Further Into the Future With Zenon

We have been using the zenon HMI software from Copa-Data in various divisions since 2013. CTE has been a partner of manufacturer Copa-Data since the beginning and was also involved in the development of the Batch Control module. Last year, we were promoted to Qualified Partner in their three-stage partner programme. This award shows that we, at CTE, have the necessary expertise to realise the maximum customer benefit in our projects.

As early as possible in the projects, the functional units of the systems are identified based on the R&I and divided into equipment modules (basic functions). This is a prerequisite for the use of zenon Batch Control and for the successful completion of the project. For interaction between zenon Batch and the PLC—What is a PLC?A PLC (programmable logic controller) is a system for process control. It acquires sensor data via inputs, processes it, and controls actuators such as motors or valves via outputs— the “Basic Function Header” library module, which we developed and validated ourselves, is used.

S88 Embedded

This GFK controller handles all communication and interactions between the HMI Batch Control, the operator, and the PLC program. Seamless switching between automatic and manual modes, Run/Stop (ISA88What is ISA-88?ISA-88 is an international standard for batch processes and continuous plants. It enables modular, scalable, and reusable automation.) handling, and a user-friendly HMIIWhat is HMI?HMI (Human Machine Interface) is the interface between humans and machines. Typically implemented as a dashboard, it serves to control and display operating data and statuses. Status messages are just a few of the features that make our GFK Head so valuable to our customers. With many additional validated PLC blocks in our library for the most common Siemens controllers—such as in CFC for the S7-300/S7-400 series or the S7-1200/1500 in the TIA Portal—we are well-equipped to meet all requirements.

We also rely on standard functions for the HMI. Everything is configured in zenon out of the box, which keeps the effort for qualification in the projects low. The standard report configured by us in the projects does not require any additional high-level languages, scripts or programs in the background.

Multi Client/Server

Thanks to the many projects it has already completed using various system architectures, CTE has built up extensive expertise with zenon. We have had very positive experiences with our zenon Multi Client and Multi Server solutions, as well as with standalone projects. In this setup, all individual production lines are equipped with zenon Batch Control and can operate autonomously (typically with operation in cleanrooms or EXzones. What are EX zones?Areas with explosive atmospheres. They are classified based on the risk and duration of this hazard to prescribe appropriate protective measures and permitted equipment.). To facilitate the creation of Batch Controlrecipes—What is a Batch Control recipe?A Batch Control recipe describes the commands, ingredients, and process parameters required by a Batch Control system to produce a fully automated and reproducible product batch— as well as for remote control, a so-called recipe station is used, which accesses the zenon server of the respective plant. This structure offers many advantages but also presents certain challenges, which can be overcome thanks to our extensive experience.

Web client

Remote access is another topic that comes up time and again. More and more customers want to be able to check the status of their systems even when they are away from the office. For this use case, we successfully retrofitted the zenon HTML5 web server into an existing application for a pharmaceutical customer. In this setup, the web client—What is a web client?A web client is a program that accesses server services via a browser. This allows users to flexibly access data from any device without installing local software— does not access the system directly, but only specific, approved images of the system stored on a separate web server. Using encrypted communication, only the current values and statuses are requested from the system and provided by the web server. Whether the customer wishes to simply monitor or also operate the system can be conveniently defined via the zenon licensing. All these functionalities comply with current IT security requirements.