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How to backup and restoreBRAUMAT compact?

BRAUMAT compact

FAQ � November 2012

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2How to backup and restore BRAUMAT compact?

1.0, Item-ID: 65693020

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QuestionHow to backup and restore BRAUMAT compact?

AnswerThe instructions and notes listed in this document provide a detailed answer to thisquestion.

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Table of contents

How to backup and restore BRAUMAT compact?1.0, Item-ID: 65693020 3

Table of contents

1 BRAUMAT compact data management ........................................................... 4

1.1 Data hosting: User Archives ................................................................. 41.2 Data storage: Text library ..................................................................... 4

2 Backup the System ............................................................................................ 8

2.1 Backup Overview ................................................................................. 82.2 Tasks on OS-Server ............................................................................. 92.2.1 Export user archives ............................................................................. 92.2.2 Export recipe names .......................................................................... 102.3 Tasks on Engineering Station ............................................................ 122.3.1 Import recipe names ........................................................................... 122.3.2 Read back AS configuration ............................................................... 132.3.3 Archive the PCS 7 Project .................................................................. 13

3 (Re-)load OS server ......................................................................................... 14

3.1 Restore User Archive Runtime data ................................................... 143.1.1 Restore UA on OS Server .................................................................. 153.1.2 Reload PLC ........................................................................................ 163.2 Delta download ................................................................................... 173.3 Full download ..................................................................................... 183.3.1 Full download to OS Server in same directory (overwrite) ................. 183.3.2 Full download to new OS Server ........................................................ 18

1 BRAUMAT compact data management


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BRAUMAT compact includes the standard PCS 7 data handling for trends andmessages. Batch and recipe related data are stored in user archives.

1.1 Data hosting: User Archives

BRAUMAT compact divides the data into 3 different data types:· Recipe data in user archives

In these archives the recipe parameters are stored. These archives are lessdynamic. They are changed when recipes are created or modified.

· Recipe configuration data in user archivesThese archives contain the phase con (=matrix) configuration for each unit.These archives are mostly static after commissioning.

· Batch report data in user archivesThe system stores each Batch start, stop and each step start, stop includingsetpoints and actual values in these archives for each unit. These archives arevery dynamic during production.

1.2 Data storage: Text library

BRAUMAT compact uses the WinCC Text Library to store project specific text(=names). The text library is preconfigured as with first BRAUMAT compact projectcreation.The following table shows the text library content:

Table 1-1

Line Content Comment

1000 Unit Name Unit Display Name1001 start - control strategies start - of BRAUMAT

compact entries1064 end - control strategies Unit 011100 Unit Configuration (# of CS, FCT, Elements,

Logic, Analogs)Unit 01

1101 start - functions Unit 011164 end - functions Unit 011201 start - control modules Unit 011296 end - control modules Unit 011301 start - unit of measurements Unit 011396 end - unit of measurements Unit 011401 start – logic Unit 011432 end – logic Unit 011501 start - analog values Unit 011516 end - analog values Unit 01



Line Content Comment

1601 start - operator requests Unit 011664 end - operator requests end - Unit 012000 start - Unit 02…2664 end - Unit 02…99000 start - Unit 99 (last unit)…99664 end - Unit 99100001 start - recipe types100064 end – recipe types100101 start - recipes for type 01100164 end - recipes for type 01…103201 start - recipes for type 32103264 end - recipes for type 32104001 start - common texts104998 end - common texts

104999 start global parameters(also end of BRAUMATcompact entries)

This data is configured via the Excel Add-In Tool. The Excel Add-In can be storedin the PCS 7 project.



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The following picture shows an overview of BRAUMAT compact data architectureon ES – Server – Client level:

Figure 1-1

OS-Client

Recipe Configuration & Parameter

BRAUMATcompact

Excel Add-In(Column 3 + 4)

UACS

UART

Txt-Lib

UACS

UART

Txt-Lib

CSV-Files

WinCCRedundancy

OS-Server Station

Standby OS-Server Station

BRAUMATtable generator

BRAUMATcompact


Txt-LibUACS

ES Station

Download

Download

UA

CS

RT

Txt-Lib

WinCC User Archive

Configuration data

Runtime data

WinCC Text Library

Backup/Restore(Export/Import Archives)



The following picture shows an overview of BRAUMAT compact data architectureon OS – AS level:

Figure 1-2

UA

AS

- Station

Open faceplate

Ø „Load from AS“ runs automatically

Open parameter view

Ø „Load from UA on Server“ runs automatically

UACS

UART

Txt-Lib

Store in AS

Upload from AS

Store in UA on Server

Load from UA on Server

CS

RT

Txt-Lib

WinCC User Archive

Configuration data

Runtime data

WinCC Text Library

OS -Server

2 Backup the System


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2 Backup the System2.1 Backup Overview

For a full project backup (with these data the project can be restored fully fromscratch) the following tasks have to be fulfilled.

Figure 2-1

The exported data CSV-files and ZIP-file should be backed up with any backup tool/ concept. This concept has to be provided by the customers IT organization.

ES StationOS Server

-Add-In CSV-Files

Read back recipenames into


Chapter 2.2.2

Chapter 2.2.1

Copy xls-files toES Station

Write recipe names intoText library

Read back parametersvia SIMATIC Manager

CFC

Archive the project viaSIMATIC Manager ZIP-File

XLS-File

XLS-File

Chapter 2.2.2

Chapter 2.3.1

Chapter 2.3.2

Chapter 2.3.3

2 Backup the System


2.2 Tasks on OS-Server

2.2.1 Export user archives

The export of the user archives should be done regularly, e.g. daily. The exporteddata should be backed up with any backup tool / concept. This concept has to beprovided by the customers IT organization.

Figure 2-2

During the archiving processes, all user archive data from the server are stored inCSV-files. The path is set in an input field. For each table in the user archive oneCSV-file is created.

NOTE The Export of the user archives on the OS-Servers contain recipe data, recipeconfiguration data and Batch report data (see chapter 1.1 “Data hosting: UserArchives”). The Exported data are stored in CSV-files.

The Import must not(!) be performed on ES to the (engineering) project but solelyon OS-Servers if a restoration is required (see 3.1.1 “Restore UA on OSServer”).

Optionally the exported CSV-files can be stored in the project on ES to bearchived together with the project (see 2.3.3 “Archive the PCS 7 Project”).

2 Backup the System


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2.2.2 Export recipe names

The recipe names are stored in the text library of the OS-project.The recipe names can be modified by the operator in OS runtime. This data mustbe transferred to the ES – Station. For the transfer the Excel-Add-In Tool is used.For each recipe type the recipe names must be read back into the Excel-Add-InTool.1. To start the Excel-Add-In Tool use the WinCC Explorer and start BRAUMAT

compact table generator.

2 Backup the System


2. After the table generator is started, choose the tab “Excel Addin” and open thexls-file for each recipe type.

3. For each xls-file the recipe names have to be read from the text library via“Read Recipe names from textlib”. This will store the recipe names into theExcel Add-In.

4. Copy the xls-files that were read back to the Engineering Station into theserver OS project below “<projectpath>\Excel Add-In”.

2 Backup the System


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2.3 Tasks on Engineering Station

On the ES (Engineering Station), the project data have to get the latest changes byimporting and read back the data. After this, the project must be archived.

2.3.1 Import recipe names

The recipe name xls-files were created and managed on the OS server (seechapter 2.2.2 “Export recipe names”) and have to be copied into the server projecton the ES.1. Open the Excel Add-In Tool and open each recipe type xls-file (see chapter

2.2.2 “Export recipe names”).2. Save the recipe names from the xls-file into the project text library via “Write

recipe names to txtlib” button.

2 Backup the System


2.3.2 Read back AS configuration

Read back the AS configuration via CFC read back mechanism in SIMATICmanager. Please take care you have to read back twice, once with option “OCMcapable parameters” set and once with “Designated Parameters” set.During the procedure all BRAUMAT compact parameters (sequence, recipeconfiguration, parameter configuration, current/next Batch ID, etc.) that are activein the PLC are read back into the CFC chart. This will not mean that anyparameters are stored into the user archives.Some of these parameters are overwritten during runtime in different dialogs.The next picture shows the main data exchange and their driving tasks:

Figure 2-3

The Batch ID information includes the last used Batch ID, minimum and maximumBatch ID. The Batch ID information is used to generate an unique Batch ID foreach new Batch started.

2.3.3 Archive the PCS 7 Project

Via SIMATIC Manager the project can now be archived.

ES AS

SequenceOperation (steps)(BR_PHC96(PL)

+ satellitesPL_EXF …)

Parameter-definition

(BRC_REAL)

ParametersBRC_REC(RECIPE)

Batch-IDBRC_BAID

(BA_ID)

Parameter valuesare read from UAand downloadedduring sequence

start

CFC CFCRead back

Store in AS

Load from UA and store in AS

3 (Re-)load OS server


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3 (Re-)load OS server3.1 Restore User Archive Runtime data

In case of a running redundant system, this step can be done on any server incase redundancy is running in normal mode. In case the redundancy is just startedand synchronization is not finished, this data must be saved on the current masterserver.The current master server can be figured out by opening the SYSTEM_WINCC.pdlvia Button “Open picture by name”.

Figure 3-1



The following picture shows how the current master server is indicated.

Figure 3-2

To restore the User Archive Runtime at any time in runtime, the saved user archiveCSV-files must be available on the OS server. This step will overwrite all userarchive runtime data and describes how to download to the AS.

3.1.1 Restore UA on OS Server

1. Open OS runtime to import the data.2. Open the engineering.pdl.3. Configure the path were the CSV-file export of the user archives is stored in

the edit field. Then run the import via the “Import archives” button.

In case of redundant severs (Operating in normal redundancy mode) the data arebacked up to the redundant server as soon they are imported.



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3.1.2 Reload PLC

The re-imported data are now stored in the user archive but not loaded to the AS.Therefore, for each(!) unit the data has to be saved to AS. In the engineering.pdlfor each unit, the matrix configuration dialog has to be opened (see chapter 3.1.1“Restore UA on OS Server”). In the matrix configuration dialog, the followingsequence has to be fulfilled.1. Opening the dialog loads the data from the AS.2. Load data from the User Archives into the dialog. The data now shown in the

dialog is the data from the user archive and not the AS data (Figure: (1)).3. Download the data to the AS via load to PLC button (Figure: (2)).



3.2 Delta download

The OS delta download is issued from the ES via SIMATIC Manager PCS 7standard function. Regarding BRAUMAT compact not all changes can be done.The user archive system is not touched for any modification at all by an OS deltadownload.

NOTE Recipe names, step names, parameter names, etc. (all stored in the text library)can be changed in OS Runtime.

In this case, the changes (text library) should be transferred to the project on ES.For the transfer export the recipe names, step names, parameter names on anOS-Server and import them on ES (see chapter 2.2.2 “Export recipe names” andchapter 2.3.1 “Import recipe names”).

Any other text (library) changes have also to be done via the Excel Add-In.

Any newly created “User Archives” that may have been developed on the ESthat don’t exist on the OS will be downloaded during a Delta Download.

Via the Excel Add-In Tool the different BRAUMAT compact text configurationstored in the “Text Library General” and in the “Text Library Unit” column of theExcel Add-In Tool.

To change any text data open the file “read data” from text library via providedEXCEL-button and make changes. After changes are done, store back the data.



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3.3 Full download

3.3.1 Full download to OS Server in same directory (overwrite)

The download is issued from the ES via SIMATIC Manager PCS 7 standardfunction. Regarding BRAUMAT compact data, all data can be changed.First follow the notes in chapter 3.2 “Delta download”.For adding a new unit a new user archive is created what requires an OS-FullDownload for updating the servers. How to create a new unit refer to theBRAUMAT compact engineering guide.During the download, any new user archive is downloaded with table configurationdata only. Any pre-configured runtime data is not(!) downloaded to the server. Thepre-configured runtime data must be inserted via the BRAUMAT compact tablegenerator. Select the previous newly created archive in the BRAUMAT compacttable generator on the OS server, either master or stand-by. If it is shown with ayellow instead of a green button, then push the yellow button to pre-configure thistable. All other user archive data in the OS server are not touched and the systemkeeps the runtime data.In case of redundant server pair any runtime data changed on master during fulldownload to stand-by server are synchronized during stand-by server runtimestartup.

3.3.2 Full download to new OS Server

The download is issued from the ES via SIMATIC Manager PCS 7 standardfunction. Regarding BRAUMAT compact data, all data can be changed.First follow the notes in chapter 3.2 “Delta download”.Additionally, it is possible to add new units. Adding a new unit can be done with fulldownload only. During the creation of a new unit, a new user archive is created,that leads into a situation where a full download is required.How to create a new unit refer to the engineering guide.During the download, all user archives are downloaded with configuration andruntime data. In this case the runtime data is not “valid” in terms of previousrunning process. In this case, an update of the runtime data is required. In case ofa redundant system, the data is synchronized via the WinCC redundancy duringsynchronization from standby server to master server.In case of single server configuration it is necessary to start the OS runtime on theserver and to import the former exported user archives. The export of user archivesis described in chapter 2.2.1 “Export user archives”.



For import of the user archives, the button “Import archives” is used. The formerbacked-up archives must be available in the configured path.

Figure 3-3

In case the AS has all current data, the system is up-to-date.In case the AS might not be up-to-date, each(!) unit must be updated with thefollowing tasks:1. Open the matrix configuration dialog.



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2. Load data from the user archive (see Figure: (1)).3. Save data to PLC (see Figure: (2)).4. Open the parameters dialog (see Figure: (3)) and close it after it is fully loaded

again.

NOTE In the parameters dialog (opened via “Parameters” button) the data willimmediately get active to the AS (BRC_REAL blocks). Therefore the functionshould not be used in runtime or the user has to sure about the handling andbehavior.

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