4 WinCC-Runtime 4.1 Start of the program without Auto Start

Do the pressure test carefully before first usage. 

4 WinCC-Runtime 

4.1 Start of the program without Auto Start 

After switching on the computer and normal Windows login (Delivery user is “Example” and password 

“example”) you see the Windows desktop with a WinCC-Symbol. You double-click this symbol and the 

program opens. Depending on how WinCC was stopped the last time, you may find yourself in the 

WinCC-Explorer surface. 

WinCC Explorer - here the project is already activated. 

In this case push the activate button or activate choosing . 

It takes some time to load all modules. 

IMPORTANT 

The delivery local Administrator besides plant is 

User: Administrator 

Password: example 

AP-Miniplant - Operation Manual Mini Batch Plant Page 23

4.2 Overview picture 

Overview picture with push buttons at the bottom line, process flow sheet and actuators and control 

loops which can be clicked on. 

The push buttons have the following meaning: 

Label Meaning 

Dummy For maintenance only, switches to an empty picture 

Recipe Shows the recipe pop up window 

(Stop Recipe) Stops the recipe 

Recipe Shows the recipe pop up window 

Shut down Starts the shut down procedure to bring the process into a save state 

Sample Opens the sampling pop up window 

(Sample ack.) Must be pressed after the sampling vial is placed to allow sampling 

Pres. Test Evaluates the presser test 

Inert Evaluates intertisation 

Curves Shows different curves of measured values 

Safety Shows safety settings 

Symbol Key Starts login procedure, opens safety settings first. 

Symbol Exit Exits this program, a safety question follows. 

DANGER 

Exiting the program before the plant is in a safe state is dangerous. The plant cannot be 

operated without the program. Press the shut down button or emergency off in case of danger 


if no program is started. If for some reason the system does not react on you interaction, you 

have the same situation. 

4.3 Alarm picture 

Alarm window in the top left region of the overview window 

The alarm window has the following buttons (left to right): 

Message list 

Shows the active messages and those which are not acknowledged 

Short term archive Shows the last messages, even if they are not active any more. 

Ind. Ackn. Acknowledges this single message. 

Group Ackn. Acknowledges all messages 

Scroll on/off Allows to select single messages in scroll mode. 

Alarm window buttons 

Please note the following colour scheme: 

Alarm/status Came in Went out acknowledged 

Text/background Text/background Text/background 

Alarm white/red black/green red/white 

Warning white/orange blue/grey orange/white 

Failure black/yellow black/white yellow/grey 

Colour combinations in the alarm window 

Messages which are gone, but not acknowledged, remain in the message list, and change the colours 

to those indicated in the “Went out”-column. Acknowledged messages which went out are erased from 

the message list. The remain in the short term archive list. 

4.4 Shut down 

In case of emergency the predefined shut down procedure shall bring the plant into a safe state. 

4.4.1 Start shut down procedure 

This procedure can be started by 

Pressing the shut down button on the window and answering the question “Do you really want to start 

the shut down procedure? 

Pressing the yellow push button at the PC-Cabinet or at the rig. 


One of the events shown in the following list: 

Hydrogen alarm (immediately after signal changes from 1 to 0) 

Extraction failure (70 s after event, 1st warning after 10 s) 

Fire extinguisher on (immediately after signal changes from 1 to 0) 

Emergency off push button (immediately after signal changes from 1 to 0) 

Safety questions after starting 

shut down 

Warning message in the alarm window, at the same time the 

button starts flashing while the shut down 

procedure is active. 

The shut down procedure brings the reactor to a safe temperature. During this procedure the stirrer 

will go to a predefined safe stirrer speed if it was switched on before the shut down procedure started. 

After reaching the safe temperature, the reactor will be vented. All feeds are blocked. 

4.4.2 Stop shut down procedure 

The shut down procedure has to be stopped manually by pushing the shut down button again and 

answering the safety question with . 

Shut down procedure can also be stopped pressing the Button at the rig or the PC 

cabinet for more then 3 seconds. 

4.5 Locking mechanism 

4.5.1 Valves 

Hydrogen input V17 is blocked as long as no pressure test has been successfully performed. 

Vacuum/Normal pressure valve H04 will switch automatically to normal pressure as soon as the limit 

of 1.2 bar is exceeded. 

Catalyst Feed H01 

Acknowledge button catalyst feed 

To prevent the catalyst feed from being used by mistake, there 

is a locking mechanism. It is necessary to acknowledge with a 

button that the catalyst unit is properly prepared for use. This 

button has to be pressed after every opening of the ball valve 

H01. 


V30 and V04 are blocked during vacuum operation (blocked < 880 mbar, released > 950 mbar) 

Distillate vessel high level reached: H21 is closed and H20 opens 

V10 can not be opened if V39 is open and vice versa. 

4.5.2 Controller priorities 

Priority settings for the feed vessel are: 

purge with overpressure 

Dosing 

Pressure control 

Priority settings for the reactor vessel are: 

pressure test 

purge with vacuum support 

Overpressure control PIC01 

Gas Feed FIC01 

Vacuum control PIC02 

In any case if an action with higher priority is performed, one with a lower priority can not be started. 

4.5.3 Others 

Solid dosing is only possible between 0.9 and 1.1 bar abs. (PIC01). 

Solid dosing will be stopped if low limit is reached. 

Liquid feed will be stopped if low limit is reached. 

The shut down procedure stops the recipe. 

4.6 Login 

Without login you cannot operate the plant. Please use the key symbol for the login procedure. You 

will see the safety settings first. This is to ensure that every new user knows the current safety 

settings. You have to push the key symbol on this screen again to get into the login picture. 


Safety settings 

Login window 

In delivery state the following logins are predefined: 

Operator “example” password “example” 

Administrator: “example” password “example” 

You may change these logins using the user administrator in the WinCC explorer. (see CD-Handbook 

for this procedure) 


You can close both windows by clicking on the cross in the top right corner. You can also do so by 

pressing respective . 

4.7 Weight button 

The weight button allows you to adjust the balances. Normally only the -button is used. 

Balance readjustment should only be made if necessary. Follow the points on the screen to do this. 

You will need suitable reference weights for this purpose. 

When leaving this adjustment window, a warning will be displayed about the risk of wrong adjustment 

of the balance. 

Distillation, input the max. weight 

which is 2 l/density. The capacity 

is necessary for on line level 

display. 

The feed vessel has the same 

input values. 

screen (left) and balance adjustment screen (top) 

Reactor, feed vessel is the 

same picture. Please enter the 

volume where you want the 

high alarm and the density. 

Manipulation of valves 

When clicking on an automatic valve, the following screen will appear: 

Solid feed: The correct setting 

is dependent from if you have 

a lid on it and what the dead 

volume is. 


Closed and open valve 

Clicking on the or button will open/close the valve. Left from the button you can see 

the current status of the valves. 

If there are safety settings that do not allow opening the valve, it is not possible to switch them 

manually. 

4.8 Controllers 

Continuous valves have to be switched on to operate them. The set point can be 

given by the slider bar or as a numerical value in the input field above the slider 

bar. 

Controllers are chosen when clicking at the controlled value in the overview screen. 

The following table gives an overview: 


Loop Function Actuator Range I-share 

on 

D-share 

on 

KP TI TD 

FIC01 Gas Feed V01 0-4 

NL/h 

- - - - - 

FIC02 Liquid feed V28/30/ 1.5 150 Yes No 2.5 *20.0 * 

V31, H07, g/min 

H03 

FIC04 Solid feed Motor 1.5 150 Yes No 10 15 0 

solid 

feeder 

g/min 

GS01 Reflux divider H20 

H21 

0-100% - - - - - 

PIC01 Pressure 

controller 

FIC01 1-20 bar Yes No 5 10 0 

PIC02 Pressure Vacuum 0-1100 Yes No 10 15 4 

controller pump mbar 

PIC03 Pressure V28/30/ 0-20 bar No No Hys. - - 

controller V31, H07 

0.1 bar 

PIS06 Pressure before V25-26 1-20 bar N0 No Hys. - - 

Feed 

1 bar 

SIC01 Stirrer speed Stirrer 30-1500 - - - - - 

motor Rpm 

TIC01 Temperature 

reactor 

HCS02 -40-200 Yes No 2 900 0 

TIC01L Temperature 

Reactor (liquid) 

HCS02 -40-200 Yes No * * * 

TIC01S Temperature 

Reactor (solid) 

HCS02 -40-200 Yes No * * * 

TIC02 Temperature 

feed 

HCS01 -20-100 Yes No 1.1 620 6 

TIS03 Partial 

condenser 

V22 0-200 Yes No 5.0 30.0 * 

TIS07 Accompanied El. 0-100 No No Hys. 3 - - 

Heating heating 

°C 

Overview controller and its settings. 

Attention: Not all settings in this table have to be optimal ones for your special requirements. 

The structures of the controller are as follows: 

Standard controller 

The standard controller picture is shown left. 

There is a bar graph and a numerical field left. 

Then there is a slider bar and a numerical field 

above for the set point input. The tick box 

activates the controller for manual and automatic 

operation. In manual mode the set point value is 

directly given to the actuator. The tick 

box switches the controller to automatic mode. and allow a change 

between controller structures. 


Structure I-share on D-share on Used constants 

P-controller Off Off KP 

PI-controller On Off KP, TI 

PID-controller On On KP, TI, TD 

Controller structures 

WARNING (concerning all controllers) 

The other settings , and the PID-controller constants KP, TI and TD should 

only be changed if you have expert knowledge about PID controllers. 

4.8.1 Feed controller FIC 01- 03 

Gas Feed FIC01 

The gas feed line can be switched on and off by 

clicking the “On” checkbox. In the case of the 

mass flow controller, the controller itself is inside 

the sensor valve system. The slider bar or the 

numerical field above can give the set point of this 

MFC. 

DANGER: 

Always make sure that the system is tight 

before hydrogen can be added. 

IMPORTANT: 

Controller can only be used after a successful 

pressure test. 

Liquid Feed FIC02 

Liquid feed is operated as a standard controller. 

Exception: The “press.” setting in the right bottom 

field will determine the pressure difference to the 

reactor. The flow will start automatically after this 

pressure difference is reached. PIC03 is used for 

this purpose. 

The minimum set point should not be less then 

1.5 g/min. 

Make sure that the liquid feed tank is filled before 

you start dosing. Low level alarm detection will 

switch off the liquid feed controller. 


4.8.2 Reflux divider GS 01 

GS 01: Reflux divider via H20 and H21 

4.8.3 Pressure controller PIC 01 

Solid Feed FIC04 

Solid feed is operated as a standard controller. 

It is necessary to have the hopper properly filled 

for the dosing of solids. When the “hopper empty” 

level is reached, this controller will be switched 

off. 

Choose the right size of the discharge tube 

appropriate to the dosing speed. 

The divider can be adjusted between 0 – 100 % 

reflux. 100 % means that no distillate will reach the 

distillate vessel. 

The process value is the position of the divider 

which can be either 0 % or 100 % (reflux = H20 

open or distillate H21 open). 

The reflux divider itself can either be open or 

closed. The reflux ratio is a ratio between open H20 

and H21 closed and the time H20 is closed and H21 

open. The time basis for the divider is 20 Sec., that 

means that changes made to the ratio will need up 

to 20 seconds until there is an effect. Minimum value 

is 5 %! 

Overpressure controller PIC 01 

PIC01 is operated as a standard controller. 

It uses Hydrogen to raise the pressure level. In 

case of a pressure > set point + 0.25 bar it will 

open V04 with a maximum opening of 20 %. If the 

delta p is smaller, the pressure reduction has to be 

done by hydrogen consumption during the 

reaction. 

To prevent over swinging, there is a hard limit 

when pressure > set point + 0.1 bar. In this case 

the hydrogen mass flow controller set point will be 

set to 0. 

IMPORTANT: 


Controller can only be used after a successful 

pressure test. 

Vacuum controller PIC 02 

PIC02 is operated as a standard controller. 

It uses the variable speed vacuum pump to control 

the pressure. To raise the pressure it can open the 

nitrogen valve V10. To ensure that the line is 

open, the manual valve V42 must be open and 

FI06 should show a flow rate when both valves are 

open. 

Only if the ball valve H04 is connected to the 

vacuum pump, the vacuum is applied to the 

reactor. 

In case of manual operation the set point will be 

scaled in percent and control the vacuum pump 

directly. In automatic mode it gives the value the 

system will try to reach automatically. 

WARNING 

Switching off the automatic mode with a high 

set point will cause the vacuum pump to run 

with high speed which can cause unwanted 

evaporation in the system. Switch off the 

checkbox instead. 

Feed vessel pressure PIC 03 

This controller can only work with a hysteresis, 

which has to be given in the appropriate field. 

Hysteresis should not be less then 0.1 bar. 

The pressurizing will always be through V28 with 

nitrogen. In case of overpressure, the pressure 

reduction will be done through V30 directly into the 

vent line. In case of vacuum in the reactor the 

pressure reduction will be done through V31 and 

H07 into the reactor vent system. 

To evacuate the feed vessel and the reactor, the 

set point has to be set to 0. 


4.8.4 Stirrer Speed control for RM 02 

RM 01: Stirrer speed control 

4.8.5 Temperature controller 

Compressor controller PIS 06 

PIC06 can be used to control approximately the 

pressure after the compressor. This is done by the 

nitrogen inlet valve V25 and the outlet valve V26. 

The set point is given like in the standard 

controller. 

The parameter you can give the controller is the 

hysteresis between upper and lower pressure. We 

recommend a value of 1.0 bar for the hysteresis. 

The stirrer can be switched on and off with 

the click box. Use the slider bar or the 

numeric field above it to change the stirrer 

speed. 


Reactor temperature TIC 01 

TIC01 is operated as a standard controller 

with one exception: 

Tick box instead of 

with the following meaning: 

= Off means the set point will 

be the one for the oil temperature. 

= On means that the set 

point refers to the temperature inside the 

reactor. 

Reactor temperature TIC 01L and TIC 01S 

by liquid and solid feed. 

TIC01L and TIC01S are operated as a 

standard controller with one exception: 

A set point for the flow rate can be given in 

the field . This set point is the basis 

flow the controller starts with. It should be the 

equilibrium flow rate at this temperature. 

Feed vessel temperature TIC 02 

TIC02 is operated as a standard controller 

with one exception: 

Tick box instead of 

with the following meaning: 

= Off means the set point will 

be the one for the oil temperature. 

= On means that the set 

point refers to the temperature inside the 

feed vessel. 


Part. Condenser Head temp. TIS 03 

TIC03 is operated as a standard controller. 

Opening the water supply of the cooling 

jacket via solenoid valve V22 controls the 

temperature above the partial condenser. 

The manual control valve V32 should be 

adjusted so that the flow rate for the 

condenser is neither too big nor too small. 

Accompanied heating TIS 07 

TIS07 is a simple on/off accompanied 

heating controller for the feed line. 

The temperature sensor is outside the tube at 

its wall. 

Hysteresis means the difference between the 

2 switching points on and off. 


4.9 On-line trend 

Trend selection Trend curves of temperatures 

Pressing the button in the WinCC-Runtime-window will open the trend selection window. 

From here you get to the trend-windows as specified on the button. On the top of the trend-window 

there are some buttons to control the appearance of the window and to look at actual or past values as 

described in the picture above. A detailed description can be found in the electronic manual of WinCC- 

Tag Logging. 

You may use the property button to change the time and value scale. The time axis register in the 

property menu is the most important one in practical use. Here you can enter a new scaling of the time 

axis. If you want any change to be persistent so that you have the same setting when you use it the 

next time, click on Persistence in RT and CS or in RT if you only need it this session. 


On-line trend property menu – Time Axis tab and General tab 

4.10 Inertisation 

Performs inertisation for the 

reactor and feed vessel. 

ATTENTION 

Choosing one of the options 

starts inertisation 

immediately. 

The first 3 options will purge the single vessels. The values right of the option fields are the end values 

where the cycle is finished and the number of cycles. 

The reset button allows resetting the status from “o.k.” to false. To stop the current cycle, the tick must 

be taken away. 

The last 3 options allow purging the complete system either without pressure, with pressure and 

vacuum or with pressure only. 


IMPORTANT: 

These values are also used by the recipe and changes will effect the next automatic recipe. 

4.11 Pressure tests 

The pressure test which can be performed within a 

recipe and by pressing the button 

can be configured in the menu which appears after 

pressing the button. 

The pressure will be reached automatically with the 

nitrogen valve V39. After closing the valve the system 

waits for 20 seconds to ensure a stable start point. 

Then the test begins and after a period specified in “hold 

time” the final pressure will be compared to the start 

pressure. The test is successful if the pressure drop 

measured is lower then the value specified in “pressure 

difference”. 

After the test the starting pressure (before the test) will 

be reached automatically by opening V04. 

resets a valid pressure test which 

means that a new pressure test is necessary. 

The settings are: 

Overpressure gives the pressure where the test is performed. 

Pressure difference is pressure drop with which test has failed. 

Hold time is the time interval which is used for this test 

Hold time done indicates the time elapsed from the beginning of the hold 

time. 

Pressure test o.K. Indicates a successful pressure test. 

Max. pressure: max. pressure during test. 

Pressure drop: final pressure drop after elapsed time from max. pressure 


4.12 Sampling 

After pressing the button, there will open 

the configuration menu shown left. 

You can either choose an automatic sampling mode 

in a given interval. Time done shows the time elapsed 

from the last sample 

With the button and 

you can immediately take a 

sample by hand.

4 WinCC-Runtime 4.1 Start of the program without Auto Start

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