Engineering Manual CEMAT V9.

0 SP2 Engineering Examples

Engineering Examples

Content
Engineering Examples i
General .................................................................................................................... 3
Basic Rules ................................................................................................. 3
Connection rules and recommendations .................................................... 4
Annunciation Release ................................................................................. 4
Impulse Processing ..................................................................................... 5
Group functions ........................................................................................................ 6
Group start/stop .......................................................................................... 6
Start-up-warning ......................................................................................... 8
Group start interlock .................................................................................... 9
Group operation interlock .......................................................................... 10
Group switch-off interlock ......................................................................... 11
Start and Stop of the drives ...................................................................... 12
Feedback ON (all drives running) ............................................................. 14
Feedback OFF (all drives stopped) .......................................................... 15
Quick stop ................................................................................................. 16
Group Links ............................................................................................... 17
Object Links .............................................................................................. 19
Acknowledgement mode........................................................................... 21
Drive functions ....................................................................................................... 22
Change of operation mode ....................................................................... 22
Start and Stop in Automatic mode ............................................................ 25
Start and Stop in Single-start mode .......................................................... 28
Start and Stop in Local mode.................................................................... 29
Start-up warning in Single-start mode (and Local mode) ......................... 36
Sporadic mode .......................................................................................... 37
Drive in Standby (Alarm message also for non-running device) .............. 38
Protection interlocks .................................................................................. 39
Speed monitor supervision ....................................................................... 41
Set point input ........................................................................................... 44
Drive with SIMOCODE .............................................................................. 45
Drives with Subcontrol function................................................................. 46
Display of an analog value in % (e. g. Motor current) ............................... 47
Display analog value ................................................................................. 48
Star-Delta Starting; Slip ring Rotor with Starter Motor .............................. 49
Operation modes and control of the damper ............................................ 50
Analog actuators ....................................................................................... 52
Damper with middle position ..................................................................... 53
Damper with torque switch ........................................................................ 54
Wagging function ...................................................................................... 55
Fan and Damper ....................................................................................... 56
Annunciation blocks ............................................................................................... 58
Drive fault annunciations ........................................................................... 59

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Warning messages ................................................................................... 60

Alarm interlocking for the annunciation block ........................................... 61
Interlocking annunciation (Silo levels) ...................................................... 62
Two-level alarm (first warning then switch-off) ......................................... 63
Annunciation for Status call ...................................................................... 64
Release supervision ................................................................................. 65
Engineering of an ANNUN8 block ............................................................ 66
Measured value ..................................................................................................... 67
Read in a measured value ........................................................................ 67
Measured values, Calculated Values ....................................................... 69
Measured values, Limit Value Supervision ............................................... 69
Alarm interlocking for the Measured Value block ..................................... 70
Using limit violation bits as interlocking condition ..................................... 71
Block Measured value, Bypass, Service mode ........................................ 72
Release limit supervision .......................................................................... 73
Pressure control ........................................................................................ 74
Route functions ...................................................................................................... 75
Feedback ON (all drives running) ............................................................. 75
Feedback OFF (all drives stopped) .......................................................... 77
Uninterrupted route change-over .............................................................. 78
Automatic Route change .......................................................................... 82
Engineering Examples for additional blocks .......................................................... 83
Display of interlocking conditions with interlock blocks ............................ 83
Query settings within the AS ..................................................................... 87
Analog Value Selection ............................................................................. 88

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

General
This description should provide support in the solution of control tasks using the CEMAT
software.
Please adhere to these recommendations that have proved themselves in practice.
Many block parameters start for historical reasons with a certain codification (name was never
changed because of Migration of existing plants). The codification is as follows:

Object type Block name Code

Unidirectional drive C_DRV_1D E
Damper C_DAMPER K
Valve C_VALVE V
Annunciation module C_ANNUNC M
Measured value C_MEASUR UM
Route C_ROUTE W
Group C_GROUP G
Selection module C_SELECT AW
Silo pilot C_SILOP SP
Counter C_COUNT CNT
Running time C_RUNNT RT

Basic Rules
It is essential to conform to the following basic rules.

Limit Switches
The break contacts from these switches should be connected directly in the contactor control
circuit. Connect the make contact elements to the AS inputs.

Binary Special Signals

Signals such as belt drift switch, pull-rope switch, silo full must always be connected to an
annunciation module. The module flag of the annunciation module (OutSig or MAU) should
then be used for the further use in the program.

Start/Operation Interlock of the Group

In order to display also the interlocking conditions in the status call-up of the group, the
interlock signals (also internal flags) should be connected to annunciation modules.

Damper Directions
The following definition applies for the end position of the damper:
direction 1 = closed
direction 2 = open

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Connection rules and recommendations

Selection and Route Module
We provide two module types for selections:
- selection module
- route module

The selection module is particularly suitable for smaller branches, standby circuits.
Advantage:
- reduced configuration effort
- reduced program run-time

The classical route module is particularly suitable for (long) transport routes that use different
drives.
Advantage:
- Through assignment of the objects to a route ‘partial groups’ are defined.
- Only the status of the objects belonging to a selected route will be forwarded to the group.
- Status call and object list call can be carried out for the individual route, which permits the
diagnostic function per destination

The question whether a selection module, a route module or various groups should be used
must be decided individually.

Annunciation Release
In all Cemat blocks through plausibility logic it is assured that in case of several simultaneous
faults only the "perpetrator" creates an alarm message.
For example, in case of a protection interlock of a motor, no alarm is created by the motor
block, it is created by the associated annunciation module.
In order not to create an alarm flush in case of loss of control power, each Cemat block has
an interface "Annunciation Release" xMFR, which has to be connected with the control power
signal.
In case of a periphery failure (such as bus failure, card failure, MCC failure) this signal must
get "0". At this moment the Cemat block does not create further messages (no incoming, no
outgoing messages).
For the annunciation of the control power failure itself an additional annunciation block has to
be programmed.

The annunciation release is one of the most important interfaces in order to achieve a smooth
! operation. The project engineer must assure that only the perpetrators of a fault create alarm
messages.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Impulse Processing
Both the pulse length and pause length must be longer than the OB1-cycle for signals that are
to be recorded from the cyclical program (OB1). As guidance value, it should be longer than
200ms.

OB1 Cycle

Process signal 200 ms 200 ms

If the signals are recorded in the 100ms-OB cycle (time-controlled alarm processing), the
pulse times and the pause times of the signal must both be longer than 150 ms.
There are signals that are created with a flag attached to the drive shaft and a BERO switch.
Such signals, for example, have a short pulse and a long pause.

BERO-Signal

Such signals must not be wired directly to an input module.

The signals must be converted with C1-technic hardware circuits or with series-connected
mini programmable controllers (binary converter) so that the programs can record them
reliably.
Such signals can occur in silo pilots or speed monitors.

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Group functions
Group start/stop
Starting and stopping of a group can be achieved via Operator Faceplate, through the
program or via a conventional Control desk (Push Buttons).

Group Start and Stop via operator faceplate

For the start and stop via operator faceplate no programming in the CFC is needed.
Group start via operator faceplate is only permitted if the start interlock and the operation
interlock have 1-Signal.
Group Stop is only permitted if the switch-off interlock has 1-Signal.

Group start and stop through the program

In order to start and stop the group via program the interface GEBG must be connected with
the start command and the interface GABG with the stop command.

Group start via interface GEBG is only permitted if the start interlock and the operation
interlock have 1-Signal. A rising edge on GEBG is required.

For the group stop via interface GABG the switch-off-interlock is not considered!
!
In project standard 004 (Holcim), the group start via interface GEBG is only permitted if the
! group is switched into Standby mode. The Standby mode must be enabled by the operator.
The group stop via interface GABG is always permitted.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Group start and stop via conventional control desk (push buttons)
For the start and stop via conventional push-buttons the interface GTA must be connected
with the Stop button and interface GTE with the start button. GTA is normally closed, which
means it must be “1” if the button is not pressed. GTE is normally open.
In order to ensure a two-hand operation, the interface GFGS must additionally be connected
with a Release button. The Release button must be pressed together with the GTE or GTA
button.

The group start via GTE is only permitted if the start interlock and operation interlock have 1-
Signal. A rising edge on GTE is required.
Group Stop via GTA is only permitted if the switch-off interlock has 1-Signal.
In order to enable the interfaces GTA and GTA the pushbutton release GPTS must be
connected with a 1-Signal. (For the operation via operator faceplate GPTS must have 0-
Signal).
If you want to allow a parallel operation, via operator faceplate and via push buttons, this can
be achieved with the following logic.

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Start-up-warning
Before the group start is transmitted to the drives, a start-up-warning must be given. The
group block has two outputs, one for a lamp and one for an acoustical signal (horn).
The lamp output GLA remains set during the complete start-up sequence and it will be
switched off when the group start is completed.
The horn output GHA will be set for the duration of parameter HORN_TIM. It can be used for
an acoustical alarm in the field.
The drives get started only after the waiting time WAIT_TIM has elapsed.

Horn time and Waiting time start simultaneously, which means that the waiting time should be
! a little bit bigger than the horn time. This insures that after the horn goes off the start is still
delayed for some seconds.

The start command is limited by the release time RELS_TIM. After the release time elapsed
no start command is given to the drives.

In case of a problem in any of the group objects during the start procedure, the dynamic fault
! of the object interrupts the group start command, but in this case the release time still
proceeds. If the problem can be solved within the release time the group start can be
triggered without creating a new start-up warning.

Time diagram:

Group start

St.-up-w. Horn GHA (HORN_TIM)

Waiting time (WAIT_TIM)

ON Command GBE

St-up-w. lamp GLA

Feedback ON GREZ

Group start Horn time Waiting time Group completely

elapsed elapsed running

Parameters and Block outputs for the start-up-warning:

For the start-up-warning in single-start-mode the HORN outputs of the drives must
! additionally be considered.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Group start interlock

Through group start interlock you can avoid a start-up-warning for a group which is not ready
to start (e. g. if a route must be selected before group start).
Two interfaces exist, which are effective at the same time, which means that they must both
have 1-Signal in order to allow the group start.
The interface GEVG has format BOOL and can be used for connecting binary signals or one
of the binary interlock blocks C_INTERL or C_INTER5.
The interface IntStart (from Cemat V7.1) has STRUCTURE format and can be connected with
a structure output or with a structure interlock block, e. g. Intlk02. If this interface is used, the
connected block can directly be opened via the faceplate of the group.
Example: One of two routes must be selected in order to allow the group start.

In order to provide this information in the status call of the group, annunciation blocks must be
! programmed for the start interlocks. See “Annunciation bocks for status call function”.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Group operation interlock

Process signals which must stop a group have to be connected to the operation interlock (e.
g. Silo full or discharging group has tripped). Stopping of the group is similar to a normal
group stop (no Quick Stop).
This kind of group stops must be acknowledged by the operator.
Two interfaces exist, which are effective at the same time, which means if one of these
interfaces has 0-Signal the group will be stopped.
The interface GBVG has format BOOL and can be used for connecting binary signals or one
of the binary interlock blocks C_INTERL or C_INTER5.
The interface IntOper (from Cemat V7.1) has STRUCTURE format and can be connected with
a structure output or with a structure interlock block, e. g. Intlk02. If this interface is used, the
connected block can directly be opened via the faceplate of the group.
Example: The feeding group must be stopped if the silo is full.

In order to provide this information in the status call of the group, annunciation blocks must be
! programmed for the operation interlocks. See “Annunciation bocks for status call function”.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Group switch-off interlock

Via switch-off interlock, stopping of a group can be inhibited; e. g. if another group must be
switched off before.
Two interfaces exist, which are effective at the same time, which means that they must both
have 1-Signal in order to permit the group stop.
The interface GAVG has format BOOL and can be used for connecting binary signals or one
of the binary interlock blocks C_INTERL or C_INTER5.
The interface IntSwOff (from Cemat V7.1) has STRUCTURE format and can be connected
with a structure output or with a structure interlock block, e. g. Intlk02. If this interface is used,
the connected block can directly be opened via the faceplate of the group.
Example: Before a group can be switched off, the feeding group must be stopped.

In order to provide this information in the status call of the group, annunciation blocks must be
! programmed for the switch-off interlocks. See “Annunciation bocks for status call function”.

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Start and Stop of the drives

For the Start of the drives, use output GBE of the group. The group output GBE is set after
the start-up-warning (Horn time and waiting time) has elapsed and if there is no fault it
remains “1” until the group is completely running.
If it comes to a fault within the start-up sequence, the group output GBE is reset.
After the release time has elapsed the group output GBE is also reset.
The group output GBE must be simultaneously connected to all drives. The start sequence is
programmed through process interlocking between the drive. The start of the drives can
additionally be delayed via parameter STARTDEL (see drive blocks).

Beside output GBE the group has an additional output GDE (continuous on command). Signal
! GDE is not suitable for starting the drives, because it is not reset in case of a fault. The drive
fault can not be acknowledged as long as there is a continuous 1-Signal on the motor
start command!

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

For the Stop of the drives, use output GDA of the group. The group output GDA is set with
the group stop and remains “1” until all drives of the group have been stopped.

There is no switch-off interlock available for the drives. For a sequential stop, the stop
condition (feeding drive has been stopped) must be connected together with the group output
GDA to the drive. The drive stop can additionally be delayed via parameter STOPDEL (see
drive blocks).

Beside output GDA the group has an additional output GBA (Off command). Output GBA is
! only a pulse, which means it is not suitable for stopping the drives (if a stop delay is
programmed, the output GBA doesn’t stay long enough).

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Feedback ON (all drives running)

Via the group feedback ON (interface GREZ) the group is informed that the start-up has been
completed and all drives are running.
Depending on the application this can be an AND-Function with the running signal of all
drives, or the last drive of a start sequence.
With 1-Signal at input GREZ the start-up warning lamp GLA goes off and the on command
GBE is reset.

In case of a group with routes, the route outputs WRE (Route Feedback ON) of the relevant
routes are connected to input GREZ of the group.

As long as GREZ has 1-Signal the start button of the group is disabled and restart is not
! possible. This especially has to be considered in case of an uninterrupted route change-over,
if one route is still running while a second route shall be started.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Feedback OFF (all drives stopped)

Via group feedback OFF (interface GRAZ) the group is informed that the stop sequence has
been completed and all drives are stopped.
Depending on the application this can be an AND-Function with the inverted running signal of
all drives, or from the last drive of a stop sequence.
With 1-Signal at input GRAZ the off command GDA is reset as well as the output GVG of the
group.

In case of a group with routes, the route outputs WRA (Route Feedback OFF) of the relevant
routes are connected to input GRAZ of the group.

Route Feedback OFF (Signal WRA) has 0-Signal if the route is not selected or if the route is
! completely stopped. For this reason, WRA must be inverted for the connection to the group
feedback OFF.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Quick stop
The group Quick Stop function is used for an immediate stop of the drives, which means the
stop delay STOPDEL is not considered.
The Quick Stop can either be carried out via the operator faceplate through the program via
interface GQSP.
In both cases the group sets an output GQS, which has to be connected to input QSTP of the
drives.

In order to display the Quick Stop Button in the operator faceplate, in the property „Styles“ of
! the block icon the attribute „StyleTag“ must be adapted accordingly.

With StyleTag 2, 6, 7 and 8 or. 102, 106, 107 and 108; the button “Quick Stop" in the group
faceplate will be visible. → See description 08_OS_Engineering_009.doc.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Group Links
All objects (Drives, Annunciation blocks, Measured values) belonging to a group must be
assigned to this group via group link. This connection is essential, in order to inform the group
about the status of the objects.
- Via the group link the group knows if one of the assigned objects has a problem. This is
important for the summarizing indication (summarizing fault and summarizing warning in
the block icon of the group) and for the status call.
- Dynamic faults interrupt the group start (GBE is reset).
- From Cemat V7.1 the group has a function to highlight all assigned objects in the process
picture.
Connect output G_LINK of the group to input GR_LINK1 (or GR_LINK2) off all related objects
(Drives, Annunciation blocks and Measured value blocks).

If the group has route modules, the output G_LINK of the group must be connected to input
! G_LINK of the route and output R_LINK of the route has to be connected to GR_LINK1/
GR_LINK2 of drives, annunciations and measured values.

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As an object may belong to more than one group, each object has two link inputs GR_LINK1
and GR_LINK2 and an additional input MUX_LINK for the connection to a multiplex block
C_MUX. With this method the object can be assigned to an unlimited number of groups.
The main group should be connected to input GR_LINK1 of the object, because the button
“Related Objects“ opens the faceplate of this group.

Caution: If a C_MUX block is used, the runtime sequence is crucial. If the same C_MUX
! block is connected to more than one object (e. g. the drive and annunciations and measures
of the same equipment), the runtime sequence is even more important.
In case of annunciation blocks we must distinguish between annunciation blocks with direct
connection to the group/route or annunciation blocks which are linked via O_LINK to a drive
(child objects).
If the annunciation block is linked directly to the route/group the C_MUX block must be called
before the annunciation block. If the annunciation block is linked via O_LINK to a drive the
C_MUX block must be called after the annunciation block. Details see below.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Object Links
Since Cemat V8 SP1 it is possible to link annunciation blocks and measurements which
belong to a motor via interface O_LINK directly to the drive block. In this case the group links
GR_LINK1, GR_LINK2 and MUX_LINK must not be used!
- The drive block itself has an object browser function and is able to show a list of linked
objects.
- Additionally the drive block transmits all information from the linked annunciation blocks
and measured value blocks to the group, which interrupts the group start in case of a
dynamic fault (or warning) and which is used for summarizing indication (summarizing
fault and summarizing warning in the block icon of the group), object list and status call.

! Caution: It is not allowed to use the Object link and the Group/Route link at the same time.
If O_LINK is used, GR_LINK1 and GR_LINK2 or C_MUX must not be connected!

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Caution: Using C_MUX blocks the runtime sequence is crucial for the functionality of the
System, especially if you connect the same C_MUX block to more than one CEMAT Object.
! The only valid order is as follows:
1. Child Objects (all Annunciations, Process Feedback blocks, Measurements and Adapter
blocks which are linked via O_LINK to the drive)
2. C_MUX block (single C_MUX or cascaded C_MUX blocks)
3. Parent Objects (C_DRV_1D, C_DRV_2D, C_DAMPER and C_VALVE) and all
Annunciations
and Measurements with direct link to Groups or Routes
4. Corresponding Routes
5. Corresponding Group
Make sure that this sequence is strictly followed and that it is not “interrupted” by the
connection to a different C_MUX block or by any direct connection to a Group or Route!!!

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Acknowledgement mode
All dynamic faults, warnings and interlocks must be acknowledged.

AS-wide Acknowledgement
Normally the fault acknowledgement goes together with the acknowledgement of the alarm
message in the alarm line and faults are acknowledged for the complete AS. In case of an
alarm message from AS1 in the alarm line, the acknowledgement will reset the faults of this
AS (only the dynamic fault of the blocks, the messages must be acknowledged individually.)
This is the default setting in the system chart SYSPLCxx at block C_FB_PLC, if parameter
ACK_GR and ACK_OB have value "0". In our opinion this is the most convenient method,
because beside the acknowledgement of the alarm message no further action is required.

Group-wise acknowledgement
Beside this there is a possibility of acknowledgement per group. In this case, in the system
chart SYSPLCxx at block C_FB_PLC the parameter ACK_GR must be changed to 1-Signal.
Additionally the output ACK of the group must be connected to the acknowledgement inputs
EQIT, KQT1, VQIT, MQIT and UQIT of all related objects.

Output ACK of the group is only set in this mode!

!
Object-wise acknowledgement
If in the setting in system chart SYSPLCxx at block C_FB_PLC the parameter ACK_OB is set
to 1-Signal, the acknowledgement is be carried out per object, which means that via the
acknowledgement of the message in the alarm line only the object which created the alarm is
acknowledged.
This method has a disadvantage: For protection interlocks only the annunciation block creates
the message but also the drive block which is stopped by protection interlock has a dynamic
fault. In this case the drive fault must be acknowledged additionally via the drive faceplate.

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Drive functions
Change of operation mode
Starting and stopping of drives can be carried out in three different operation modes. The
most important operation mode is the Automatic mode. In the Automatic mode the drives are
started and stopped via a group. All process interlocks are effective.
In Local mode the drives can be started and stopped via locally installed push-buttons. In this
operating mode the process interlocks are not effective.
In Single-start mode the drives can be started and stopped via operator faceplate from HMI.
Regarding process interlocks the behaviour is different in the individual project versions:
- In project version 004 the single-start mode is meant for maintenance only, and the
process interlocks are therefore not effective.
- Im Project veraions 006 and 007 there is a possiblility of a non-interlocked single-start
mode. But this mode must be explicitely released.

In some of the project versions (000, 007, 023, 024,025, 028) the operation mode is enabled
by the group block, the faceplate of the group has buttons for operation mode change and the
group block has outputs for enabling the corresponding operation mode of the drives.
Therefore the group output GES must be connected to drive input xEIZ and group output GLO
must be connected to drive input xLOC.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

In all other project versions (004, 006, 026, 027) the operation mode can be changed
individually via the drive faceplate. Some project versions additionally allow group-wise mode
change from local to automatic (004, 002, 026) or from automatik to local (004, 026).
In Project version 004 group output ENLM switches the drives into local mode and output
DILM switches the drives back to automatic. Both outputs are only pulses and must be
connected to the input of the drives with the same name.
The feedback to the group (LOCAL to FB_L) is used for the indication in the block icon and
tells the operator that at least one drive is in local mode.

In Project version 026 group output GVE must be connected to drive input xVFE and group
output GVA must be connected to drive input xVFA. The outputs of the group are pulses and
only used for switching over.
The feedback to the group (EBV to GRVO) is used for the indication in the block icon and tells
the operator that at least one drive is in local mode.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

In Project version 006 the group has an output GAU (Pulse) which must be connected to
input xAUT of the drives, in order to switch all drives of a group back into automatic mode. In
case of a group with routes, the switch-back can be carried out per route. In this case output
GAU of the group must be connected to input WAUT of the route and output WAU of the route
must be connected to input xAUT of the drives.
The feedback to the group (EHV to GZHV) is used for the indication in the block icon and tells
the operator that at least one drive is in ‘Manual interlocked’ mode.
The feedback to the group (EHE to GZHE) is used for the indication in the block icon and tells
the operator that at least one drive is in ‘Manual non-interlocked’ mode.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Start and Stop in Automatic mode

For the Start of the drives in automatic mode the output GBE of the group must be connected
to input EBFE, KEB1, KEB2 or VBFE of the drives.
Output GBE remains "1" until the group is completely running. In case of a fault during the
start-up of the group, output GBE is reset.
Output GBE is connected simultaneously to all drives. The start sequence is determined
through interlocking among the drive. The start of the drive can be delayed additionally via
parameter STARTDEL.

Output GDE of the group is not suitable as drive start command, because this signal is not
! reset in case of a fault. The drive fault cannot be acknowledged as long a there is a
continuous 1-Signal at the on command!!

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For the Stop of the drives in automatic mode the output GDA of the group must be connected
to input EBFA or VBFA of the drives.
Output GDA is set with the group Stop and remains "1" until the group is completely stopped.
As the drives to not have a stop interlocking, for a sequential stop the stop condition (feeding
drive is stopped) must be connected together with the group output GDA to the drive. The
drive stop can additionally be delayed via parameter STOPDEL.

Group Output GBA (Command Off) is only a pulse and normally not suitable for stopping the
! drives (if a stop delay is used output GBA does not stay long enough).

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

For the Quick stop of the drives the group output GQS must be connected to input QSTP of
the drives. In case of a Quick Stop the drive is stopped immediately (without considering the
Stop delay).

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Start and Stop in Single-start mode

For start and Stop in single-start mode no additional connections are required. Only the
permission must be given.
In some of the project versions the change into single-start mode can be inhibited by
switching the faceplate buttons of the drive to invisible. This can be achieved in project
version 004 and 026 via interface EN_SINGL and in Project version 006 via interface EEIZ.
At this point we would like to mention again the non-interlocked single-start mode of project
versions 004, 006 and 007.
- In Project version 004 the single-start mode is always non-interlocked.
- In Project version 006 the drive faceplate has a button fort he so-called non-interlocked
mode. In this case only the fix start interlocks and operation interlocks are effective. Some
of the start interlocks and operation interlocks will be bypassed.
- In Project version 007 there is also a possibility for a non-interlocked single-start mode,
but it needs a special permission and must additionally be enabled.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Start and Stop in Local mode

In local mode the start and the stop of the drives is carried out via a local switch. This can
either be a switch or start and stop buttons, located beside the device.
Local switches differ a lot and are described separately. In most cases, the signals of the local
switch go into the PLC; which means, also in local mode the drive is started and stopped by
the SIMATIC.
In old installations, it also happens that the signals from the local switch controls the drive
directly, which allows the local mode even if the SIMATIC is not running. In this case a signal
is needed which tells the SIMATIC that the drive is in local mode, otherwise the local start
leads to a feedback fault.

Variants of Local switches:

1. Switch with positions Remote – Local Stop – Local – Local Start
The position ’Local Start’ is non-locking, which means after starting the switch goes back
into position ’Local’. Local start is a make contact (normally open) and local stop is break
contact (normally closed).
2. Switch with position Local Stop – Remote – Local Start
The position ’Local Start’ is non-locking, which means after starting the switch goes back
into position ‘Automatic’. Local start is a make contact and local stop is break contact.
3. Buttons for Start and Stop, where the start button is a make contact and the stop button is
a break contact.
An additional input permits the local mode (for the mode change from automatic to local).
4. Buttons for Start and Stop, where the start button is a make contact and the stop button is
a break contact.
The permission of the local mode is exclusively given through HMI.
5. Buttons for Start and Stop, where the start button is a make contact and the stop button is
a break contact.
An additional repair switch (with locks) is effective in all operation modes and inhibits the
drive start during maintenance action (Signal ’Local Isolated’). The permission of the local
mode is exclusively given through HMI.
6. Start button (make contact). An additional local switch is effective in all operation modes
and inhibits the start of the drive.
The local mode is always enabled or must be enabled exclusively through HMI.
7. Start button (make contact). The local mode is an inching mode, which means the motor
remains started as long as the button is pressed.
The permission of the local mode is exclusively given through HMI.

Regarding local mode the project versions are different, which means depending on the local
switch which is used one project version is more or less suitable.
Probably other variants of local switches exist. In case you have any doubts and cannot
decide which project version fits best, please contact the Cemat Competence Center.
On the following pages you find examples for the different project versions:

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Project versions 000 and 028:

ESR Local Start (normally open)
ESP Local Stop (normally closed)
EVO Local Selection Switch (1 = Remote; 0 = Local)
ELOC Enable local mode via HMI

The Project versions 000 and 028 can be used for variant 1, variant 3 and variant 4.
The Local mode is enabled per group. Additionally the switch EVO must be in position Local.

If no additional switch for the selection between Remote/Local is available, the input EVO
must be simulated using inverted group enable GLO.

If the enable via HMI shall not be used, the input ELOC must be simulated by using inverted
EVO signal.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Project version 004:

G Local Start (normally open)
S Local Stop (normally closed)
U Local repair switch (Local Isolated) must always be “1“.
ENLM Pulse for change into local mode
DILM Pulse for change into automatic mode

The Project version 004 is suitable for variant 5.

The local mode is enabled via the faceplate of the drive or the faceplate of the group and can
only be given when the drive is not running.
Change into automatic mode can be carried out via the faceplate of the drive or via the
faceplate of the group as well as automatically during group start.

Project version 006:

TSE Local Start (normally open)
EAUT Switch back into automatic mode

The project version 006 is suitable for Variant 7.

The local mode is enabled via the faceplate of the drive. Switching back into automatic mode
can be carried out via the faceplate of the drive and also via the faceplate of the group (or the
route).

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Project version 007:

EVT Local Start (normally open)
EVO Local switch (must always be “1“)
ELOC Enable local mode via HMI

The Project version 007 is suitable for variant 6.

The local mode is either always enabled (ELOC is preset with “1“) or can be enabled by the
group.

Project version 023:

G Local Start (normally open)
S Local Stop (normally closed)
ELOC Enable local mode via HMI

The Project version 023 is suitable for variant 4.

The local mode is enabled group-wise (through the group faceplate).

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Project version 024:

KX Local input KX
K0 Local input K0
ELOC Enable local mode via HMI

The project version 024 is suitable for variant 1, but it requires a special matrix. In this matrix
4 different situations are simulated with only two signals.

Switch position K0 KX
Automatic 1 0
Local Stop 0 0
Local 0 1
Local Start 1 1

The local mode is enabled group-wise (through the group faceplate).

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Project version 025:

EVO Local input EVO
ESR Local input ESR
ELOC Enable local mode via HMI

The project version 025 is suitable for variant 2, but it requires a special matrix. In this matrix
3 different situations are simulated with only two signals.

Switch position EVO ESR

Automatic 1 0
Local Stop 0 0
Local Start 1 1

The local mode is enabled group-wise (through the group faceplate).

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Project version 026:

ESR Local Start (normally open)
ESP Local Stop (normally closed)
EVO Local repair switch (Local Isolated) must always be “1“.
EVFE Pulse for change into local mode
EVFA Pulse for change into automatic mode
The Project version 026 is suitable for Variant 5
The local mode is enabled via the faceplate of the drive or the faceplate of the group and can
only be given when the drive is not running.
Change into automatic mode can be carried out via the faceplate of the drive or via the
faceplate of the group as well as automatically during group start.

Project version 027:

L1 Local Start (normally open)
LS Local Stop (normally closed)
DLOC Enable local mode

The Project version 027 is suitable for Variant 4.

Local mode is enabled via the faceplate of the drive or via interface DLOC.

Caution: If DLOC is connected the mode change via drive faceplate is no longer possible!
!

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Start-up warning in Single-start mode (and Local mode)

In the automatic mode the start-up warning is carried out through the corresponding group.
However, if the drive is started in single-start mode then at least in remote it must be insured
that before drive start an acoustic alarm is created.
This is done via output HORN of the drive blocks. The duration of the start-up warning can be
set via process parameter HORN_TIM. The contactor command is only given after this time
has elapsed.
Connect output HORN of the drives together with the start-up warning signal of the group to
the corresponding hardware outputs.

If the start-up warning shall be given also in local mode, you have to change parameter
L_STA_WA of the drive to 1-Signal. See drive M3.

Caution: In local mode the start button must remain pressed until the start-up warning is
! completed.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Sporadic mode
Concerns Unidirectional drive, Bi-directional drive and Valve
Sometimes it is required to start and stop drives dependent on a process signal or time
controlled. This concerns devices for heating, cooling, lubrication or valves for silo aeration.
In this case the drives have to be activated via group start signal GBE or via route start signal
WBE and can then be switched on and off via the status at interface ESPO.
0-Signal at interface ESPO stops the motor without reset of the command memory EKS. The
motor remains activated and starts automatically with 1-Signal at this interface.
To switch off the drive completely it needs a 1-Signal at EBFA or 0-Signal at the operation
interlock (EBVG or IntOper). If the drive has been stopped by fault the group must be started
again.
For the feedback to the group signal EVSP must be used. EVSP has 1-Signal, as soon as the
drive is activated.

This interface is only effective in automatic mode. In Single-start mode or in Local mode
ESPO is not considered. In case of a mode change the behaviour is as follows:
- If a drive which is running in automatic mode is switched to single-start mode, it will then run
continuously.
- If a drive which is running in single-start mode is switched into automatic mode, the signal
status of ESPO is considered. If ESPO = 0-Signal the drive is stopped (EKS is reset). If
ESPO = 1-Signal the drive will proceed in sporadic mode.

Caution: Modified function for project version 007

! - If a drive which is running in automatic mode is switched into single-start mode it will
continue to run sporadically until the drive gets stopped.
- If the drive was started in single-start mode or in local mode, ESPO is not considered, the
drive is running continuously.
- If a drive which was started in single-start mode is switched into automatic mode, at the
moment of the mode change the signal status of ESPO is considered: If ESPO = 0-Signal
the motor will be stopped (EKS is reset). If ESPO is 1-Signal the drive continues to run in
sporadic mode.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Drive in Standby (Alarm message also for non-running device)

If a drive is not started or if it is in local mode, in case of a fault no dynamic fault and no alarm
message is created. This is important in order to avoid alarms during maintenance, or if the
plant section is not in operation.
However, in some occasions it might be required to get the alarms, even if the drive is not
running at this moment, e. g. if the drive has a ’Standby-Function’.
Through 1-Signal at interface ESTB (VSTB, KSTB) also for a non-running device alarm
messages are created, which must be acknowledged by the operator.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Protection interlocks
Protection interlocks are interlocking conditions which must stop the drive in case of a fault, in
order to protect machines or persons.
In case of a missing protection interlock the drive indicates ‘faulty’ (red indication), similar to
normal drive faults (static fault if the drive was not running, dynamic fault if the drive was
stopped through protection interlock.)
Unlike for normal drive signals as e. g. electrical availability or overload, the drive block does
not create alarm messages for protection interlocks. An annunciation block has to be
programmed for this purpose. See chapter ’Drive fault annunciations’.

Always active protection interlocks

In all drive blocks you find 2 interfaces which are effective in all operation modes. If one of
these interfaces has 0-Signal the drive will be stopped.
The interface ESVG (VSVG, KSV1, KSV2) has format BOOL and can be used for connecting
binary signals (e. g. output MAU of the annunciation block or an output of the binary interlock
blocks C_INTERL or C_INTER5).
The interface IntProtG (from Cemat V7.1) has STRUCTURE format and can be connected
with the structure output OutSig of the annunciation block or with a structure interlock block,
e. g. Intlk02. If the structure interface is used, the connected block can directly be opened via
the faceplate of the drive.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Protections only active in Automatic mode and Single-start mode

For Unidirectional drives and Bidirectional drives you additionally find two interfaces which are
effective only in automatic mode and Single-start mode. These interfaces can be used for
signals like Drift switches, where the local start must be permitted.
The interface ESVA has format BOOL and can be used for connecting binary signals (e. g.
output MAU of the annunciation block or an output of the binary interlock blocks C_INTERL or
C_INTER5).
The interface IntProtA (from Cemat V7.1) has STRUCTURE format and can be connected
with the structure output OutSig of the annunciation block or with a structure interlock block,
e. g. Intlk02. If the structure interface is used, the connected block can directly be opened via
the faceplate of the drive.

In Project version 004 the binary interfaces are called PINT1, PINT, PINTX and PINTY, the
structure interfaces are called IntProt1, IntProt, IntProtX and IntProtY. These interfaces are
effective in all operation modes.
The Unidirectional drive and the Bi-directional drive have an additional binary interface PINT2
and an additional structure interface IntProt2, which can be by-passed in local mode with the
local start button. In this case the motor will run only as long as the start button is pressed.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Speed monitor supervision

Speed Monitor signals are detected by the drive block and the drive block also creates the
alarm message. This is valid for all project versions except 004. An example for project
version 004 is described behind.
Input ’Speed Monitor’ can be a continuous signal or a pulse. The drive block can handle both
types. In both cases the process parameter SPEEDTIM must be set to the time after which
the process feedback supervision has to be activated.
Via parameter SM_EVS_I you can decide whether the signal ‘motor running’ is created after
the supervision time SPEEDTIM or if signal ‘motor running’ should immediately be given with
the process feedback.
Some examples with explanations:
1. The process feedback is a continuous signal. The signal must be connected to interface
EDRW and parameter REL_SSM must have 0-Signal.
The feedback supervision time SPEEDTIM is set to 10 seconds and parameter
SM_EVS_I is configured in a way that outputs EVS and RunSig are immediately set when
the process feedback is true.

2. The process feedback signal is a pulse. The signal must be connected to interface
SW_SPEED and parameter REL_SSM must have 1-Signal. The feedback supervision
time SPEEDTIM is set to 10 seconds and parameter SM_EVS_I is configured in a way
that outputs EVS and RunSing are set after the feedback supervision time.

The tolerance value for the detection of pulses TOL_SSM is preset to 50 cycles, which
means if after 50 OB1 cycles no signal change at input SW_SPEED is detected, the
motor is switched off with ‘Speed monitor fault’.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

In Project version 006 the drive block has an additional interface EVQD for the
acknowledgement of the speed monitor fault. The speed monitor must be acknowledged from
local. Via the normal fault acknowledgement the speed monitor fault cannot be reset.

In Project version 004, block C_PROFB is used for process feedback supervision and alarm
message. Also this block has two options, the supervision of a continuous signal or the
supervision of pulses
Via connection of drive output STAT_DRV to input STAT_DRV of block C_PROFB the
process feedback block receives the status of the drive.
The output ‘ProFb’ of block C_PROFB transmits the process feedback to the motor and
output ‘Fault’ of block C_PROFB must be used as protection interlock in order to switch off
the drive in case of a fault.
Dependent on the function, different options exist:
1. The process feedback is a continuous signal. The signal must be connected to interface
IN_SIG and parameter EN_SSM must have 0-Signal.
The feedback supervision time during start-up ON_DEL is set to 10 seconds and
parameter OUTIM is configured in a way that outputs EVS and RunSig are immediately
set when the process feedback is true.

Via parameter EN_OFFDM the supervision during switch-off is activated and parameter
OFF_DLY is set to 15 seconds.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

2. The process feedback signal is a pulse. The signal must be connected to interface
PULS_SSM and parameter EN_SSM must have 1-Signal. The feedback supervision time
during start-up ON_DEL is set to 10 seconds and parameter OUTIM is configured in a
way that outputs EVS and RunSing are set after the feedback supervision time.

The tolerance value for the detection of pulses TOL_SSM is preset to 50 cycles, which
means if after 50 OB1 cycles no signal change at input PULS_SSM is detected, the motor
is switched off with ‘Process feedback fault’. The supervision during switch-off is
deactivated.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Set point input

A set point, as e. g. the speed can directly be entered via the drive faceplate and will be
transmitted to output SP_O of the drive block. From there the value can be connected to an
analog output or to another block.
In order to display the set point input field in the drive faceplate the function must be enabled
via interface EN_SP.
The set point limits are configured via parameter SP_HLM and SP_LLM. The default unit
’rpm’ can be modified via signal attributes.
The actual value (e.g. actual speed) must be connected to structure input PV_IN.

If the set point is given by a program, e. g. by a primary controller, this function must be
enabled via interface EN_SPEX and the external set point must be connected to input
SP_EX.
For set point tracking SP_TR must have 1-Signal.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Drive with SIMOCODE

The SIMOCODE Adapter block C_SIMOS reads the cyclic data from SIMOCODE transmits
this information to the drive. The start commands from the drive are transmitted to the
SIMOCODE. Block C_SIMOS can be used for unidirectional drives, bi-directional drives,
valves and dampers.
Block C_SIMOS and the corresponding faceplate are only templates and may have to be
adapted. The block is ‘open’ (not protected) and can be modified by the user.
Connections between drive block and C_SIMOS:

The name of the SIMOCOE Adapter must be similar to the drive + ’_SC’. In the example
above the motor block is called ’M1’ and the Adapter block is called ’M1_SC’.
Parameter REL_SC must contain the block type for the SIMOCODE Adapter, in this case
C_SIMOS.
The drive gives the start command (output EBE) to the C_SIMOS (input START2).
The C_SIMOS gives the feedback (output FEED_ON2) to the drive (input ERM).
The C_SIMOS transmits the status (output STAT_SC) to the drive (STAT_SC). The status
contains the information ’General Fault’ and ’General Warning’, which is displayed in the
diagnostic window of the drive block.
If the motor current in % shall be displayed in the drive faceplate, the function must be
enabled via parameter REL_MVC and output I_PERC of C_SIMOS must be connected to
input MV_PERC of the drive.
At the SIMOCODE Adapter block you have to configure the Basic type and the start address
for inputs and outputs. Make sure that the inputs and outputs are in the process image!

Additional connections:
The 4 free configurable outputs INPUT1_O, INPUT2_O, INPUT3_O and INPUT4_O of the
C_SIMOS are not predefined and can be used in order to transmit additional information (e. g.
electrical availability or overload) from the SIMOCODE block to the drive.
Input RESET of C_SIMOS can be used in order to acknowledge the SIMOCODE fault via
program.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Drives with Subcontrol function

For complex functions like weigh feeders, filters etc. you may get blocks and faceplates from
sub-suppliers. These functions often have a completely different operator interface and
cannot directly be connected to the Cemat group without using an adapter block.
We recommend using a unidirectional drive block in order to control the function. The
advantage is that you can use the drive interfaces for process interlocks, change of operation
modes, process parameters as usual, and that the operation is identical to the rest of the
system.
Subcontrol Function controlled by a C_DRV_1D block

The Subcontrol does not have its own block icon. If required, the subcontrol faceplate can be
opened via the drive faceplate.
The block icon of the drive must have special attributes, containing the information about the
subcontrol name and type.
Additional Link Attributes for Subcontrol Functions (only for C_DRV_1D, Index 150):
SubText is the button Text, displayed in the motor faceplate
SubTag is the TAG (Tagname) of the Subcontrol
SubType is the S7 Structure name (Block type)

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Display of an analog value in % (e. g. Motor current)

In the drive faceplate a percentage value of a measure (e. g. for motor current or power) can
be displayed.
To enable the function the input REL_MVC of the drive must be set to 1-Signal and input
MV_PERC of the drive must be connected with output MV_PERC of the measured value.
Caution: The output MV_PERC of the measured value is calculated based on the upper limit 1,
which means VAL_H corresponds to 100%.

If you want to display a power instead value of a current value, you have to modify the
description at parameter CURR_OS:

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Display analog value

In the drive faceplate an analog value including its status information (limit exceeded,
simulation) can be displayed.
The output PV_Out of the measured value must be connected to input PV of the drive and the
output PV_Stat of the measured value to input PV_Stat of the drive.
The structure connections allow the direct faceplate call of the measured value from the drive
faceplate.

If you want to link more than one measured values to the drive and select one of those for
display in the drive faceplate, you have to use the function C_ANASEL. This block is
described under additional blocks.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Star-Delta Starting; Slip ring Rotor with Starter Motor

For drives with star-delta starting or slip ring rotor with starter motor, the contactor feedback
ERM may be created after a big delay (20-30 seconds).
For these drives the feedback time in seconds must be adapted at process parameter
FEEDBTIM.

Note: In the local operation (local control using the AS), the Local-On push-button must
! remain depressed until the drive runs fully (ERM=1).
The ERM signal provides the criteria for maintaining the On command. If the On command
was stored immediately and the drive for some reason did not start, then dangerous
operational states could arise, because the motor could start subsequently without the push-
button being activated.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Operation modes and control of the damper

Like all drive blocks, also the damper has the operation modes Automatic mode, Single-
start mode and Local mode in which the damper is either controlled via automatic program
(group or route), operator faceplate or local switch from one end limit to the other. Only a
pulse is required to start the drive, and the motor will be switched off if the damper has
reached the limit position.
Beside this the damper can be controlled into a certain intermediate position. This can be
achieved via Inching mode or Positioning mode.

Caution: In all Operation modes (Automatic mode, Single-start mode, Local mode, Inching
! mode or Positioning mode) the damper is controlled via two binary outputs.

Inching mode is possible via conventional control desk buttons or via the operator faceplate.
In case of control desk buttons the damper is opened/ closed as long as there is a 1-Signal at
the corresponding input. In case of Inching mode via HMI the damper is opened and closed
step-wise via faceplate buttons.

For the inching mode a special release function is required (KTFG = 1) which disables the ON
commands for automatic mode.

a) Inching via conventional control desk buttons

b) Inching via HMI

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

The Positioning mode allows entering a set point (as external set point or via damper
faceplate) and the damper is opened or closed until the actual position matches with the set
point. In this case a position feedback is always required.

- The release of the positioning mode is achieved through a 1-Signal at interface KPOS and
KTFG
- Output ‘PV_Out‘ of the measured value for damper position must be connected to interface
POS_IN of the damper.
- Via parameter SCB, SCE and UNIT Scale beginning, Scale end and Dimension
for the Set point can be defined. The actual value (damper position) is always in %.
- Set point tracking can be enabled via parameter KSNF.
- Via parameter KWUG and KWOG the set point limits can be defined.
- You also have to parameterize the minimum pulse length TMIN, the damper runtime TM,
and
..for a Hysteresis function the response threshold AN and the dropout threshold AB.

a) Positioning via operator faceplate:

b) Positioning via external Set point (e. g. PID-Controller)

Via interface KWEE the external Set point is enabled and via interface KWEX the set point
value is transmitted.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Analog actuators
If the damper/actuator needs an analog signal for the control (like e. g. analog actuators from
AUMA), this can be achieved as follows:

Caution: These actuators can exclusively be controlled in positioning mode, because in all
! other operation modes the output W_ACT_O is not actualized.
In local mode the analog output must be controlled directly (not via PLC)!

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Damper with middle position

The damper block includes the supervision of 2 limit positions. Limit position 1 = Closed, Limit
position 2 = Open. In some cases the supervision of 3 limit positions is needed (Open position
– Middle position – Closed position).
The following example shows a solution for a damper with middle position.

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Damper with torque switch

In order to stop the damper in case of a torque switch fault, the torque switch signals must be
connected to interface KDR1/KDR2. An alarm message “Torque switch” will be created.

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

Wagging function
If the wagging function is enabled (KWED = 1-Signal), in case of a torque switch trip the
damper will be controlled back to the old position. After this it will try again for the controlled
position. This behaviour is called ‘wagging’.
The number of trials (wagging number) can be configured at process parameter WAGG_NO.
If after the maximum number of trials the selected limit position is still not reached, an alarm
message is given for ’Mechanical fault’.
Example for a damper with torque switches, in case the wagging function is enabled:

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Engineering Examples Engineering Manual CEMAT V9.0 SP2

Fan and Damper

The big fans can only be started of the damper is closed. If the process allows, it makes
sense to close the damper automatically when the group is stopped.
The following example shows how this task can be solved. Also after an eventual damper
fault the damper can be closed through group stop, or it will be closed during group start.
In example a) the positioning of the damper is carried out via the inching commands of the
damper block. This solution is suitable for conventional control desks or local control panels.
In example b) the positioner function is used for the same task. This allows entering a numeric
set point via HMI.

a) Connections between fan and damper in case of positioning through control desk buttons:

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 Engineering Manual CEMAT V9.0 SP2 Engineering Examples

b) Connections between fan and damper positioner

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Annunciation blocks
Annunciation blocks are used to for the supervision of binary process signals. The signal
status is displayed in the process picture (ok, fault or warning) and in the summarizing
indication of the group. In case of a fault a message (fault message or warning message) can
be created in the alarm line.
Depending on the format of the input to be evaluated, the annunciation block has different
interfaces.
MST0 for the evaluation of a Boolean signal

MST0 + QUALITY for the connection of channel driver block CH_DI

PV for the evaluation of a structure input (e. g. from APL channel driver Pcs7DiIn)

Parameter OKS decides how the signal is evaluated. The status of OKS corresponds to
status ’input signal ok’. As most of the process signals are fail-safe, which means in good
condition they are “1”, we recommend to set parameter OKS to 1-Signal in order to avoid the
negation of the input.
The simulation value M_SIM should be similar to the OK-Signal.
Via the process parameters IN_DEL and OUT_DEL incoming and outgoing faults can be
delayed.
Parameter WMOD decides if a fault or a warning is displayed. (WMOD = 1-Signal for
warnings).

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The following pages show different applications for annunciation blocks:

Drive fault annunciations

All protection interlocks which lead to a drive stop (e. g. pull rope switch, belt drift switch,
bearing temperature) must create an alarm message at this moment.
The alarm message shows the operator which condition caused the drive stop and only in
case of a present alarm the drive fault can be acknowledged with the acknowledge button in
the alarm line.

- In the example above the binary signals are directly read from the process image. For this
purpose interface MST0 is used. Both signals are fail-safe (in good condition ’1’);
therefore OKS and M_SIM are set to 1-Signal.
- The message for the pull rope switch must be created without delay (process parameter
IN_DEL = 0). The message for the belt drift switch has to be delayed for 10 seconds
(Process parameter IN_DEL = 10).
- In order to create the message at the same time as the drive stop, the output of the
annunciation block (MAU or OutSig) bust be used for the connection to the protection
interlock. It must be distinguished between protection interlocks which are always
effective (ESVG or IntProtG) and protection interlocks which are effective only in
automatic or single-start mode. (ESVA or IntProtA).
- In order to trigger the alarm with each drive fault (even if the operator tries to start an
already faulty motor) the alarm activation MAAT of the annunciation block must be
connected with the output ‘dynamic fault’ (EST, VST, KST) of the drive block.
- The annunciation release of drive block and annunciation block must be connected with
the same signal for ‘control power ok’.

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Warning messages
Via parameter WMOD is defined if in case of a bad input signal a fault or a warning is
indicated. (WMOD = 1-Signal for warning).
If the signal is used for interlocks with other blocks, block output ’Warn’ must be used,
because MAU and OutSig are always ‘good’.

Another example you find under “Interlocking Annunciation”.

Caution: Output ‘Warn’ does not depend on OKS. In case of a fault output ‘Warn’ has
! 1-Signal!

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Alarm interlocking for the annunciation block

For drive blocks it is assured that a fault message is only created if the drive is “active”, which
means
a) if a running drive stops with fault,
b) if a start command is given for an already faulty drive and
c) if the drive is in standby mode and a fault occurs.
For the annunciation blocks (C_ANNUNC) you have to insure that only plausible alarm
messages are created. In case of drive fault annunciations this is already guaranteed through
the connection of the alarm activation (MAAT).
For the annunciation of process signals which do not belong to any drive, the alarm
interlocking MAMV must connected in order to create only plausible messages. Which signal
is used for the alarm interlocking depends on the technological function of your application.
Criteria for the plausibility of a message could be group running completely, drive running,
group status etc.

Example:
The alarm message must only be created if the group was started (and not stopped).

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Interlocking annunciation (Silo levels)

Annunciation blocks are not only used for the indication of faults but also for interlocking
conditions. In the following example the silo levels “High“ and “Maximum“ are used as
interlocking conditions for the group.
At level “High“ only the group start shall be inhibited. If the group is running and level “High“ is
reached, a warning message is created but the group will continue to run.
Level “Maximum“ must inhibit the group start and must also switch off the group together with
a red (fault) message.

- Via connection of WMOD with 1-Signal, in case of level “High“ a warning message is
created instead of a fault message. Output “Warn“ is used as start interlocking of the
group.
Caution: Signal must be inverted (does not depend on OKS).
- The connection of MMZS with 1-Signal effects that the fault or warning is not included in
the summarizing indication of the group. After all, the silo levels are no faults or warnings,
they are only interlocking conditions.
- If GFSO is connected with 1-Signal the interlocking would be excluded form group status
call as well. However, this behaviour is not wanted, because the interlocking should
appear in the status call as well.
- Through connection of the alarm interlocking MAMV with signal GVG of the group, the
message is only created if the group was started. If the group is was not started only a
static indication is given (without message).
- The annunciation release must be connected with the signal for ‘control power ok’.

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Two-level alarm (first warning then switch-off)

In the following example, for the same process signal (belt drift switch) first a warning
message is created and after a time delay a fault message is created.
The warning does not switch off the motor. Only with the fault message the motor is switched
off via protection interlock.

- As parameter IN_DEL has 0-signal, the warning message is created without delay.
However, a time delay for the warning is also possible.
- Via parameter WARN_DEL the time delay between warning message and fault message
is configured.
- Signal OutSig is not influenced by the warning and switches off the drive only in case of a
fault.
- Input AWAN activates the two-level alarm and must be connected with the running signal
of the motor.
Only for a running drive (EVS = 1-Signal) the belt drift fault leads to a two-level alarm.
In case of a present belt drift fault at the moment of a drive start, the fault message is
created immediately.

Caution: In project version 004 the running signal EVS cannot be used for AWAN because in
! single-start mode the running signal is not created. You must use a logic instead: Contactor
feedback ERM & not LOCAL.

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Annunciation for Status call

Annunciation blocks can also be used in order to visualize software interlocks in the status
call of the group.
In the following example, before starting the group it has to be insured that at least one route
is selected. In order to visualize the interlocking condition in the status call, an annunciation
block is programmed.

- Interface MMZS is connected with 1-Signal in order to exclude the annunciation block in
the summarizing indication of the group.
- Interface MAMV is connected with 0-Signal, this kind of annunciation block must never
create an alarm.
- This annunciation block does not need a block icon. Deselect the option in the block
properties.

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Release supervision
Certain process signals must only be evaluated if the associated device which creates or
influences this signal is running.
The following example shows a pressure supervision which should only be active if the
associated pump is in operation.
If 10 seconds after the pump start the pressure is not yet built or in case of pressure loss
during operation, the pump will be stopped immediately (via protection interlock).

- The supervision gets enabled through connection of interface RELS with the running
signal EVS of the drive. The time delay of 10 seconds for the supervision is configured at
parameter REL_DEL.
- If the input signal which is connected to MST0 is additionally connected to MSIG, the
block icon in the process picture shows green colour as soon as the pressure is built.
- With 1-Signal at interface MTRIP you achieve that after the stop the fault is memorized
until acknowledgement. If MTRIP has 0-Signal, immediately after the drive stop the status
of the annunciation block is ‘good’ again.

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Engineering of an ANNUN8 block

Instead of the annunciation block C_ANNUNC the annunciation block C_ANNUN8 can be
used.
Block C_ANNUN8 is capable to create 7 fault messages or warning message and can be
used if you want to show the status of these signals in a common block icon. The block icon
only has a summarizing indication and always shows the worst status.
Example: Annunciations of 6 Rope switches for a long belt conveyor.

- Via connection of the protection interlocking IntProtG with the summarizing fault FX of the
annunciation block (negation required) the motor will be switched off if one of the ropes is
pulled.
- Through connection of the alarm activation FAT1 – FAT7 with the dynamic fault of the
drive, the fault message is only created if the motor is stopped by fault.
- Don’t forget to enter the individual fault texts via property ‘identifier’ at parameter FLS1 –
FLS7. The texts are used in the diagnostic window and in the status call function. The
maximum text length is 16 characters.
- The annunciation release SWK must be connected with the signal for ‘control power ok’.

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Measured value
Read in a measured value
Measured value blocks are used for the supervision of analog process signals. The value and
the signal status are displayed in the process picture and in the summarizing indication of the
group. In case of a fault a message (fault message or warning message) will be created in the
alarm line.
Depending on the format of the input to be evaluated, the measured value block has different
interfaces. Parameter TYP defines which input is evaluated:
TYP = 77 Reading a card value from input MV_CARD
TYP = 10 Reading a REAL value form input MV_PHYS
TYP = 20 Reading a REAL structure from input PV

Reading a card value (WORD Format)

- With TYP = 77 reading from MV_CARD is selected

- The analog input must be connected to input MV_CARD of the C_MEASUR.
- Scale beginning, scale end and dimension must be defined at parameter SCB, SCE and
UNIT.
- In this case the measured value block must do the conversion of the card value into the
physical value. Scale beginning and scale end of the card value have to be defined at
parameter CARD_SCB and CARD_SCE.

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Reading a physical value from the channel driver block CH_AI

- With TYP = 10 reading from MV_PHYS is selected

- The output V of the channel driver block must be connected to input MV_PHYS of the
C_MEASUR.
- Output QUALITY of the channel driver block must be connected to input QUALITY of the
C_MEASUR.
- Scale beginning, scale end and dimension must be defined at parameter SCB, SCE and
UNIT.
- In order to use similar scaling for measured value and driver block, you should connect
the outputs SCB_OUT and SCE_OUT of the measured value to the inputs VLRANGE and
VHRANGE of the driver block.
Caution: In case of thermo elements (PT100) don't connect!!

Reading a physical value in structure format (e. g. from APL driver block Pcs7AnIn)

- With TYP = 20 reading from PV is selected

- The structure output PV_Out of the channel driver block must be connected to structure
input PV of the C_MEASUR.
- Scale beginning, scale end and dimension must be defined at parameter SCB, SCE and
UNIT.
- In order to use similar scaling for measured value and driver block, you should connect
the outputs SCB_OUT and SCE_OUT to structure converter StruScOu which provides an
output ‘Scale’ for connection to the driver block.

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Measured values, Calculated Values

Certain values are calculated during the plant configuration, e. g. total amounts from sub-
amounts, temperature or pressure average values.
Similar to analog signals coming from the periphery, also for the calculated values a
measured value block should be programmed. The measured value block simplifies the
integration in the HMI system.
To improve the readability, the calculation should be performed before the invocation of the
measured value block.

Measured values, Limit Value Supervision

The measured value block has 8 limit values. The violation of limit values VAL_HH, VAL_H,
VAL_L and VAL_LL leads to a message, the limit values VAL_SHH, VAL_H, VAL_L and
VAL_LL are only switching limits and don’t create messages.

- If UGWB = 0-Signal the limit supervision is completely blocked.

- In case of a limit violation the corresponding output HH, H, L, LL, SHH; SH, SL or SLL is
set.
H and L lead to a warning message and HH and LL to a fault message.
- If parameter RA_HH, RA_H, RA_L or RA_LL are connected with 0-Signal the
corresponding limit behaves like a switching limit, the fault bits are not set and no
message is created. The outputs HH, H, L and LL are still set.

If you want to inhibit the outputs HH, H, L and LL in the above mentioned situation as well,
you have to connect interface RA_OI with 0-Signal.

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Alarm interlocking for the Measured Value block

For drive blocks it is assured that a fault message is only created if the drive is “active”, which
means
a) if a running drive stops with fault,
b) if a start command is given for an already faulty drive and
c) if the drive is in standby mode and a fault occurs.
For measured value blocks (C_MEASUR) you have to insure that the alarm message is only
created if the corresponding plant section is running and the message is plausible.
The alarm interlocking UAMV has to be programmed individually, dependent on the
technological function. Criteria for the plausibility of messages could be group running
completely, drive running, group status etc.

Example:
The message for the limit supervisions should only be created if the group is completely
started.

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Using limit violation bits as interlocking condition

In the following example the silo levels are used as interlocking condition for the group.
The violation of upper limit 1 inhibits the group start and leads to a warning message.
The violation of upper limit 2 stops the running group and leads to a fault message.

If the limit bits are used for start interlock or operation interlock of the group the following
aspects have to be considered:
- Upper limit 1 and upper limit 2 are interlocks and should not be included in the
summarizing indications of the group block icon. Therefore UMZS has to be connected
with the limit bits.

If UMZS is connected with a continuous 1-Signal (LOG1) also Life Zero fault (bad quality)
is excluded from the summarizing indication.
- By connecting the alarm interlocking UAMV with Signal GVG of the group, the measured
value block only creates alarm messages when the group is started.
- Via status call function the operator can check for existing interlocks at any time (also if
the group has not been started).

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Block Measured value, Bypass, Service mode

There are two possibilities to block the measured value:
a) The bypass function is not activated:

In this case the measured value is blocked with a 1-Signal at interface UGWA (for
example while the calibration is running).

If UGWA = 1-Signal the measured value is not read in anymore and the last value is
frozen. The limit bits are frozen as well.

b) The bypass function is activated:

In this case the bypass is carried out via HMI (Service mode).

In the Service mode the measured value is still read but all limit bits are forced to “0“.

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Release limit supervision

For some analog values the limit supervision must only be enabled if the associated device is
running.
The following example shows the supervision of a motor current. Violation of lower limit 2 as
well as violation of upper limit 2 shall stop the drive by protection interlocking.
The evaluation should begin 10 seconds after the drive start.

- The limit supervision is enabled via connection of interface RELS with the running signal
EVS of the corresponding drive. The time delay of 10 seconds is configured at parameter
REL_DEL.
- With 1-Signal at interface MTRIP you achieve that after the drive stop the fault is
memorized until acknowledgement. If MTRIP has 0-Signal, immediately after the drive
stop the status of the measured value block is ‘good’ again.

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Pressure control
A pump shall be switched on if the minimum pressure is reached and switched off with
maximum pressure.

- The switching limit ‘SL‘ is used for switching ON and the switching limit ‘SH‘ for switching
OFF.
- Start and stop of the pump is carried out via interface ESPO.
- For the feedback to the group EVSP is used instead of EVS.

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Route functions
Feedback ON (all drives running)
Via the route feedback ON (interface WREZ) the route is informed that the start-up has been
completed and all drives are running.
Depending on the application this can be an AND-Function with the running signal of all
drives, or the last drive of a start sequence.

With 1-Signal at input WREZ, for a selected route the binary output WRE is set, which is used
as feedback to the group.

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a) Feedback to the group if one out of two routes must be running:

b) Feedback to the group if both routes may run at the same time:

If one route is already running and a second group shall be started additionally, you have
to take care that with the selection of the new route the group feedback gets “0“.
Otherwise restart of the group is not possible.

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Feedback OFF (all drives stopped)

Via route feedback OFF (interface WRAZ) the route is informed that the stop sequence has
been completed and all drives are stopped.
Depending on the application, this can be an AND-Function with the inverted running signal of
all drives or with the last drive of a stop sequence.

With 1-Signal at input WRAZ the binary output WRA which is used for the feedback to the
group is reset.

The route feedback OFF (Signal WRA) gets "0" if the route is not selected or completely
! stopped. For the connection of the group feedback OFF the output WRA must therefore be
inverted!

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Uninterrupted route change-over

Task:
The change for charging into Silo1 or Silo 2 has to be without interrupt, i.e., the feeding drives
should not be stopped during the switching operation.
Both air slides E02 and E03 must run while the damper is being moved. The part of the old
transport direction that is no longer required is switched off only when the new direction has
been traversed completely.
The following connection example provides a solution for a transport group with two routes:
The air slides E02 and E03 and the damper position K1 (direction silo 1) belong to route 1.
The air slides E01 and E03 and the damper position K2 (direction silo 2) belong to route 2.

Operation:
During the switching, the new route must be selected first and then the group started.
Whether the route selection and the group start takes place manually or automatically is not
relevant.

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The connection example becomes clearer by looking at the individual conditions that must be
fulfilled for a change of routes without interrupt.
- The route change can only take place when the group is stationary or runs completely
 refer to WHVR
- If a route was pre-selected and the pre-selection of another route is added, then the own
pre-selection must be removed.
 refer to WVWL and WUUS
- In case of a route change without interrupt the group has to be started while it is
completely running (because the drives of the “old” route are still running).
To permit the group to give the start command again, the “group feedback On / route
feedback On“ must be removed. This is done by linking the route pre-selection WVE with
the drive feedbacks.
 refer to WREZ
- The old route is deselected automatically once the newly started route runs completely.
 refer to WVWA
- The de-selection of the “old” route stops the drives that are no longer required.
 refer to EBVG from E02 and E03
- The disconnection of the complete group is performed only for group stop (use GDA
signal) or for a fault if the switching has not been performed within a specified time.
 refer to EBFA from E01

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Automatic Route change

In this example the route change and start is not performed manually but with a process
signal (e.g., silo filling level). The process signal (start condition) must be unique. If
necessary, use an interlock to ensure that only one signal is pending!
Example:

The process signal automatically pre-selects the route.

 Refer to WVWE

Note: The automatic group-On command must be supplied only when the GREZ signal of the
! group becomes zero (otherwise no start is possible).
 refer to GEBG.

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Engineering Examples for additional blocks

Display of interlocking conditions with interlock blocks
Via interlock blocks interlocking conditions can directly be called from the diagnostic window
of the Cemat block.
Using structure interlocks the faceplate of the interlock block can be opened directly from the
faceplate of the Cemat block. (It is also possible to open a connected Cemat block instead.)

a) Structure interlocks Intlk02, Intlk04, Intlk08 and Intlk16

The name of the Interlock block is not relevant.

Exception: don’t use the naming conventions for binary interlock blocks (in this case do not
use M1_IntProtG1), otherwise the interlock faceplate will be opened two times.

In the faceplate of the interlock block at each input the name of the connected block is
displayed automatically, here e. g. 100_BC2/RS01. For additional information you can enter a
text at the corresponding input under Object properties → Text 0 and Text 1 (maximum 16
characters).

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b) Binary interlock block C_INTER5 (can only be called from diagnostic window)

C_INTER5 is called via the variable name. The interlock block must therefore be named as
follows:
Name of the Cemat block + Underline + Name of the interface + Index (1/2/3).
You can connect 3 blocks of type C_INTER5 to each interface.
The text for the inputs is configured via parameter S_TEXT (5 texts a 16 characters,
separated by semicolon).

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c) Binary interlock block C_INTERL (can only be called from diagnostic window)

C_INTER5 is called via the variable name. The interlock block must therefore be named as
follows:
Name of the Cemat block + Underline + Name of the interface + Index (1/2/3).
You can connect 3 blocks of type C_INTERL to each interface.
The text for the inputs is configured via parameter S_TEXT (5 texts a 16 characters,
separated by semicolon).
The texts for the inputs are defined via object properties of the corresponding input (I1_1 to
I1_5 and I2_1 to I2_5) under Text 1 (text length max. 16 characters).

Caution: A mix of C_INTER5 and C_INTERL at the same interface is not permitted.
!

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Query settings within the AS

Via the function "Object Browser" the operator can search for simulations and operation mode
settings within an AS. See description 08_OS_Engineering_009.pdf under “General Cemat
Functions“.

The function for left mouse click must be adapted (enter number of the AS):

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Analog Value Selection

Via block C_ANASEL up to 16 measured values can be linked to a drive C_DRV_1D,
C_DRV_2D or C_DAMPER.
Via the drive faceplate the faceplate of the C_ANASEL block can be opened, and from there
you can select the desired measured value.
In the drive faceplate you will see the selected measured value + Unit as well as the status
(limit violation, simulation, quality).

- You have to connect output PV_Out of the measured value to input Inxx of the
C_ANASEL and output PV_Stat of the measured value to input InxxStat of the
C_ANASEL.
- The output Out_Val of the C_ANASEL must be connected to input PV of the drive and the
output Out_Stat of the C_ANASEL to input PV_Stat of the drive.

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