Tools

Tools

Braumat

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Braumat / Sistar Apps and Tools

Tools for Braumat on S7-400
and S7-1500
 
Auxiliary programs, Braumat Apps and more!
 
Warranty and liability
The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples are intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make improvements to these Application Examples. We cannot give any liability for the information contained in this document.
 
Braumat calculator
With this you can quickly and easily find the relevant addresses in Braumat (flag or data words). In addition, an overview of all system flags. For programming with Braumat very useful.

dBase-File Editor
New Office-Versions > 2011 cannot manage dBase-Files anymore, but Libre-Office can do that. So a useful Tool to edit and modify dBase-Tools for Braumat. Libre Office is license-free also for commercial and industrial purpose. The Total-commander with dBase-Editor plugin. can edit dBase-Files as well.

Set / Reset all Simulation-Flags (FC486)
in the AIN-Block (Analogue), Timer-Blocks (Digital In) and ICM-Block. Remove the Network you do not need, all ICM to Manual, Auto and more

Generate the Order-Number for the Units by date (FC 487).
Example 20405 makes 4. May 2012.

Braumat Symbolic-File-Generator
Automatic creation of the Simatic symbol list by Excel
Making Braumat-Engineering by using the Excel-Tool Param_PCU00x.xls is very useful. This provides Braumat with a central database for all relevant data. It can also be used to automatically create the symbol list. For this purpose a new sheet "Symbols" has been added at the end, which automatically creates the symbol list from all existing information.

Library of EMF symbols (pipes, tanks, etc.) for creating background images directly with Braumat.


ANA extended
The FIXV_extended is an extended ANA with format conversion and any other functions.
It can be used as a normal extended ANA (type = 0). Or converter integer to real with 0-3 decimal places (type = 1).
Or converter real to integer with 0-3 decimal places (type = 2).

MULT extended
The MULT_ext block can be used to switch 2 value inputs to one output (like that standard-MULT) by a flag. One input can be written back to the other input. The input can be an integer, a double integer or a real. The output can be integer, double integer and real. 0,1,2,3 decimal places can be defined and the value is converted. A format conversion takes place, depending on whether integer, double integer or real is used.


Danfoss VLT-Drives including Danfoss Softstarter Braumat-Plug-in

Features

- Control of Danfoss VLT-Devices by Braumat with ICM-Group and number

- Additonally Control of the Danfoss VLT-Device by a flag-Byte

- Transfer of the Setpoint direct from Braumat Data-Sets like PID, DFM etc

- Transfer of Feedback and Alarm to according Braumat-Flags

- Acknowledge Alarm by Faceplate or global Acknowledge

- Display of the calculated current in the Data-Set

- Support for Danfoss-Softstarter

Status: in use, runs on S7-400 and S7-1500

Siemens Simocode-Module Braumat-Plug-in

Features

- Control of Simocode-Devices of Siemens by Braumat with ICM-Group and number

- Additonally Control of the Simocode-Device by a flag-Byte

- Transfer of Feedback and Alarm to according Braumat-Flags

- Acknowledge Alarm by Faceplate or global Acknowledge

- Display of the calculated current in the Data-Set


Status: implemented in Ursus Breweries, Romania
Profibus-Diagnostic by Braumat

With this module you get the Alarm-Messages from Profibus-Modules

Features

- Check Siemens and other Vendors Profibus-Modules for Alarm

- Process-Image for Display available

Status: tested in Ursus Breweries, Romania but not used at the moment

Intervall-Timer with 32 Setpoint on/off, Enable-Mask and much more

Details:
Braumat is missing a function for Pulses for example for the flushing of different CIP-Valves or for a cascaded switch on of the Malt-Transport and other purpose.
This new Pulse-Generators has following Features
•Up to 32 different Set-points for Pulses switch on and 32 different Set-points for Pulses switch off.
•Up to 32 Outputs with minimum one Output with a defined on/off-Time.
•Start-Input, Hold and Reset-Input
•Additional you have a enable-flag for each Pulse. Thus interlock in the Malt-Transport can be realized (Stop starting-up in case of Fault)
•Additional you have a Mask for to disable each Pulse and go to the next one
•Can work in normal Mode (one by one)
•With overlapping of the Outputs (for to avoid noise during CIP). The overlapping-Time can be changed.
•It can switch on all Outputs cascaded (Outputs remains on) for example to switch on the Malt-Transport one by one.
•After switch on all Outputs it can switch off all Outputs one by one; There is a extra Time for to switch off.
•Open Source for own improvements
 

Status: implemented in Ursus Breweries, Romania

Tank-Temperature-Control with BRAUMAT

Features of the Tank-Temperature-Control-Module
•max. 8 Zones
•max. 8 Sensors
•max. 8 Temperature-Controller with Hysteresis and Pre-Stop-Value
•Level-dependent Zone-Selection
•Level-dependent Temperature-Sensor-Selection
•Free selection Temperature-Sensors to Zones
•Auto-Select Zones at fermentation: top-Down
•Auto-Select Zones at storage: button-up
•Setup of Minimal Number of Zones
•Optional one additional Level for emptying of the Tank

•Setpoint-Ramp defined by Actual Temperature, Setpoint and Time or by Temperature increase / decrease per hour.
•The lowest cooling zone is monitored to avoid freezing
•The lowest cooling zone is monitored for deviating too high and too low and a Alarm is generated
•There is an Alarm for Max-Time fermentation and germination
•There is an Alarm for Max-Time Storage
•There is an Alarm for Max-Time CIP
•There is an Alarm for Max-Time Sterile

•There is a Summary Alarm Flag
•There is a Summary Reset Alarm
special Features
•Tank-Status with max. 255 entries independent from the Step
•Number minimal Zones for Auto-Select Zones at fermentation
•lowest Zone on during fermentation?
•All Data can be modified by Braumat Parameterization

Status: implemented in Wuerzburger Hofbraeu and Ursus Breweries, Romania
runs on S7-400 and S7-1500
 
Tank-Data-Management-Functions

Up to 10 Dataset for max. 10 Brews are stored and displayed with
•Sort
•Quantity
•Total Quantity
•Brew-Number
•Batch-Number
•Tank-Status
•Max. number of brews in the Tank and actual Brew-Number
 

 
•Status: implemented in Wuerzburger Hofbraeu and Ursus Breweries, Romania, but lots of improvement since.

Selected Tank is empty
Small Tool to check that the selected tank is empty or fill (CIP etc).

•Check the flushing-quantity for each Tank by the Tank-number


Silo-Data-Management

Features
•Completely standalone application, no changes to the necessary steps etc.
•graphical programming and display by process-picture
•Overview-picture with up to x Silos and all Data
•Manual correction of all Data
•Calculation and actual display of content as bar
•Data Management with up to 10 additional data:
•-      Malt_Type
•-      Delivery_Number 1-3 (3 fillings)
•-      Supplier 1-3 (3 fillings)
•-      Betaglucan
•-      EBC

Status: implemented in Ursus Breweries, Romania
Status: runs on S7-400 and S7-1500

Ramp-Function by Time and Delta x / min

(For Temperature, Pressure-Controller etc)
Regulating the Steam-valve by increasing the Temperature only 1°C/min saves a lot of energy and is good for the product.
This function can work in two modes
Linear Mode
Calculation by Start-Value, End-Value and given Time
Ramp-Mode
The Setpoint-Temperature is increased by °C / min which can be input by DFM. It starts with the actual value which is increased by °C / min.

Status: implemented in Ursus Breweries, Romania
Braumat SE-Timer
With this modification the Timer can generate a Delay on and Delay off Pulse at the same time.

Status: tested

Average-calculation

Sometimes a measured value is quite unstable. With this Tool you can make a Average-calculation; It can be all second or any defined time. It can be external triggered by SQL-Data. Up to 20 values..


Status: in use, runs on S7-400 and S7-1500

Datalink-OCX
Unfortunately no more official Element of Braumat-CD but very usefull to access the S7 by Visual Basic etc.
With Datalink OCX you can upload and  Flag, DB, Input, Output outside Braumat, but the PCU-Srver need to be active

Status: used in several applications.

Alternative Double Seat Valve based on 3 ICM
Double Seat Valves are frequently used in Breweries, especially in the cellar-area. Here you find a applicative solution for to handle that with Braumat.

Status: in use, runs on S7-400 and S7-1500

Sequence-Add-on

Activation of the outputs, operator-request, messages, adapting the next-step-conditions and more without programming, realized by a process image
Modifying ICM-activation and Transitions requires a programmer. With this feature you can modify a lot of Braumat-elements in the Steps and outside.

Braumat Data-base-generator for free Protocols with Excel-Evalation based on Templates


Solution for to extract Process-Data at dedicated Steps as a basis for a Brew-Report and for a Database on the Computer.
If the SQL-Database Braumat driver is installed this Data will be integrated in the SQL-Data-Base as well

Status: in use, runs on S7-400 and S7-1500

Recipe-based Process-Control for Output and Transition
 
This function offers the possibility to modify the Outputs in the Step and the Next-Step-conditions using the recipe-System and the Binary-functions “Bitfield”.

Features
-Evaluate a Binary Bitfield-DFM to activate the according output.
-Evaluate a Binary Bitfield-DFM to display a feedback of a output.
-Evaluate a Binary Bitfield-DFM to activate the according Flag (Message etc).
-Evaluate a Binary Bitfield-DFM for to check the next-Step-conditions by flag (DFM / Input / ICM-Feedback)
-Check for True / False.
-Check for “AND” and “OR”.
-Maximum 8 DFM
-A Operator-request can be activated combined with other conditions.
-The function can be used parallel to a Step7-programming with priority Add-on or programming.

Recipe-based Process-Control for Output and Transition if the ICM and DFM are not in a block

Recipe based activation of Actuators and modification of transitions ensure high flexibility to adapt the process to specific needs. It gives the operator transparency about the action of the specific step and the Transition-conditions.
 
Features
Template with 2 DFMs using Decoder 1 and 2;
32 Outputs, ICM or more can be activated by recipe
Operator-request can be activated
Transition: 8 DFM with compare > or <;
16 more additional functions like Message etc

Weighing with Braumat and Siwarex FTA
Dokumentation

Braumat with Energy-Monitor PAC 3200

Saving energy by Load-shedding

Almost all small and medium-sized enterprises, when their connection power exceeds x kW (depending from the power supplier), have to pay a higher price in addition to the working price. An energy peak within a measuring period beyond the agreed power supply limit can increase the electricity cost for the entire year drastically.
With this function, it is possible to deactivate different units independently, depending on the energy
consumption. This allows the customer to easily implement a load shedding system and to save energy
and reduce costs.
 Up to 32 Units can be managed independent.
 32 outputs can be freely defined for 32 units.
 Each output-function can be activated and deactivated individualistic.
 Freely programmable priorities for the devices for load shedding
 Additionally an output-flag can be defined in order link the function with a subsequent module
for additional logic.
 2 digital inputs for the energy-counting pulse and for the synchronization impulse.
 The measuring pulses have a variable ratio (for example, 1000 pulses / kWh)
 The measuring period or synchronous pulse is variable, usually every 15 min.
 Minimum switching-on time as well as maximum switch-off times for each output.
 The timing of a measuring period is set by the power-supplier via a synchronous pulse. If not
existing an internal timer can be used.
 If the contact closes for at least 150 ms, it is recognized as a synchronous pulse and the measuring period is restarted.
 
Universal-Function for Energy-optimization and any switching function

To reduce the Energy-demand this function can be used.
Any numbers of Modules are possible, depending from the DB-length.
•Each module has a weekly program Off, all day, Monday-Friday, Monday-Saturday, Sat/Sunday, only Sunday.
•For each module one Time-Program can be defined (from… till).
•Several modules can work on the same output, so different time-slots are possible.
•For each output an analog Input can be defined with a Setpoint, Hysteresis and compare on “>” or “<”. This can be for example a Light Sensor in case of illumination or a Temperatur-Sensor etc.
•For each module a Digital Input (Sensor) can be defined for to activate the output.
•For each module another Digital Input (Sensor) can be defined for to switch off the output.
•For each module an Output can be selected freely.
•The Status of the Time-Function, Analog-Input and Digital Input is displayed.
•The functions of Time-Unit, Analog-Input and Digital Input can be cascaded or used individually.
•Each output can be switched on manually
•The modules can be linked with each other (cascaded).
•No additionally programming is necessary.
•All necessary Text can be input directly in the application.
•This module can be combined with the function load-shedding.
•The output can be used in several modules and parallel to other User-programming in the PLC (OR-Logic).

DFM-Call in FB100x obsolete
With this call “UC FB715” or UC “TA_CALL_DFM_FB” the call of the FC736 etc. for DFM is not necessary any more.
In Version V7.0 there the User-Block FC 2715 can be used. (see )

Status: in use, runs on S7-400

Monitor and control a S7-300/400-PCU with Braumat-OS without Braumat-Software in the PCU
Run Braumat with S7-300 or S7-400 without Braumat-Software
 
Softcell: Universal-Module for Braumat

Customized software is very expensive and often not very flexible for changes or adjustments.
To save engineering costs and to give the customer more flexibility and transparency, this universal module has been created.
It offers the possibility to realize a variety of different functions without having to program it by a process image. Also in the field of energy-management.
The function work parallel to the sequential control but is the Master for the Output. That means additional functions can be realized (conditional set, reset of an output) influencing the same Outputs like in the sequential control.

Replace Code by a list based on Excel-Makro

in order to Clone Units it could help to replace Merker and Tags by a list.
With that Word-Macro it might be possible.

List actual messages, which ICM is in Simulation, forcing, messages high Score

In Braumat the messages are in a buffer and old messages not easy to find, if they happened some time ago, So although some is still in Alarm, the message is not visible. To avoid that this Message-Picture was created to show all actual Alarms.
Furthermore the ICM with the most Alarms are displayed.
All ICM which are in Simulation or forcing enable are listed as well
Status: in use, runs on S7-400 and S7-1500

Route-control engineering by Excel and Import partial routes

Template Overview picture
Everyone makes their own new overview picture for each project, this is a important "window" also for guided tours etc. The optics of a system is extremely important nowadays.
Here the basic menu was reproduced on a process picture image and some further functions are in an overview picture. This can be freely designed. Flexible templates for basic and overview images, with many options and templates.

Fuzzy controller in Braumat
This is the high music of the regulations, which is highly appreciated by professionals, for certain applications.
Features
•Up to 16 instances.
•Up to 7 Fuzzy sets and associated membership functions for each of the three quantities.
•Completely independent of the Braumat controller.
The controller was tested so far and made available to me by a partner for free use. It's been adapted for Braumat now.

RCS tools
Furthermore a Tool for Route control (RCS) to easily parameterize the routes via Excel and then export them. This saves a lot of valuable time!

Cross-communication template
A template to create a structured cross-coupling

Excel Sequence Code Generator

An Excel matrix is often created for the step chains. The Braumat code for S7-400 and SCL code for the S7-1500 can now be automatically generated from these. This could help a lot to finish programs within a short time.
This results in transparent Braumt-compliant programming. This allows an easy transition to the S7-1500. This makes FDS creation and programming much more efficient and transparent.
This also allows the subsystem module and interlocks to be programmed via matrix. 
•There is now a tutorial on how to export and import recipes very easily.
•The cloning of recipes is well described and becomes easier and easier. 

 Siwarex-Weighing Controller

For the Siwarex balance processors a detailed manual has been created

Data Pre-Processing

Recalculating and processing data for the protocol in Excel or SQL requires time and skills how to handle that.

The PLC S7-400 or S7-1500 gives us an excellent and flexible way to do functions by parametrization instead of programming. This means the result of these pre-processing only needs to be transferred to Braumat, Excel or SQL and necessary results are available.

Key process values KPI and any other data that is needed are available without additional programming.
Function can be used for monitoring an input value (ex: water, malt, etc) dosed in a batch and stored in a counter/output.

Features
Focused on the consumption of water or raw-material it can summarize according counters.
Highest input value in a batch will be stored and added to the output.
•No additional programming or Excel actions are necessary.
•Even complex functions like the relative evaporation etc. can be implemented in this universal pre-procession module.
•Transfer of the Actual value direct from Braumat/SISTAR Data-Sets like DFM, AIN, etc.
•Counters can be Source as well.
•Maximum-values can be detected.
•Reset output counter manually or by Scheduler (every year, month, day, etc)
•Detection of a new batch is made each time the input value drops to 0. This will make function know there is a new batch so it will add the actual input to the previously stored values from other batches.
•There is the option to manipulate the input value (add, substract, divide, multiply) with a Calculation Factor and transfer the result to output counter.
•Function can work with different datatypes like Real, Dint and Int.
•Up to 128 data sets that can be parametrized as actual standard but more is possible.
•Enable function flag for each data set.

Golden Batch

Comparing individual batches with the batch as it should be offers instant few of the quality of the current batch. Thus, modifications can be done to optimize the process.
Alarm triggers can show values which are beyond good limits.

KPV – Key Process Value

Is a history record triggered by the last EOP and counts all essential data that need to be stored and compared with older runs to see if we have improvement of efficiency or we have some problems.