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Service Documents

Software Documents Type Management Using the zenOn Touch Version: 1.0 Update: 05.2004

These documents are intended for trained professionals only. These professionals must guarantee personal safety and the prevention of machine damage during any operations. Appropriate safety instructions for other persons have not been provided.

KRONES AKTIENGESELLSCHAFT D-11-E0-0-03-64

KRONES AG R & D Dept., Visualisation

As of: 05.2004

Table of Contents

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Introduction ............................................. .................................................................... .............................................. .............................................. ............................. ...... 3 1.1 Requirements............................................................... Requirements........................................ .............................................. .............................................. ......................... 3 1.2 Background of the Type Management System ........................................ .......................................................... .................. 3 1.3 Overview .......................................... ................................................................. ............................................. ............................................ ............................. ....... 4 1.4 Screen Images Parameter ......................................... ............................................................... ........................................... ............................ ....... 5 Type Change-over Screen Images............................. Images.................................................. ........................................... .................................... .............. 6 2.1 Production Data Image..................... Image ........................................... ............................................ ............................................. .............................. ....... 6 2.2 Type Selection ............................................. ................................................................... ............................................ ......................................... ................... 7 2.3 Selection Filters ........................................... .................................................................. .............................................. ........................................ ................. 8 Type Management Screen Images .......................................... ............................................................... ......................................... .................... 10 3.1 Selection Screen ........................................... .................................................................. ............................................. ..................................... ............... 10 3.2 Define Customer Objects ............................................ .................................................................. ............................................. ....................... 11 3.3 Create new Type............................................... Type..................................................................... ............................................. .................................. ........... 12 3.4 Copy Type ............................................. .................................................................... .............................................. ............................................ ..................... 13 3.5 Rename Type............................................... Type..................................................................... ............................................ ....................................... ................. 14 3.6 Delete Type .......................................... ................................................................ ............................................. ............................................. ........................ 15 3.7 Learn Type .......................................... ................................................................. ............................................. ............................................ ........................ .. 16 3.8 Import / Export ............................................ ................................................................... .............................................. ...................................... ............... 17 3.9 Backup Data Directory ........................................... ................................................................. ........................................... ............................ ....... 18 Parameter Management Screen Images .......................................... ............................................................... ................................. ............ 19 4.1 Recipe Editor..................... Editor ............................................ .............................................. .............................................. ......................................... .................. 19 Type Management Files .......................................... ................................................................ ............................................ ................................... ............. 20 5.1 Data Directory ........................................... ................................................................. ............................................ ......................................... ................... 20 5.2 File Format ............................................. ................................................................... ............................................ ............................................ ...................... 21 5.3 Customer Objects File ............................................ ................................................................... .............................................. ........................... .... 21 5.4 Recipe Names File ............................................ ................................................................... .............................................. ................................ ......... 22 5.5 Recipe File................................ File....................................................... .............................................. .............................................. .................................. ........... 23 Working with Recipes .............................................. ..................................................................... .............................................. ................................. .......... 24 6.1 Create, Load, Restore ............................................ .................................................................. ............................................ ............................. ....... 24 6.2 For Service and Commissioning Engineers .......................................... ............................................................. ................... 24 6.3 Create and Set up a new Type .......................................... ................................................................ ........................................ .................. 25

Software Documents Type Management on the zenOn Touch

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1 Introduction 1.1 Requirements •

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The new zenOn visualisation system is used to save and manage type parameters from the PLC as recipe files on the visualisation computer. During type change-over, the parameters from one of the previously saved recipe files are downloaded and the new values are transferred to the PLC. The type names are displayed in plain text and can be changed by the customer. The recipes are saved as text files and can be processed off-line. The recipes can be imported/exported from/to a disk for backing up data, for external processing (editor, Excel, Access) or for the transfer to another machine.

1.2 Background of the Type Management System The type management system is used to save production-specific parameter records. These parameters can, at the same time, depend on several criteria (customer objects), e.g., container weight colour. • • •

Each independent criterion is identified by an unambiguous number ("type number"). The combination of the individual independent criteria yields a code which clearly identifies the parameter record (recipe) for a specific production process. In addition to the individual criteria ("type numbers") and the combination ("type code"), the corresponding type names and the name of the recipe are saved in plain text on the touch-screen computer.

001 container A 002 container B

001 weight: 1.0g 002 weight: 2.0g

001 colour: red 002 colour: blue

001-001-001 container A, weight: 1.0g, colour: red 001-001-002 container A, weight: 1.0g, colour: blue 002-001-001 container B, weight: 1.0g, colour: red 002-002-001 container B, weight: 2.0g, colour: red Figure 1 The combination of the independent "type numbers" yields the "type code".


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1.3 Overview The type management is used to save process parameters as files on the touch-screen computer, or to download these parameters from the files saved there to the PLC (according to file operations). The currently used process parameters (which are active in the control unit) are in the working database of the PLC and are not automatically saved as a recipe file on the touch computer.

PLC

Type management PowerPanel Ethernet

Disk drive

Laptop Changeable storage medium

Figure 2 Type management overview

Type parameters are saved in separate recipe files on the CompactFlash of the control panel. The file name comprises of the unambiguous type code and the f ile extension .rcp (e. g., 001-001-001.rcp). The Krones type management system is part of the machine-specific reference projects and can be flexibly adapted and expanded if necessary. The common screens are used in the three fields of application: type change-over, type management and parameter management.


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1.4 Screen Images Parameter The conventional screen pages for the viewing and processing of type parameters in the PLC are still provided in the visualisation. As a rule, changes on these screen pages have an immediate effect on the PLC. Important: However, changed values are not recorded in the recipe file unless they have been transferred by pressing "Save" in the Type selection screen image. Without saving, the changes will be lost when the next recipe is loaded.


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2 Type Change-over Screen Images 2.1 Production Data Image

The type designations are displayed in plain text in the production data screen image. The texts are saved on the visualisation computer and can be adapted by the customer. The operator can use the push-button on the left next to the type name to go to the type selection screen image.


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2.2 Type Selection

The type selection includes a list indicator of the types which are available. The current type is highlighted and displayed on top. The type code precedes the type name. The type code comprises a combination of the type numbers for, e.g., containers. The "Load" push-button can be used to download the parameters from the recipe file and to transfer them into the PLC database. During loading, an animated progress bar is displayed at the bottom border of the image. Note: The old parameters are not saved automatically! Use the "Save" button to upload the parameters from the PLC working database and to save them in the corresponding recipe file on the CompactFlash. During saving, a backup copy of the last status with the file extension .bak is always created. You must not exit the screen page during loading and saving, that is why the push-buttons will not be displayed by the PLC during this process. Use the "Type management" button to go the the selection screen of the type management.


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2.3 Selection Filters

The list which is displayed can be restricted by the type numbers. To do so, you can use the filters (here: weight) on top of the list. A window showing a list of all entries can be opened with the arrow button. The selection remains visible in the text field, once the window has been closed with OK. The use of a pre-selection makes the type change-over clear and comfortable, even if a large number of recipes has been provided for the machine.


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Figure 3 Type selection with filtered list

To remove the filter, select the top entry (empty line) in the list of filters. Note: If no appropriate recipes have been found for the selected filter criteria, an empty selection list will be displayed. Just reset the filter criteria as described.


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3 Type Management Screen Images 3.1 Selection Screen

The "Change/add" push-buttons on the left can be used to define the type numbers and the designations of the individual customer objects (criteria: container, weight, colour, labels etc.). The functions to combine the individual types/criteria to form new recipes and the common file operations are called up in the middle row. Methods for importing/exporting the recipes to a disk are offered on t he right. In the control bar, you can go to the recipe editor and back to the type selection.


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3.2 Define Customer Objects

A list displays the customer objects that have already been defined. Enter an unambiguous type number and any designation in both entry fields at the bottom. An existing designation can also be changed subsequently here. Use the "Transfer" button to transfer the entry into t he list. With the "Delete" button, the selected entry can be removed from the list. Note: •

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The type number must be unambiguous. Several entries with the same number are not permissible. Type number 0 (zero) is invalid. The name that has been assigned is used as a reference for recipes to be created ("Add type" screen image) and as a criterion in the selection filters ("Type selection" screen image). If the name is changed subsequently, the corresponding part of the name is not automatically adapted in the existing recipe names. The respective recipe names must be adapted individually ("Rename type" o screen image). A more comfortable way is to export the Type.lst file to a disk ("Import/export" o screen image) and to process the recipe names provided on the notebook, e.g., using the "Search and Find" function in the W indows Editor.


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3.3 Create new Type

You can compose new types from all existing customer objects in the selection lists. W hen doing so, an unambiguous, not changeable type code will be created, which is then used for file management. Even a combination of the type names is suggested as a new designation for this recipe. The plain text designation can be changed here. The name can be changed subsequently in the "Rename type" screen image at any time. Note: If, for example, recipes for the new colour "green" are to be created, the list of colours must first of all be amended by the entry "003 colour green" in the "Change/add colour" screen image. Once this has been entered, new recipes can be created for the "green" type.


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3.4 Copy Type

During copying, two existing recipes are selected and the contents of the source f ile are transferred to the target file. One recipe each must be selected in the source and in the target list. The selected recipe file (source) is then copied to the target file.


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3.5 Rename Type

The recipe name from the list which is displayed can be changed subsequently in the entry field at the bottom. The type code is not changeable. Press "Rename" to transfer the change into the list.


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3.6 Delete Type

The selected type is finally deleted.


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3.7 Learn Type

The "Learn" function can be used to upload the current parameter values from the PLC working database into any target recipe, i. e. the selected recipe "learns" the parameter values from the PLC. Learning corresponds to the principle of a "Save as" operation with the PLC being the data source and any target file. Notes: •

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In contrast, the "Save" function in the "Type selection" screen image saves the PLC parameter record only in the corresponding recipe file of the currently selected type. The recipe of the current type cannot be changed by the "Learn" function. For information, the current type is displayed yellow on top of the image.

The "Learn" function can be used to quickly create a series of recipes for similar types without having to copy reference recipes in an elaborate way prior to changing the type. Note: Once a recipe has been created with the "Learn" function, either the recipe that has been learned last or the currently displayed recipe must be loaded in the "Type selection" screen image. During set-up, the currently displayed type in the production data image does not correspond to the parameter record provided in the PLC!


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3.8 Import / Export

The import/export functions for the recipe f iles can be found on the general screen page for the central data import/export. Use the export push-button to copy all recipe files and type name files of the type management system from the touch computer to a disk. The import push-button can be used to copy the saved files from the disk back to the touchcomputer. Note: All recipes are always exported and imported. All existing recipes with the same name will be overwritten during import. It is better to keep the disks a few seconds longer in the disk drive, so as to ensure that the download/upload operation has really been completed (LED on the disk drive will be extinguished).


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3.9 Backup Data Directory Independently, the panel manager can be used to completely backup and restore data of the type management system in the form of a packed archive (> Screen image selection > System > Panel manager).

When a data archive is being restored from the disk, the current contents of t he data directory will be deleted first, and then the archive will be unpacked. Thus, the exact state of the directory at the time of the backup is restored. Note: Types which have been newly created meanwhile and all other changes will be lost.


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4 Parameter Management Screen Images 4.1 Recipe Editor

The recipe editor can be used to process recipes or parameters independently of the control system (i. e., off-line). To open a recipe, first of all go to the adjacent data directory in the file dialog and enter *.rcp as a file name (filter). Changes in the list which is displayed will not be restored in the file until t he "Save recipe file" push-button has been pressed. Only the actual value is to be processed with this editor. For a complete description of the file format, please refer to the next section. Note: Make sure to save the data directory before working with the recipe editor. (Refer to the export or panel manager description in the previous section.)


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5 Type Management Files 5.1 Data Directory

The type management files reside in the data directory of the Zenon folder: D:\Zenon\Data with XP Embedded \harddisk\zenon\Data with CE.NET. • •

The data directory includes the order-specific recipes in *.rcp files. Type codes and the corresponding type names are saved as *.lst files. Note: Prior to overwriting a file during the restoring of a recipe, a copy is automatically saved as a bak file. If necessary, the old status can be restored in the service mode using the Windows Explorer, or it is possible to trace the last changes. Furthermore, the master recipe 000-000-000.rcp also resides in this directory. It can be used as a source template for the creation of new recipes and as a reference for the validity check of data structures of the other recipe files during loading and saving. The machine configuration M01.rcp is also saved in the data directory. It is always saved and restored on the disk together with the recipes.


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5.2 File Format The type management files are provided as text files and can be viewed with each conventional editor. All files have a header with important file information such as, e. g., date and time of the last storage, a continuous counter for each storage and f urther file-specific information. Comments: The single quotation mark (‘) at the beginning of the line is used as a comment sign. This line will be ignored during the download.

5.3 Customer Objects File

This file contains the customer objects that have been created. There is a separate file for each type criterion. It is used as a reference for the creation of new recipes and for the recipe list filter in the type selection. Note: The blank in the line above the first list entry is important. It creates an empty list entry in the filter list which can be used to reset the filter.


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5.4 Recipe Names File

This file contains a list of all recipes that have been created. For each recipe, the list includes the combined type code and the recipe name in plain text.


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5.5 Recipe File

This file contains the parameter record for the corresponding recipe. The file name corresponds to the type code. Apart from the usual information, the file header includes the recipe name in plain text. The parameter record starts with the name of a zenOn variable, e.g., [O_TYPE01_DB51], which is linked with the type parameter database in the PLC. It is followed by lines with the corresponding parameters. Each line includes, separated by semicolons (;), the parameter name (from the PLC programme!), data type, standard value and current value of the parameter. This sequence of zenOn array name and parameter description can be repeated if necessary.


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6 Working with Recipes Type parameters are saved in separate recipe files on the CompactFlash of the control panel. The file name comprises of the unambiguous type code, the file extension .rcp (e. g., 001-001-001.rcp), and not the plain text name.

6.1 Create, Load, Restore Prior to the creation of new recipes, the individual type numbers must be defined for each part of the type code in a separate step: e.g., 001 container A. A new recipe is created by combining the previously defined type numbers to form a new code, e.g, 001-001-001 container A, weight: 1.0 g, colour: red. •

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The recipe must be created in the recipe management system before a parameter record for a "new" type can be saved. The corresponding customer objects (type numbers) must have already been defined, in order to be able to create a new recipe. 0 (zero) as a type number is not permissible. A new type which has been created in the recipe management is not filled with valid data and cannot be selected. Only a new, empty file with standard values has been created on the touch computer. It is not possible to create 2 recipe files with the same 3 criteria. Type numbers and recipe code can not be changed subsequently. A recipe file which has been created cannot be renamed subsequently. The type and recipe designations (plain text) in the touch computer can be renamed. The plain text name is only an addition in the touch computer. A new recipe can only be selected by loading! The current process parameters in the PLC are overwritten with the recipe from the touch computer during loading. If required, restore changed values of the current type from the PLC into the recipe on the touch computer before! Restoring is possible for the currently selected recipe only! To save a parameter record as one other than the current type, use the following functions: "Copy type": off-line file operation with r ecipe, or o "Learn type": on-line from the PLC into any target recipe. o

6.2 For Service and Commissioning Engineers •

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When a new project is imported using the panel manager, the old type files will be overwritten. If valid recipes have already been saved in the machine, these must be backed up (exported) before! The new project can be imported then. Afterwards, the backed up type files must be re-imported. Data can be backed up in two different ways: Backup/install data using the panel manager (zipped) o Using the import/export screen image (unzipped with log file *.log). o


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6.3 Create and Set up a new Type Correct procedure: One type completed: restore (if not yet done and only if necessary). Create new recipe. Fill new recipe with data: When starting from the very beginning, this type can be loaded to the PLC, o however, all settings will be lost! or: When starting from the current status, the type t o be newly selected must be o filled with the current parameters before it is loaded. There are two ways to proceed: Create type, fill type by copying (copy from previously restored to newly created type) and then load! or: Create type, fill type by learning with current PLC settings and then load. • • •

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Frequent mistakes: New process parameters are set for the machine to change the product (or to create a new type). However, a wrong (old) type is still set in the touch computer (new types have not been created and loaded yet). In order to back up the newly set parameters now, i. e. to restore them in a new type file on the touch computer, this data must not be restored to the selected type in the "Type selection" screen. To do so, create a new type on the touch computer, have it learned first (!) and then load it. This is the only way to be able to properly restore data to this t ype at a later point in time. If the new type is only created but not learned and then loaded to the PLC, all settings will be lost because a newly created recipe is always "empty" (i. e. standard values of the master recipe 000-000-000.rcp) or invalid. •

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