light

Automation and Engineering Co. Ltd.
Sep., 2014
Content
1. System introduction.......................................................................................................4
1.1. Hardware................................................................................................................4
1.1.1. Cane preparation house..................................................................................4
1.1.2. Dewatering control room.................................................................................4
1.1.3. Clarification and evaporation control room.....................................................4
1.1.4. Boiling control room.........................................................................................4
1.1.5. Recycling water pump control room................................................................4
1.1.6. Central control room........................................................................................5
1.2. HMI.........................................................................................................................5
1.2.1. Cane preparation.............................................................................................5
1.2.2. Extraction.........................................................................................................5
1.2.3. Dewatering......................................................................................................6
1.2.4. Air compression and steam cooling................................................................6
1.2.5. Clarification......................................................................................................7
1.2.6. Filtering............................................................................................................7
1.2.7. Evaporation.....................................................................................................8
1.2.8. Milk of lime house and chemical cleaning.....................................................9
1.2.9. A Sugar (No.1).................................................................................................9
1.2.10. A Sugar(No.2)................................................................................................10
1.2.11. A sugar (No.3)...............................................................................................10
1.2.12. water system..................................................................................................11
1.2.13. B seed pan.....................................................................................................11
1.2.14. B CVP............................................................................................................12
1.2.15. A B C Molasses.............................................................................................12
1.2.16. C seed pan....................................................................................................13
1.2.17. C sugar boiling..............................................................................................13
1.2.18. C magma crystallization................................................................................14
1.2.19. Sugar handling, drying and bagging.............................................................14
1.2.20. Recycling water pump...................................................................................15
2. System operation.........................................................................................................16
2.1. System start and shut down.................................................................................16
2.1.1. System start..................................................................................................16
2.1.2. System power off...........................................................................................19
2.2. Log on and athorizaition.......................................................................................22
2.3. Graphic System operation....................................................................................23
2.3.1. Introduction....................................................................................................23
2.3.2. Appearance of the cursor during process operation.....................................24
2.3.3. Overview area...............................................................................................25
2.3.4. Work area......................................................................................................26
2.3.5. Button area....................................................................................................26
2.3.6. Operation introduction about motor, Valve and other control unit................29
2.4. Alarm....................................................................................................................39
2.4.1. Alarm classification........................................................................................39
2.5. Archive and reports..............................................................................................40
2.5.1. Archive and print of process values..............................................................40
2.5.2. Archive and print for Operation records (Logs).............................................44
2.5.3. Archive and print for alarm message............................................................45
3. Troubleshooting...........................................................................................................45
3.1. No feeback on hierarchy area and system function button area.........................45
3.2. Licence error.........................................................................................................46
3.3. System restart while WinCC running....................................................................46
1. System introduction
1.1. Hardware
The hardware components of the DCS system includes UPS system, I/O control cabinets,
power distribution cabinets, servers, operation panels. These hardware are located in six
control rooms, cane preparation control room, dewatering control room, clarification and
evaporation control room, boiling control room, recycling water control room and central
control room.
1.1.1. Cane preparation control room

Hardware configuration：
 Power distribution cabinet PWS13A
 I/O control cabinet IO13A
 Operation station OP13A
1.1.2. Dewatering control room

 Power distribution cabinet PWS15A

 I/O control cabinet RIO15A01,RIO15A02
 Operation station OP1501,OP1502
1.1.3. Clarification and evaporation control room

 Power distribution cabinet PWS20

 UPS cabinet ：UPS20
 I/O control cabinet CON20,RIO21
1.1.4.Boiling control room


 I/O control cabinet RIO2401,RIO2402
1.1.5. Recycling water pump control room

 I/O control cabinet RIO53

1.1.6. Central control room

Hardware configuration
 Server SVR1,SVR2
 Engineering station ENG1;
 Operation station OP2901、OP2902、OP2903、OP2904
 UPS and battery sets
 Printer
1.2. HMI
1.2.1. Cane preparation

The implementation of DCS is to achieve the even grinding and automatic control via DCS
system, the equipments of the section are as follows, Cane carrier （ X1301 ） ,bent
conveyor（X1303）,leveler（K1301）,knife sets（K1302）、shredder（K1303）、cane
feeder table(X1103~X1104 ） , control points of lubrication oil system such as running
status, current of motor, temperature of bearing etc.
Figure 1
1.2.2. Extraction
Control points of the diffuser（F1401）include running status of the diffuser, level control,
temperature control etc.
Figure 2
1.2.3. Dewatering
The control points of the section include the running status of mill No.1 、 mill
No.2,lubration system and oil pump.
Figure 3
1.2.4. Air compression and steam cooling

The control points of the section include the pressure of condensate tank No.1,
condensate No.2 , temperature and pressure of input and output of high temperature type
freeze drier ,temperature of step-down transformer and pipeline pressure device
Figure 4
1.2.5. Clarification
The control points of the section include the level, temperature, pressure, flow , PH of the
equipments .the following is the HMI of this section.
Figure 5
1.2.6. Filtering
The control points of the section include the running status , level, temperature about the
equipments of No filter cloth vacuum filter machine No.1 , No.2 and No.3, juice pump
No.1, No.2 and No.3,mud conveyor ect. The following is the HMI of this section.
Figure 6
1.2.7. Evaporation
The control points of this section include the temperature, level, pressure of evaporator
No.1 ,No.2,No.3, No.4,No.5 and No.6, the running status of steam condensate pump,
syrup balancing tank, and the temperature, level of other equipments of this section. The
following is the HMI of this section.
Figure 7
1.2.8. Milk of lime house and chemical cleaning

The control points of the section include the running status of the pump installed there, the
Figure 8
1.2.9. A Sugar (No.1)

The control points of this section include the level, brix, temperature, pressure and
vacuum of A sugar No.1. The following is the HMI of this section.
Figure 9
1.2.10. A Sugar(No.2)
The control points of this section include the level, brix, temperature, pressure, vacuum of
A sugar No.2. The following is the HMI of this section.
Figure 10
1.2.11. A sugar (No.3)
A sugar No.3. The following is the HMI of this section.
Figure 11
1.2.12. water system

The control points of the section include the running status, level control of the pumps
installed in tank washing system, steam condensate system, cool water and hot water
system. The following is the HMI of this section.
Figure 12
1.2.13. B seed pan
B seed pan. The following is the HMI of this section.
Figure 13
1.2.14. B CVP
The control points of B CVP include the brix, state of input valves of the equipments. The
Figure 14
1.2.15. A B C Molasses
The control points of ABC Molasses include the level ,temperature and the status of the
valves in raw sugar molasses and B&C molasses section. The following is the ABC
molasses HMI in this section.
Figure 15
1.2.16. C seed pan
C seed pan. The following is the HMI of this section.
Figure 16
1.2.17. C sugar boiling

The control points of C sugar CVP include the brix, state of input valves of the
equipments. The following is the HMI of this section.
Figure 17
1.2.18. C magma crystallization

The control points of the this section include level, temperature, status of the valves,
running status of the pump in C magma crystallizer. the following is the HMI of this
section.
Figure 18
1.2.19. Sugar handling, drying and bagging
The control points of the section include the running status of the equipments,
temperature, brix, level in this section. the following is the HMI of this section.
Figure 19
1.2.20. Recycling water pump

The control points include the running status of the pumps and level of the tanks in this
section. the following is the HMI of this section.
Figure 20
2. System operation
2.1. System start and shut down
2.1.1. System start
（1） Main distribution cabinet power on
Step 1：Main distribution cabinet power on(PWS20)
 Switch on Q1 first，then switch on air-switch Q2, Q3, F1, F2, F3, F4, F5, F991, F992,
F993 in sequence.
Step 2：UPS cabinet (UPS20) power on
 Switch on Q1 first.
 UPS power on
 Switch on air switch Q4, F2, F3, F4, F5, F6, F991, F992, F993 in sequence.
Note, in addition to the malfunction of UPS, please switch off Q1 first, and switch on air-switch
Q2,F1,Q3,Q4,F2,F3,F4,F5,F6, F991,F992,F993, then the power supplied is not by UPS but bypass
circuit.
The following step can be done accordingly after DCS main distribution cabinet powered
on.
（2） System power on of central control center

Step 1,open servers (SVR1,SVR2)
 Turn on the power of server 1and server2 (SVR1,SVR2)

 Turn on the display of the servers
 Input the password (14002Bhlae),the operation system is windows server 2008.
 Double click the icon of , and start the WinCC Explorer project.
 Single click the icon of in top left corner and activate SVR1 and SVR2
Step 2, Open the operation stationOP2901, OP2902, OP2903, OP2904
 Turn on the power of operation station OP2901, OP2902, OP2903, OP2904.

 Turn on the display of the PC
 Input the password(14002Bhlae)，the operation system is windows7.
 Double click the icon of , start WinCC Explorer project
 Single click the icon of in top left corner and activate operation station OP2901,
OP2902, OP2903, OP2904.
 Log on as operator, details refer to the users' authorization definition.
（3） System power on of cane preparation control room

Step 1, Power distribution cabinet (PWS13A) power on
 Switch on Q1 first，then switch on air-switch F1,F3,F991,F992,F993 in sequence.
Step 2 , I/O cabinet(RIO13A) power on
 Switch on air-switch F1, F2, F101, F102, F103, F104, F991, F992,F993 in sequence.
Step 3, Start operation station (OP13A)
 Turn on the power of the operation station (OP13A).

 Turn on the display of the operation station.
 Input password(14002Bhlae)，the operation system is windows7.
 Double click the icon ，then start WinCC Explorer and run the project.
 Click the icon in top left icon and activate the operation station(OP13A).
 Log on as operator, details refer to the users' authorization definition.
（4） System power on of dewatering control room

Step 1, Power distribution cabinet (PWS15A) power on.
 Switch on Q1 first, then switch on the air-switch F1, F2, F6, F7, F8, F9, F10, F11, F12,
F13, F14, F17, F18, F200, F201, F202, F203, F204, F205, F991, F992, F993 in
sequence
Step 2, I/O cabinet (RIO15A01) power on
 Switch on air-switch F1, F2, F101, F102, F103, F104, F991, F992, F993 in sequence.
Step 3, I/O cabinet (RIO15A02) power on
 Switch on the air-switch F1, F2,F101,F102,F991,F992,F993 in sequence.
Step4, Start operation station (OP1501,OP1502)
 Turn on the power of operation station (OP1501,OP1502).

 Turn the display of the operation station (OP1501,OP1502).
 Input the password (14002Bhlae) , the operation system is windows 7.
 Double click the icon then start WinCC Explorer and run the project.
 Click the icon on top left corner of the screen and activate the operation station(
OP1501, OP1502).
 Log on as operator, details refer to the authorization definition.
（5） System power on of clarification control room

Step 1: Power distribution cabinet (PWS21) power on
 Switch on Q1 first, then switch on air-switch F1, F2, F11, F12, F13, F14, F15, F16,
F17, F18, F25, F200, F20, F202, F991, F992, F993 in sequence.
Step 2：CPU cabinet (CON20) power on
 Switch on air-switch F1, F2, F3, F4, F5, F6, F101, F102, F103, F104, F991, F992,
F993 in sequence.
Step 3：I/O cabinet ( RIO21) power on
 Switch on air-switch F1, F2, F3, F4, F101, F102, F103, F104, F105, F106, F107,
F991, F992, F993 in sequence.
Step4 ：Start the operation station (OP2101,OP2102)
 Turn on the power of operation station (OP2101,OP2102)

 Turn on the power of the display of the operation station.
 Input he password (14002Bhlae), the operation system is windows7.
 Double click the icon ,then start WinCC Explorer and run the project.
 Click the icon on the top left corner of screen and activate the operation station
(OP2101,OP2102).
（6） System power on of boiling control room

Step 1：Power distribution cabinet ( PWS24) power on
 Switch on Q1 first, then switch on air-switch F1, F2, F5, F6, F7, F8, F9, F10, F12, F13,
F17, F18, F200, F201, F202, F203, F204, F205, F206, F207, F208, F209, F210,
F211, F212, F213, F214, F215, F216, F217, F218, F219, F220, F221, F222,
F223,F224, F225, F226, F227, F228, F229, F230, F231, F232, F991, F992, F993 in
sequence.
Step 2：I/O cabinet (RIO2401) power on
 Switch on air-switch F1, F2, F3, F4, F101, F102, F103, F104, F991, F992, F993 in
sequence.
Step 3：I/O cabinet (RIO2402) Power on
 Switch on air-switch F1, F2, F3, F4, F101, F102, F991, F992,F993 in sequence.
Step 4：Start the operation station (OP2401,OP2402)

 Turn on the power of the operation station (OP2401, OP2402).
 Turn on the power of display.
 Input the password (14002Bhlae)，the operation system is Windows.
 Double click the icon ，then start WinCC Explorer and run the project.
 Click the icon in top left corner and activate the operation station
(OP2401,OP2402).
（7） System start in recycling water control room

Step 1：I/O cabinet (RIO53) power on
 Switch on Q1 first，then switch on air-switch F1, F2, F101, F102, F103, F104, F991,
F992, F993 in sequence.
Note: There is no power distribution cabinet and operation station in this control room.
2.1.2. System power off
（1） System power off of cane preparation control room

Step 1：Exit runtime and operation station shut down
 Press ' Deactivate' to exit the project in the pop-up box 'exit runtime' after single click
the icon (close process mode) of operation station (OP13A).
 Shut down the computer (OP13A).
Step 2, I/O cabinet (RIO13A) power off
 Switch off the air-switch F1, F2, F101, F102, F103, F104, F991, F992, F993 in
sequence.
Step 3, Power distribution cabinet (PWS13A) power off
 Switch off the air-switch F1, F3, F991, F992, F993 in sequence.
 Switch off Q1.
Figure 21
（2） System power off of dewatering control room

Step 1：Exit runtime and operation station shut down.
the icon (close process mode) of operation station (OP1501,OP1502).
 Shut down the computer (OP1501,OP1502) .
Step 2：I/O cabinet ( RIO15A01) power off.
 Switch off the air-switch F1, F2, F101, F102, F103, F104, F991, F992, F993 in
sequence.
Step 3：I/O cabinet (RIO15A02) power off.
 Switch off the air-switch F1, F2, F101, F102, F991, F992,F993 in sequence.
Step 4：Power distribution cabinet (PWS15A) power off
 Switch off the air-switch F1, F2, F6, F7 ,F8, F9, F10, F11, F12, F13, F14, F17, F18,
F200, F201, F202, F203, F204, F205, F991, F992, F993 in sequence.
 Switch off Q1.
（3） System power off of boiling control room

Step 1：Exit runtime and operation station shut down：
Step 2：I/O cabinet RIO2401 power off

 Switch off the air-switch F1,F2,F3,F4,F101,F102,F103,F104,F991,F992, F993 in
sequence.
Step 3: I/O cabinet RIO 2402 power off.

 Switch off the air- switch F1, F2, F3, F4, F101, F102, F991, F992, F993 in sequence.
Step 4, Power distribution cabinet PWS 24 power off.

 Switch off the air-switch F1, F2 , F5, F6, F7, F8, F9, F10, F12, F13, F17, F18, F200,
F201,F202, F203, F204, F205, F206, F207, F208, F209, F210, F211, F212, F213,
F214, F215, F216, F217, F218, F219, F220, F221, F222, F223, F224 ,F225, F226,
F227 , F228, F229, F230 ,F231, F232, F991, F992 ,F993 in sequence.
 Switch off Q1.
（4） System power off of recycling water control room

Step 1：I/O cabinet RIO 53 power off.
 Switch off the air-switch F1, F2, F101, F102, F103, F104, F991, F992,F993 in
sequence.
 Switch off Q1.
（5） System power off of clarification control room

 Step 2：I/O cabinet RIO21 power off

 Switch off the air-switch F1, F2, F3, F4, F101, F102, F103, F104, F105, F106, F107,
F991, F992, F993 in sequence.
Step 3：CPU cabinet (CON20) power off

 Switch off the air- switch F1, F2, F3, F4, F5, F6, F101, F102, F103, F104, F991, F992,
F993 in sequence.
Step 4, Power distribution cabinet ( PWS21) power off.
 Switch off the air-switch F1, F2, F11, F12, F13, F14, F15, F16, F17, F18, F25,
F200,F201,F202,F99,F992,F993 in sequence.
 Switch off Q1.
（6） System power off of central control room

the icon (close process mode) of operation station (OP2901, OP2902, OP2903,
OP2904).
 Shut down the computer (OP2901,OP2902,OP2903,OP2904) .
Step 2：Project termination and servers shut down.

the icon (close process mode) of operation station (SVR1,SVR2).
 Shut down the computer (SVR1、SVR2).
（7） Main Power distribution cabinet power off

Step 1, UPS cabinet (UPS 20 ) power off.
 Switch off the air-switch Q4, F2, F3, F4, F5, F6, F991, F992, F993 in sequence.
 Power off the UPS ( press the power button for 10 seconds or more).
 Switch off Q1.
Step 2, Power distribution PWS 20 power off.
 Switch off the air-switch Q2, Q3, F1, F2, F3, F4, F5, F991, F992, F993 in sequence.
 Switch off Q1.
2.2. Log on and athorizaition

The following is system log on interface after project activation.
Figure 22
It's easy to realize the fucntion of user access management, different users can be
authorized to different system application. There are two level role authorization in this
DCS system.
Administrator /Admin；
Operator
/OP13A、OP1501、OP1502、OP2101、OP2102、OP2401、OP2402、OP2901、OP29
02、OP2903、OP2904；
Authorization allocation：
Administrator：full privileges of monitoring, process control ,advanced process control for
all section.
Operator：Monitoring, process control for designated section
After single click icon of ，One can switch the role as the tips of the system login pop-
pu dialog box. The following is the login dialog box.
Figure 23
Note:
 Login name of operation station OP13A is ' OP13A '，the privilege of this user
is only designated for section of cane preparation section.
 Login name of operation station OP1501 is ' OP1501 ' ， the privilege of this
user is only designated for section of extraction, dewatering and air-pressure.
user is only designated for section of extraction and dewatering.
user is only designated for section of clarification, filtering, evaporation and milk
of lime.
user is only designated for section of clarification, filtering, evaporation and milk
of lim.
 Login name of operation station of OP2401 is ' OP2401 ',the privilege of this
user is only designated for section of A sugar boiling No.1, A sugar boiling No.
2, A sugar boiling No. 3, B seed boiling, B CVP, C seed boiling, C CVP, ABC
molasses, sugar handling, drying and bagging, and recycling water.
 Login name of operation station OP2402 is ' OP2402 ',the privilege of this
section is only designated for section of A sugar boiling No.1, A sugar boiling
No. 2, A sugar boiling No. 3, B seed boiling, B CVP, C seed boiling, C CVP,
ABC molasses, sugar handling, drying and bagging, and recycling water.
 The privilege of OP2901 、 OP2902 、 OP2903 、 OP2904 is not control but
monitoring of all sections.
2.3. Graphic System operation

2.3.1. Introduction
The total graphic system can be divided into the following areas.
 Overview area, shown as area No.1

 working area, shown as area No.2
 Button area, shown as area No.3
The size of the user interface and the sizes of the three areas within it are specified by the
configuration. The overview area and button area are always displayed. The working area
displays message lists and individual process pictures that may have faceplates and
operator control windows superimposed for process control or dialog boxes superimposed
for system operator inputs. The button area consists of two sets of buttons. The operator
can switch from one set to the other. An additional button set is provided for operator
control of the message system.
2.3.2. Appearance of the cursor during process operation

Operator can perform control functions in the 'overview area', 'work area' and 'button area'
by moving the cursor to a command button or an icon and pressing the left mouse button.
operator can perform control functions when the cursor turns into a control cursor. No
operation control can be performed if the cursor does not change. The cursor becomes a
text cursor when operators enter set points:
Figure 24
2.3.3.Overview area
（1） Purpose of the overview area
The overview area provides the operator with a constant overview of the status of the
entire plant. The overview area is used for monitoring and fast detection of problems in
the various areas of the plant. The overview area is displayed in various layouts according
to the configuration. The operator can define an OS-specific layout in the OS project
editor. The illustrations in this description are based on the "SIMATIC standard 1024*768"
(standard resolutions up to 2560*1600 maybe selected).
Each plant area is represented by an area selection button in the overview area. If the
operator click on an area selection button, the corresponding process picture of the
highest picture hierarchy level is displayed in the working area. The message with the
highest priority is displayed in the overview area. If two messages have the same priority,
the latest one is displayed.
（2） Operator control functions in the overview area

Assignment
Icon Function Description/functionality to function
area
Extended Opens a list displaying all received messages. The list is Message
message line displayed as a message window in the working area. system
Acknowledges the currently displayed message in the
Message message line. When the currently displayed message in
acknowledgment the message line is acknowledged with the Message
button acknowledgment button, it disappears from the message system
line. The now current and still unacknowledged message
is displayed.
Opens a process picture or faceplate containing the
source of the message or caused by the message
Loop in Alarm displayed in the message line. The configuration in the Graphic
block list editor on the OS determines whether the system
process picture or the faceplate is displayed. The
process picture is displayed as a new picture in the
working area. The faceplate is displayed as a loop
display in the working area and is superimposed over the
process picture.
Enabled area Displays the corresponding area picture in the working
selection area. The process picture configured at the highest level
button is displayed. An activated plant area is identified by a
change of color of the area selection button. The Graphic
operation of the area selection button depends on the system
Disabled area permissions that have been allocated to the current user
selection button (operator) in the WinCC User Administrator. The button
labels are formed from the names of the hierarchy
folders in the plant view in SIMATIC Manager. All of the
hierarchy folders created here are entered in process
mode in the overview area.
The group display shows the states of messages
associated with a plant area in graphic form. The
operator must click on each individual message button in
Group display for the group display to display the corresponding process Graphic
the picture with the source of the message. A distinction is system
plant area made between the following message states in the group
display: A = Alarm violation of the alarm limit (white on
red) W = Warning violation of the warning limit (black on
yellow) S = Process control fault (yellow on black) O =
Operator prompt (white on purple) X = On
Open Picture Opens the process window of the Picture Tree Navigator
Tree Navigator in the working area. The Picture Tree Navigator helps System
the operator to quickly select secondary process pictures function
in a plant area and to display them in the working area of
the user interface.
Screen printout/ Starts a printout of the screen content. The currently System
hardcopy displayed process control screen content is written to a function
temporary file and immediately output to a connected
printer.
Status of The status of the redundant server pair and the non-
assigned servers redundant server assigned to the OS client are displayed System
on the OS clients in the right section function
of the area overview.
2.3.4. Work area

The individual process pictures of the various plant areas are displayed in the working
area. The process is displayed, controlled and operated in the process picture. Process
pictures are displayed in the working area as a result of the following operator actions:
 Selecting an area selection button in the overview area.

 Selecting a process picture via the Picture Tree Navigator in the overview area.
 Select via the function "Loop in Alarm" in the overview area if a message is
pending.
 Selecting one of the picture selection dialogs "Picture selection via measurement
point" or "Picture selection by name" in the button set.
 Selecting one of the navigation buttons for the picture hierarchy in the button set.
 Selecting the "Recall screen composition" function in the button set, if the operator
(as the logged on operator) have assembled process pictures using the "Save
screen composition" function.
 Selecting the picture memory function in the button set such as "Output picture" or
"Previous picture"
2.3.5. Button area
（1） Introduction
Two button sets with standardized operator buttons are defined for process control in the
OS. Button set 1 is displayed when the operator start process mode. Use the operator
buttons in the button
sets to toggle between them.
Button sets 1
Button sets 2
Button color scheme

Some buttons are display in color in two ways as can be seen in the figure above, 'Button
set 1.fourth button from right'.
● Grayed out: The operator buttons in the button set are not active and cannot be used.
For example, the operator does not have the required authorization or process pictures
are missing.
● Colored: The operator buttons in the button set are active and can be used.
Switching between the button sets
The operator can switch between the two sets of buttons with the following operator
buttons:
Tooltips for the operator buttons.

When the operator place the cursor on one of the operator buttons within the set, the
corresponding tooltip is displayed. It contains a brief explanation of this operator button.
The function is executed when the operator click the right mouse button.
Operator control functions in button set 1：

Assignment
Required
permission
area
If the operator have logged on to process
Change to System
control, button set 1 is displayed. To switch to None
button set 2 function
button set 2, click the button shown here.
Logs a user on and off for process control.
Clicking on the "Password" icon displays the
"System Logon" dialog box in the work area. If
the operator have installed SIMATIC Logon,
the "SIMATIC Logon Service" dialog box
opens instead for user logon. System
Password None
When the operator click the "Logout" button in function
the logon dialog box, the current user is
logged off, process control closes, and all
operator controls are disabled. The operator
controls are enabled only after the operator
log on again for process control.
Opens the message system with the incoming
alarm list displayed in the work area. The
incoming alarm list shows the messages from
Message areas for which the user has permission and System
None
system are not yet acknowledged. If the message function
system is open, a new button set (specifically
for the message system) is displayed in the
button area.
Logs Opens the "Logs" system dialog box that Authorization System
provides the operator with an overview of all for area function
logs. The dialog box provides the operator

with additional information on the print jobs
used in process mode.
Opens the "Load/configure trend groups"
Load/configure system dialog box. This function is used to Authorization
Trend system
trend groups display graphically how selected process for area
values change over time.
Opens the "Picture selection via measurement
Picture
point" system dialog. This function is used to Graphic
selection via None
select a graphic based on the measurement system
process tag
point name and to display it in the work area.
Opens the "Picture selection via name"
Picture via system dialog box. This function is used to System
None
name select a graphic based on a name and to function
display it in the work area.
Previous Displays the process picture last displayed in System
None
picture the work area. function
Displays the process picture selected next in System
Next picture None
the work area. function
This function saves the currently displayed
System
Save picture process picture enabling the operator to later None
function
display it using the "Output picture" command.
This displays the process picture saved with System
Recall picture None
the "Save picture" function in the work area. function
Opens a screen composition of pictures and
windows that has been previously saved. Only
the screen compositions stored with the "Save
Recall screen Authorization System
screen composition" function can be selected
composition for area function
in the dialog box. Screen compositions are
assigned to the operator logged on and are
available only to this operator.
Saves the current composition of pictures
Save screen Authorization System
and windows on the screen, enabling the
composition for area function
operator to call it up again later.
Delete the
Deletes a screen composition of pictures and Authorization System
screen
windows that has been previously saved. for area function
composition
Displays in the work area the picture of the
plant configuration that was configured in the
'Life beat Monitoring' editor on the OS. This
function is used to monitor OS servers, OS
clients and automation systems (AS) that can
Plant be accessed over PC networks and industrial Authorization System
configuration networks. The program displays the operating for area function
state of all monitored objects of the active
process. The following states can be
displayed:
● Connection established
● Connection not established = Fault
Opens a dialog box in the work area providing
Picture System
information on the currently displayed process None
information function
picture.
Acknowledges the active signal of a signaling
device, such as a horn. However, the alarm
Acknowledge System
that triggered the horn is not acknowledged None
horn function
with this function. This function is also
available in toolbar set 2.
Acknowledge Acknowledges all the visible messages Process System

message displayed in a process picture in the work control function
area. The same function is available in button
set 2.
Control functions in the button set 2
Assignment
Required
permission
area
Change to Switches from button set 2 back to button set System
None
button set 1 1. function
Opens a dialog box in the working area in
Change System
which the operator can select the required None
language function
language for the user interface.
The "Lock messages" function is used to lock
Lock the triggering of messages for all single control Authorization System
messages units in the process picture affected by group for area function
displays directly in the automation system.
The "Unlock messages" function is used to re-
release the triggering of messages for all
Unlock Authorization System
single control units in the process picture
messages for area function
affected by group displays directly in the
automation system.
Acknowledges the active signal of a signaling
device, such as a horn. However, the alarm
Acknowledge System
that triggered the horn is not acknowledged None
horn function
with this function. This function is identical to
the function in button set 1.
Acknowledges all the visible messages
Acknowledge displayed in a process picture in the work Process System
message area. The same function is available in button control function
set 2.
2.3.6. Operation introduction about motor, Valve and other control

unit.
（1） Motor state display and operation
a) general motor
The following motor states are shown here:
Display State Color Description/Functionality
Green, direction arrow flashing Motor started
Green The motor is running
Grey, state display flashing Motor stopped
Grey Motor idle
Error at motor (monitoring error, motor

Red
protection)
Grey with Tag Motor controlled by local
Green with tag M Run by manual
Green with Tag A Auto run
Grey with lock Interlock protection
Motor start and stop
Open the motor/ pump faceplate after single click the icon of ， the pop-up
command box will be opened after single click of the button on the right of textbox 'stop',
then the operators can close the face plate after the operation of confirmation about start
or stop motor or pump.
Let take start motor 13MIC_K1102 as a example.
Note：
 Please make sure the motor state is in accordance with the command before
face plate close.
 If the motor display is flashing, the operator should check whether there is error
at motor or not.
Figure 25 general motor / pump start
Manual auto switch
Open the motor/ pump face plate after single click the icon , the pop-up manual box
will be opened after single click the button on the right of textbox ' manual/ auto'. then the
operators can close the face plate after the operation of confirmation about manual auto
switch.
let's take the motor of cylinder screen as an example. The operator can switch the motor
from manual to auto according to the following steps.
Figure 26 general motor manual / auto switch
2）Variable speed motor

The following motor states are shown here:
Display state color Description/functionality
Green, direction arrow flashing Motor started
Green The motor is running
Grey, state display flashing Motor stopped
Grey Motor idle
Red Error at motor (monitoring error, motor protection)
Grey Motor stop
Grey with Tag Motor in local
Grey with tag M Run by manual (HMI)
Grey with tag A Auto run (interior)，No operation can be done
Grey with tag blue E Auto run (exterior), No operation can be done
Operation of variable speed motor
Open the variable speed face plate after single click icon , the operator can close the
face plate after the operation of speed value sets in the pop-up box after click the white
button on the right of text box 'set point'.
Let's take the following motor speed set points as an example.
1) Start the motor

2) Set speed
The operator also can set the speed via the button on the left of command box , the
quantity can be '-2.5%', '-0.5%', '+0.5%', '+2.5%'.
Notes:
 The speed of motor will speed up gradually, Please make sure the state of motor
is in accordance with the set point before face plate close.
 If the motor display is flashing, the operator should check in local, there must be
motor error.
Figure 27 Figure 28
（2） Valve state display and basic operation

1）On/ Off valve（start/ stop, remote/local, interlock, exterior error, flashing state)
State display：
Green Open
Grey Close
Red malfunction
From grey to green Valve is being opened
From green to grey Valve is being closed
Grey stop
Grey,tag M Run in manual
Grey,tag A Run in auto, No operation can be done
Red Exterior malfunction
Open/ Close valve:
Open on/off valve operation face plate after single click the icon ， then enter the
pop-up command box after click the button on the right of text box ' close', the operator
can open or close the valve.
Let's take the valve open as an example.
Figure 29
Notes:
 Please make sure the valve state is in accordance with the command before face
plate close.
 If the valve display is flashing, the operator should check valve, there must be
error in local .
2）Adjustable valve
Display state:
Green Open
Grey Close
Red Valve Error
From grey to green Valve is opening
From green to grey Valve is closing
Keep grey Valve keep stop
Keep light green Valve close, the position is in accordance with the
set point
Grey with Tag M Run in manual
Grey with tag A Run in auto, No operation can be done
Red Exterior error
Valve position set
Open the adjustable valve operation faceplate after single click the icon ， then
enter the pop-up command box after single click the button on the right of text box '
manipulated var.'. The operator can input the set points of the adjustable valve.
The operator also can set the position via the button on the left of command box , the
quantity can be '-2.5%', '-0.5%', '+0.5%', '+2.5%'.
Notes:
 The adjustable Valve will open gradually, Please make sure the display valve is
in accordance with the set point before face plate close.
 If the valve display is flashing, the operator should check in local, there must be
valve error.
Figure 30
Open/ Close adjustable valve:

Open the adjustable valve operation face plate after single click the icon ， then
enter the pop-up command box after single click the button on the right of text box 'close'.
The operator can open or close the valve.
let's take the hot water outlet valve in imbibition water tank as a example. the details can
refer to the figure 31
Figure 31
3）Electric butterfly valve

State display:：
Display/state clour Description/Functionality
Green Open
Grey Close
Red Error
From grey to green Valve is opening
From green to grey Valve is closing
Keep light green Valve is in the position
Electric butterfly valve open/ close：
Open the electric butterfly valve operation face plate after single click of icon ，then
enter the pop-up command box after single click the button on the right of text box 'close'.
The operator can open or close the electric butterfly valve.
Let take the electric butterfly valve 23HIC01 as an example.
Figure 32
2.4. Alarm
2.4.1.Alarm classification
There are three types of alarm information in this project: alarm, warning, error, the
display is yellow, red and black. The operator can deal with the alarm(yellow) and warning
(red) according to the relative principle , as for the error(black), the operator should inform
the maintenance personnel or system engineers.
 yellow alarm: The operator should check whether some parameters reach the
limits or not.
 Red warning, The operator should deal with the warning information.
 Black error, The operator should inform the maintenance personnel or system
engineers to deal with the error.
2.5. Archive and reports
The archive system consists: process values, operation records(logs) , warning
messages.
2.5.1.Archive and print of process values

The process values include all values created by all sections, such as level, temperature,
pressure, flow, current, PH, Chlorine content, Oxygen content, Ammonia nitrogen content
etc.
Open the HMI of archive for process values after single click of icon , there are
process values in the table of WinCC Online Table Control, The operator can increase of
decrease the form, change the time column or do some other changes.
The operator can print the process values via single click the icon on the left top of
WinCC Online Table Control.
Figure 32
Figure 34
The operator can edit the process value after single click the icon when the state of
WinCC Online Table Control is stop.
The operator can explore the statistic information via the WinCC Trend Ruler Control
after single click the icon on the let top of WinCC Online Table Control, and the
operator also can configure the properties in the property dialog after single click the
button on the right top of WinCC Trend Ruler Control.
Figure 35 Property dialog of WinCC Online Table Control
The operator can print the statistic report via single click the button in WinCC Trend
Ruler Control.
The operator can export the statistic report to local disk after single click the button in
WinCC Trend Ruler Control, and also can choose the storage fold after single click the
button .
Figure 36
Figure 37
Back to monitor screen after single click the button on the right bottom of Wincc
online table control.
2.5.2. Archive and print for Operation records (Logs)

System can record all logs of operation and the precise time of each operation that the
operators carried out in the control room. The operation records include not only the
operations of open/ close of valves and motors, parameters set and modification, but also
the time, device no. state before modification, state after modification, user name etc.
The operator can see the new information, acknowledged information, process
information, operation record, system logs after single click the button . The following is
the display state of the buttons in information system.
The function of the button
Button Function
Back for main monitor screen
Display the new entered message list
Display the acknowledged message list
Display the exited message list
Display the process control message list
Display the operation record message list
Display system logs
Hidden message list.
The list of messages to be hidden
Operation record list will be shown after single click of button , the following is the HMI
of operation record list.
Figure 38
The operator can print the operation record list after single click the button on the right
top of the screen.
2.5.3.Archive and print for alarm message

The alarm message include new entered alarm message, acknowledged alarm message,
exited alarm message, process control alarm message, the operator can check the
according alarm message list after single click the button or print the alarm message list
after single click the button .
3. Troubleshooting
3.1. No feeback on hierarchy area and system function button
area
Treatment1: Exit from graphical operation system and restart the graphical operation
system.
Details as follows：
 press 'windows' button on the keyboard, right click the 'WINCC running
system' after press the 'display or hide icon' in the right bottom of task bar,
then choose ' exit from graphical operation system' .
 Right click the 'WINCC running system' after press the 'display or hide icon'
in the right bottom of task bar, then choose ' run graphical operation system'.
If the problem still can't be solved, please refer to treatment No.2

treatment 2：Deactivate running system and reactivate running system.
Details as follows:
 Press 'windows' button on the keyboard, right click the 'WINCC running
system' after press the 'display or hide icon' in the right bottom of task bar,
then choose 'Deactivate running system' .
 Right click the 'WINCC running system' after press the 'display or hide icon'
in the right bottom of task bar, then choose ' activate running system'

Treatment3 ： reactivate running system after run 'reset_wincc.vbs' command to restart
the operation station.
Details as follows：
 Press and release 'windows' button and 'R' button on the keyboard together,
input ' reset_wincc.vbs ' in the running dialog box, press 'ok', the press 'ok'
again after pop-up box' ready'.
 Press 'start' button on the left bottom of the screen, click the right arrow on the
left of text box 'power off' and run the command ' system restart'
 Double click the icon ' SIMATIC WinCC Explorer' on the screen after system
reboot, press 'file' in the menu and click 'active' in the drop-down menu.工控
3.2. Licence error
Treatment 1. Check the USB key link status
details as follows:
 Press 'windows' button on the keyboard, click 'safely remove hardware and
eject media' after press 'display and hide icon' button on the left bottom of task
bar, then click 'usb mass storage device'and eject usb mass storage device.
 Unplug the usb license key hard lock.
 Reinsert the license key hard lock into the usb slot
treatment 2, license key damage, please contact Siemens for after sales service
Details as follows:
 Double click the icon in screen and start 'automation license manager', click
'cancel' if 'SIMATICA Logon service' dialogue shown.
 Press E disk in 'my computer', right click 'check' after select all software
licenses, if the result is 'defective' , that means the licenses damaged.
 Contact local SIEMENS for after sales service.
3.3. System restart while WinCC running

Treatment 1：Restart as system reminder
Details as follows
 Press 'ok' as system restart reminder dialogue.

 Select 'file' in the menu list of ' SIMATIC WinCC Explorer', press 'log out' and
log out ' SIMATIC WinCC Explorer'.
 Click the button 'start' on the left bottom of the screen, click the right arrow of
'shut down' and click ' restart'.
 After system reboot, click the 'start' on the left bottom of the screen, press
'computer' first, then press 'network' and 'network and sharing center', press
'change adapter setting', if there is forbidden network card, right click the
button and click 'enable'.
 Double click the icon and restart 'SIMATIC WinCC Explorer'

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Beijing High Light Automation Engineering Co. Ltd.

For Bolivia San

Beijing High Light

1.1.1. Cane preparation control room

1.1.2. Dewatering control room

 Power distribution cabinet PWS15A

1.1.3. Clarification and evaporation control room

 Power distribution cabinet PWS20

1.1.4.Boiling control room

 Power distribution cabinet PWS24

1.1.5. Recycling water pump control room

 I/O control cabinet RIO53

1.1.6. Central control room

1.2.1. Cane preparation

1.2.4. Air compression and steam cooling

1.2.8. Milk of lime house and chemical cleaning

1.2.9. A Sugar (No.1)

1.2.12. water system

1.2.17. C sugar boiling

1.2.18. C magma crystallization

1.2.20. Recycling water pump

Step 2：UPS cabinet (UPS20) power on

（2） System power on of central control center

 Turn on the power of server 1and server2 (SVR1,SVR2)

Step 2, Open the operation stationOP2901, OP2902, OP2903, OP2904

 Turn on the power of operation station OP2901, OP2902, OP2903, OP2904.

（3） System power on of cane preparation control room

 Switch on Q1 first，then switch on air-switch F1,F3,F991,F992,F993 in sequence.

Step 2 , I/O cabinet(RIO13A) power on

Step 3, Start operation station (OP13A)

 Turn on the power of the operation station (OP13A).

（4） System power on of dewatering control room

Step 3, I/O cabinet (RIO15A02) power on

 Switch on the air-switch F1, F2,F101,F102,F991,F992,F993 in sequence.

Step4, Start operation station (OP1501,OP1502)

 Turn on the power of operation station (OP1501,OP1502).

（5） System power on of clarification control room

Step 2：CPU cabinet (CON20) power on

Step 3：I/O cabinet ( RIO21) power on

Step4 ：Start the operation station (OP2101,OP2102)

 Turn on the power of operation station (OP2101,OP2102)

（6） System power on of boiling control room

Step 2：I/O cabinet (RIO2401) power on

Step 3：I/O cabinet (RIO2402) Power on

Step 4：Start the operation station (OP2401,OP2402)

（7） System start in recycling water control room

2.1.2. System power off

（1） System power off of cane preparation control room

 Shut down the computer (OP13A).

Step 2, I/O cabinet (RIO13A) power off

（2） System power off of dewatering control room

Step 2：I/O cabinet ( RIO15A01) power off.

Step 3：I/O cabinet (RIO15A02) power off.

Step 4：Power distribution cabinet (PWS15A) power off

（3） System power off of boiling control room

Step 2：I/O cabinet RIO2401 power off

Step 3: I/O cabinet RIO 2402 power off.

Step 4, Power distribution cabinet PWS 24 power off.

（4） System power off of recycling water control room

（5） System power off of clarification control room

 Step 2：I/O cabinet RIO21 power off

Step 3：CPU cabinet (CON20) power off

Step 4, Power distribution cabinet ( PWS21) power off.

（6） System power off of central control room