3 Options SIMATIC WinCC
3.2 Increased availability
3.2.3 SIMATIC Maintenance Station Definition
SIMATIC Maintenance Station provides diagnostics func- tions for maintenance that enable precise analysis of the plant components, namely the assets; and as such it is an asset management system at the plant level. The diagnos- tics screens, which are generated automatically from the hardware configuration, show maintenance-related informa- tion from the entire automation system, for example, from
SIMATIC PCs, networks, programmable controllers, HMI devices, etc.:
● ALARM_S messages ● Maintenance requests
● Uniform, integrated status displays
All data, visualization, and operator control from the SCADA system and Maintenance Station are consistent and uni- form.
Application
Maintenance technicians not only prevent production loss, but also optimize the plant over the long term. Preventive maintenance has the following effects:
● Prevention of expensive production downtimes and rejects
● Creation of planning security in terms of resource expenditure: Imminent orders are signaled in due time. ● Increased system availability
● More cost-effective than corrective intervention ● Reduced stockkeeping costs
From a machine manufacturer's perspective, maintenance applies to packaging or filling machines, for example. For a plant engineer, maintenance is limited to the servicing of the process plant. However, the plant operator sees mainte- nance from an integral perspective and would like to keep track of the entire process sequence at a glance.
Totally Integrated Maintenance
Completely in keeping with the concept of Totally Integrated Automation, SIMATIC Maintenance Station is automatically generated from the hardware configuration of the automa- tion systems displayed in STEP 7. Based on this configura- tion, the Maintenance Station detects which devices belong to the plant and generates an image with universal symbols for maintenance in an existing or separated WinCC station.
Figure 83 SIMATIC Maintenance Station
Operators continue to monitor the production process, while maintenance technicians acquire specific information about the status of the production equipment. The Maintenance Station is available for the PCS 7 process control system as well as for the WinCC SCADA system with STEP 7.
3.2 Increased availability Options SIMATIC WinCC With SIMATIC Maintenance Station, you can perform
intelligent, preventive maintenance with minimal resource utilization, for example, less staff, material, energy, and cost with the following options:
● Overview of information for assessment of plant and component status and comprehensive analysis of weak- nesses
● Electronic identification of components, for example, firmware version, manufacturer, and order number ● Reporting of system errors, overview of long-term
archives
● Assistance with decisions concerning maintenance measures such as plant service, inspection, repairs, and elimination of weaknesses
● Maintenance request and status management. If the premium add-ons Alarm Control Center (ACC) or PM-MAINT are installed on the WinCC system, mainte- nance requests from the operator can also be directly forwarded to these systems.
Figure 84 Electronic identification of components Structure
To set up a diagnostic system, proceed as follows: 1. In SIMATIC Manager in the STEP 7 project, set up a
"Maintenance Station" PC station with a communication module such as PROFINET.
2. In the "HW Config" Editor, add the network components. 3. Using the Compilation Wizard in SIMATIC Manager,
assign the STEP 7 programs to the Maintenance Station and network connections; a diagnostics screen will then be derived automatically from this.
4. For each automation system, initiate the automatic generation of the associated diagnostics screen includ- ing the picture hierarchy and diagnostic faceplates. You can modify the generated diagnostics screens with WinCC at a later point.
5. In SIMATIC Manager, transfer the generated diagnostic faceplates to the associated automation system and click with the mouse to compile.
Tools
When SIMATIC Maintenance Station is started up, the fol- lowing elements are displayed in the diagnostics area: ● An overview of the entire automation system of a plant:
PC stations, network and automation components, dis- tributed field buses, and external I/O.
● A message table, including, for example, a message list and a long-term archive list
● Faceplates, operating windows, message lists, and diagnostics windows called during operator control ● Group displays of queued diagnostic messages with
loop-in alarm: This takes you directly to the diagnostics screen of the component that caused the message to be issued in the respective plant section. If more than one diagnostic message is in the queue, the system displays the diagnostics screen that is the highest in the hierarchy and that shows the status of all queued diagnostic mes- sages.
● A section selection button: This takes you directly to the top diagnostics screen in the picture hierarchy of the as- sociated plant section.
● Diagnostics screens of individual components: From the overview of an AS component or PC station with diag- nostics status, for example, "Maintenance alarm", you jump to the diagnostic faceplate. This faceplate shows the component data, status displays, and queued mes- sages, as well as the requested and initiated mainte- nance measures. The same applies to lower-level com- ponents such as field bus systems, drives, sensors, and switchgear. Messages in this view can be acknowledged and managed.
● In the Picture Tree Navigator, you navigate to PC sta- tions, network components, and AS components in a hi- erarchical tree structure - otherwise, you have the same functional scope as with diagnostics screens.
● If SIMATIC STEP 7 is installed with an associated STEP 7 project: you jump from a network component to the HW Config Editor, where you check the hardware data.
Figure 85 SIMATIC Maintenance Station: diagnostics screens of individual components
Special features
● Maintenance measures are documented via WinCC operator messages. This supports the work flow and creates a comprehensive database for subsequent plant optimization. This database is evaluated with WinCC as a Maintenance history.
● Just as in WinCC, the appropriate access rights are required to perform diagnostics with SIMATIC Mainte- nance Station.
● New hardware components from the latest STEP 7 ver- sion are automatically available for SIMATIC Mainte- nance Station and therefore do not have to be added manually.
Options SIMATIC WinCC 3.3 Plant Intelligence