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1. Device medium partial unit Mash Kettle Monitoring time min sec 18 00 min sec Mash Kettle Step duration min sec 15 00 min sec Mash Kettle Temperature Regulate 52 00 C Mash Kettle Steam Pressure Regulate 0 50 bar Mash Kettle Temperature Delaytime for Device min sec 2 00 min sec Valve 06V0502 on off Number choice 1 00 0 Off 1 On Mash Kettle Agitator Speed Manual value 30 00 Speed Mash Kettle Temperature in setpoint diff Step release 2 00 C Mash Kettle Temperature over setpoint fault 55 00 C Mash Kettle Monitoring time Ion sec 20 00 SS Mash Kettle Temperature at Setpoint min increase regulation 1 00 C min Mash Kettle Steam Pressure Regulate 0 70 bar Valve 06V0502 on off Number choice 1 00 0 Off 1 On Mash Kettle Agitator Speed Manual value 75 00 Speed Mash Kettle Temperature over setpoint Step release 65 00 C Mash Kettle Temperature over setpoint fault 70 00 C Here you can change the name of the step inside the yellow bar Don t forget to hit the Enter key after typing The grey and white bars are parameters contained in the step from the above yellow bar You can change parameter set points by just clicking on the numbers blue circle and acknowledge with the Enter key After finishing changes in all needed steps just press m to get back to the recipe editor and save changes with ed Berabreuw User Manual doc
2. Language set at a time AN 3 1 3 2 C F switcher at Opens a program which calculates from C to F and reverse La 4 3 1 3 3 Trend Various Motor trends 3 1 3 4 External software MOPE SEW Frequency Converter software Suite Siemens Developing Environment brie Hq BeraBrew_User_Manual docx doc Version 0 1 Seite 6 23 Copyright a on AG Munchen All rights reserved w l automation EC 3 1 3 5 System au System settings beraBREW Ga Opens a calculator Prints the actual screen Ea Log off the user from the system bs Various Trends Le Alarms Page Notifications can also been de activated here KH Opens Start screen BeraBrew_User_Manual docx doc Version 0 1 Seite 7 23 Copyright a on AG Munchen All rights reserved Q Of automation amp Gei 3 1 3 6 Screen Navigation By switching the screen with the Buttons described above new buttons appear to navigate within screen or access further options This is the Exit button It appears as soon as the operator enters an additional navigation layer e g Sequence Protocol With this button the prior screen can be reached and it disappears back at the main Level Navigation in the Main navigation bar is always possible BeraBrew_User_Manual docx doc Version 0 1 Seite 8 23 Copyright a on AG Munchen All rights reserved Q Of automation Gei 3 1 3 6 1 Device screens In beraBREW every part of
3. doc Version 0 1 Seite 22 23 Copyright a on AG Munchen All rights reserved Q Of automation Gei 5 FAQ 5 1 Is it Possible to automate a Brew house with beraBREW Yes beraBREW is developed by brew masters in collaboration with automation specialists The main focus was to create an easy to learn affordable and handy automation system for efficient every day production 5 2 Is reporting available beraBREW includes reports such as a brew protocol step protocol and tank protocol There are also some Trends available which contains data for certain parts of the brew house e g Lauter Trend Lauter flow lauterpump speed Dosed water amount We are working at the moment to create an advanced reporting tool which will be available as an option to beraBREW 5 3 Can I create my own Steps Valves and motors are actuated by the PLC code The operator can change the step s behavior by changing its parameters 5 4 I cannot see the Mash kettle temperature from yesterday There are two different kinds of trending within beraBREW Trends which are accessed by clicking on the object are short term trends and are deleted when the trend screen is being closed Production data for a longer period of time is tracked within long term Trends Those are combined trends like the Mash kettle Trend It contains data according to the Mash kettle temperature Volume Water counter BeraBrew_User_Manual docx doc Ve
4. docx doc Version 0 1 Seite 10 23 Copyright a on AG Munchen All rights reserved d on OS automation 4 Gei 3 2 Automation objects Automation objects in beraBREW are those parts of the plant which can be controlled and or monitored from the Visualization The most common automation objects are e g Valves Motors and analog Values such as Temperature probes 3 2 1 Valves Se This picture shows a Valve how it is visualized in beraBREW ready for manual operation The valve can be operated by clicking on it An opened valve is Shown as bright green iF When the Valve is occupied by a device recipe active it becomes dark grey and cannot be operated manually anymore 26V0002 Ss Dark green valves are automatically opened valves from the Device 26V0002 BeraBrew_User_Manual docx doc Version 0 1 Seite 11 23 Copyright a on AG Munchen All rights reserved Q Of automation 4 Gei 3 2 2 Motors 34SICP0001 34SICP0001 34SICP0001 Motors are visualized as can be seen above The color code is the same as the valves Bright grey means Manual mode bright green show a manually operated running motor Active automatic mode is displayed as dark grey A running motor in automatic mode becomes dark green 3 2 3 Interlocks Valves and Motors can be interlocked due to process or security reasons In this case they cannot be operated clicking on them won t actuate them and the color of the interlocked object
5. right and all available steps for the device which recipe the operator is editing on the left The steps are being marked by clicking on them To add a step just select one on the left and then select a step on the right the position the new step is supposed to be ei By clicking on this button the step on the left is inserted above the selected one on the right This button E replaces the selected step in the recipe with your selection from available steps To be able to delete steps and recipes you must first to unlock the delete buttons with SE This is a safety feature proven by working with beraBREW After a click the background of this button gets red and delete keys will be visible To delete a step from the existing recipe not possible for available steps just select the mt desired step on the right and hit There is also an option to delete the whole recipe but it is not recommended It is easier and more practical just to overwrite the recipe as described in 4 3 1 1 Recipes are deleted with All changes described in this chapter must be saved with ed otherwise they will get lost when exiting the recipe editor BeraBrew_User_Manual docx doc Version 0 1 Seite 21 23 Copyright a on AG Munchen All rights reserved d on OS automation Q 4 3 3 2 Steps To change the step parameters just click on E again while inside the recipe editor This leads you to the following screen C1 ager ON
6. Q Of 9S automation Ae Gei Specification beraBREW User Manual Created by Andrej Torubara a on a on AG automation Grundfeld 6 85445 Oberding phone 49 08122 94446 40 www a onag de Authors Andrej Torubara a on Issue 15 12 2014 Version 0 1 Subject to change Valid for beraBREW greater V13_1_13 BeraBrew_User_Manual docx doc Version 0 1 Seite 1 23 Copyright a on AG Munchen All rights reserved Q Of automation 4 Gei Table of contents 1 PROLOG Hl EEN 3 2 FIRST STEPS eege 4 3 NAVIGATION EE EEN 5 3 1 EEN 5 3 1 1 Section ZSelechon 5 3 1 2 Plant SC CCUON EE 6 3 13 Miscellaneous TU CCOMNS e eae tense eens as oe ee be E 6 3 2 AUTOMATION fer en KEE 11 3 2 1 VI CS a ou EE EE EE EE 11 32 2 MOO EE EE EE EE 12 3 2 3 THE CHIOCKS EE 12 3 2 4 ETO gts se as es sn ae we en Pe ee nes oe ek EE 12 3 29 SEET 12 3 2 6 VW O PS wer we rac tenawexsweses seadesceaweperes sacnas ooeverencetacher or se evescesseneroeewoussusteebetods 13 3 2 7 Ea li E E eerie re sees hu scan ae ws sn oe ee se eee A T oe een he ee seen emia a Poise senses 13 4 RECIPES EEN 14 4 1 STARTIN RE de 15 4 2 WORKING WITH RECIPES EEN 16 4 2 1 Charge Ball NUMDOT ee e ee EE ee ee ee 17 4 2 2 Jumping between stepS s s ssssrssssrusssssersssensrsennessnnesssnessnnsssssensssensessnnnr 17 4 2 3 Restart a recipe after unwanted Cancelling 17 4 3 EDIT RECIPES EE 18 4 3 1 RCE CO OTF eaaa EA AAE ee ee eee ere eee 19 4 3 2 COD T Gt CCDC E 20 4 3 3 Alter
7. Silos 03 Reset Scale 6 06 Milling Malt Special Malt 1 03 Reset Scale 3 13 Milling Malt Bigbags 03 Reset Scale OI Total Scale Ir 16 postrun Motors 2 12 Paused Mode Start Mash In 7 4 04 Start Mash Kettle 1 11 Synchronization with Mash Kettle 05 Mashing in as we know from starting recipes 0S ek First the operator has to select a recipe on the left side which he wants to edit or copy Then the recipe editor is available by pressing ee md oO OMe GH 10 1 12 13 16 01 Basic Step 02 Milling Malt S os 03 Resat Scale 04 Start Mash Kettle 05 Mashing In 06 Milling Malt Special Malt 1 07 Total Scale 08 Milling Malt Special Malt 2 10 Basic Position Check Way and Devices 11 Synchronization with Mash Kettle 12 Paused Mode 13 Milling Malt Bigbags 16 postrun Motors E T in the bottom right corner Matt Milling D Boner Pils 1 01 Basic Step 10 10 Basic Position Check Way and Devices 2 02 Milling Matt Silos 03 Reset Scale 56 06 Milling Matt Special Malt 1 03 Reset Scale 13 13 Milling Malt Bigbags 0S Reset Scale 7 Di Total Scale 1 16 postrun Motors 12 12 Paused Mode Start Mash in 7 1 04 Start Mash Kettle 11 11 Synchronization with Mash Katte 05 Mashing In 11 11 Synchronization with Mash Kettle On the new opened window the selected Recipe nr name and the actual step are located on the right side On the left we see available steps for t
8. his device Which can be inserted into the selected recipe BeraBrew_User_Manual docx doc Copyright a on AG Munchen All rights reserved Version 0 1 Seite 19 23 Q Of automation Gei 4 3 2 Copying a recipe The selected recipe is copied by clicking on the recipe nr Malt Milling Boner Pils 1 01 Basic Step 2 10 10 Basic Position Check Way and Devices 3 2 02 Milling Malt Silos changing it to a new number and hitting the Enter on the Keyboard If a recipe already exists under this number it will be overwritten and is lost then It is recommended to choose the same recipe number for every brand in each device This Sera to Sup track of E and Zei alt miling Dep EE gt Now the recipe name can also be changed to the new brand Malt Milling 1 1 01 Basic Step 10 10 Basic Position Check Way and Devices 02 Milling Malt Silos 3 03 Reset Scale A N sch NO Do not forget to hit Enter after changing it too The next step is to save this new recipe with ME The new recipe under the chosen number in the recipe editor is now ready to be modified without destroying the old recipe BeraBrew_User_Manual docx doc Version 0 1 Seite 20 23 Copyright a on AG Munchen All rights reserved Q Of automation Gei 4 3 3 Altering an existing recipe 4 3 3 1 Recipe Steps Recipe In the recipe editor window the operator sees the selected recipe with its steps on the
9. ing an existing recipe ssssssssusssssensssensssensessnnessnnessnnensosensssensnssnnns 21 5 FAO E E E E E E E 23 5 1 IS IT POSSIBLE TO AUTOMATE A BREW HOUSE WITH BERABREW d 23 5 2 IER elt dief CARE 23 5 3 CAN I CREATE MY OWN STEPS d 23 5 4 I CANNOT SEE THE MASH KETTLE TEMPERATURE FROM YESTERDAY d 23 BeraBrew_User_Manual docx doc Version 0 1 Seite 2 23 Copyright a on AG Munchen All rights reserved Q Of automation Gei 1 Prologue The beraBREW automation system has been developed in close cooperation between brewing specialists and automation technicians Objective has been to create a functional automation which is easy to operate and used internationally standardized but reasonably priced components and software licenses In order to guarantee availability and reliability only high quality components of recognized manufacturers are used The selected components are constantly developed and brought up to date The beraBREW automation system is proven in numerous breweries beverage companies and in the food industry world wide In its actual version V13 it fulfills all latest demands to a process automation platform in combination with practical system operation We give our best to make this Manual as complete as possible Due to the fast evolving brewing Industry and infinite number of possible plant constellations some parts of this guide may differ This Manual aims to introduce the operators to the Visualiza
10. lection J Brewhouse S Fermentation The most important function is switching between the brew house and the Fermentation section If your plant is divided on two PLC s you can change the section you want to control and monitor with these two buttons Otherwise the buttons are not visible You can only access the devices which are on the same section as chosen Also only the alarms will forwarded which appear on the section you are at gt BeraBrew_User_Manual docx doc Version 0 1 Seite 5 23 Copyright a on AG Munchen All rights reserved a on ge automation Nyy 3 1 2 Plant selection Accessories sl O l With the plant selection you choose the part of your Plant you want to control Also the main navigation bar will be changed automatically The combinations are available as follows depends on your plant Accessories gt Water Household Steam Malt gt Silos Mill Brew house gt CIP Maschkettle Mashtun Lautertun Spent Grain Prerun Tank Wortkettle Whirlpool Wortcooling Yeast Tanks Yeast gt Wortcooling Yeast Tanks Yeast Tank 1 Yeast Tank 2 Yeast Tank X Fermentation gt CIP Tanks FTselection Fermentation Tanks 1 x BBT s Recipes gt Recipe Editor si CIP Brewhouse Mash Kettle Lauter Tun Spent Grain Wort Kettle Whirlpool Wort Cooling 3 1 3 Miscellaneous Buttons 3 1 3 1 Language selection Switching the Language is just as easy as clicking on the flag The Flag e p represents the
11. ng also very good beer Both devices synchronize and communicate automatically Malt department finishes mashing in very good beer ends and the mash kettle continues with heating resting As very good beer reaches a certain point in the mash kettle it starts the lautertun This goes on and on from device to device several times until we get a very good beer into our fermentation vessel BeraBrew_User_Manual docx doc Version 0 1 Seite 14 23 Copyright a on AG Munchen All rights reserved Q On de automation Ae Gei 4 1 Starting Recipes The most common way is starting a recipe from the device screen by clicking the _ Recipes button on the bottom right side This button leads to the recipe editor screen Recipes Recipe The recipe is selected by clicking on it on the left side and acknowledge ll it Now you get back to the device screen with Malt Milling WW Aa WW K B Ei Brew Protocol Week Schedule Recipes Sequence Protocol The chosen Recipe is now displayed on the left side red circle and the process can be started with LE button in the bottom center of the screen There are four different kinds how a recipe usually is started in normal operation Production gt BeraBrew_User_Manual docx doc Version 0 1 Seite 15 23 Copyright a on AG Munchen All rights reserved goer Goo D a es St Kg vi En automation kel 4 2 Working with recipes This chapter describe
12. r This is a continuous number which gets increased every time a recipe is being started It can be manually edited at any time The previous device which starts an upcoming device overwrites this number with the one of its own The charge number is also being used to select and look up brew protocols The charge number must be the same for two devices to be able to synchronize EASILY SPOKEN When mashkettle runs a recipe with charge 225 and starts the lautertun No matter what the recipe which is being started in the lautertun will also have the number 225 gt brew protocol 225 is the exact same brew for all devices 4 2 2 Jumping between steps During a running recipe the operator can skip steps or go back to a step which has been WW Ad H already processed with those buttons After every activation of one of these buttons the new actual step will be set in pause mode to avoid unforeseen circumstances e g wort to drain and must be unpaused manually with by the operator 4 2 3 Restart a recipe after unwanted cancelling A running recipe does not need to be interrupted When manual intervention is needed this can be achieved by pausing the recipe If it happens that the recipe was aborted by pressing b accidently or not the recipe can be restarted simply by choosing the recipe as described in 1 2 In the screen of the device clicking on the Recipe button selecting the right recipe and acknowledge it Afterwards ju
13. rights reserved Q Of automation 4 Gei The pause button pauses the actual recipe All automation objects e g Valves and Motors will be deactivated The active pause mode is signalized by the yellow background and an alarm message The monitoring time will still be counted which may lead to an additional alarm when it expires This button is called Brew Protocol at normal devices and Tank Protocol at Tank device screens It opens a Protocol screen with additional information for the Brew Protocol particular device The actual brew protocol is being showed Older protocols can only be selected when no recipe is active within this device Here the operator can set a week schedule can be planned by the operator which starts the needed recipes Week Bobet at a certain time As recipes are getting started by the Week Schedule prior device and the first device usually is the Mill this function should be used there The Recipe editor can be accessed with this button It opens the editor for the device on which screen it was Recipes being pressed Opened through the device screen recipes can only be edited when no recipe is active within this device With this button sequence protocols can be reviewed which provides information on values and steps While a Sequence Protocol recipe is running only the actual protocol can be seen otherwise also older batches can also be reviewed BeraBrew_User_Manual
14. rsion 0 1 Seite 23 23 Copyright a on AG Munchen All rights reserved
15. s the Recipe part of the device screen if Malt Milling Monitoring time min sec J 0 21 min sec Malt Milling Step duration min sec 0 00 min sec Malt Weight Kg Regulate i 0 00 kg Malt Weight Kg over setpoint Step time release 0 00 kg Malt Quantity in kg in the Conveyor Number choice 75 00 kg Setpoint only Malt Silo Number Number choice l 0 00 Silo Number Malt Sort Number Number choice 1 00 Malt Sort Number Malt Milling mam ee RA Brew Protocol Week Schedule Recipes Sequence Protocol Inside the bar following Statuses are indicated shows the active recipe number and name ORANGE displays the actual active Step function number and step name PURPLE here the Charge Batch number is stated For further explanation see below The lines below are showing the selected parameters for the particular step Each text within the lines is black at the beginning and gets dark green as soon as the parameter is satisfied All lines parameters needs to be dark green satisfied for the step to advance GREEN shows the unit the parameter is referencing BLUE shows the function of the parameter This is the setpoint of the parameter YELLOW here the Actual value and unit can be found BLACK This is an additional parameter which is hardcoded in the code Must be dark green as well BeraBrew_User_Manual docx doc Version 0 1 Seite 16 23 Copyright a on AG Munchen All rights reserved Q Of automation Gei 4 2 1 Charge Batch numbe
16. st starting it with KR Now the operator can forward the recipe to the step it was before and continue with brewing BUT as here we do not have a prior device starting the recipe and the Charge number gets increased by restart the recipe the operator has to decrease it by 1 before the restart This is necessary to let the devices synchronize automatically with each other and fill in the right Brew protocol BeraBrew_User_Manual docx doc Version 0 1 Seite 17 23 Copyright a on AG Munchen All rights reserved d on OS automation 4 Gei 4 3 Edit recipes The customer will be provided a basic recipe during commissioning It is called Default Recipe It is possible to create new recipes from scratch but more useful just to copy this default recipe and delete or add steps and change parameters The recipe editor is available under the Recipe button located on the device screen It can only be opened here if no recipe is active within this device A second way is to access it through the Plant selection by selecting Recipes in the drop down menu BeraBrew_User_Manual docx doc Version 0 1 Seite 18 23 Copyright a on AG Munchen All rights reserved 4 3 1 Malt Milling This is the basic recipe selection screen Recipe editor Recipes from 1 to 25 1 2 3 4 5 6 H 8 9 11 11 Synchronizat d on automation 01 Basic Step 10 10 Basic Position Check Way and Devices 2 02 Milling Malt
17. the automated section is called a device Easily spoken every part which can be accessed from out of the main navigation bar is one device Those devices and their functions will be explained later Gen L 7 7 ej a i ej s Comment 3 1 3 6 2 Device screen main navigation menu Malt Milling Im KN bi DI E Brew Protocol Week Schedule Recipes Sequence Protocol These buttons are for navigation within a started recipe The left button jumps to the first step of an activated recipe The middle button is for accessing the step before the actual running step The right button skips the actual HH 4 aad step and go to the next step even if conditions are not met Each Time one of this buttons is pushed the recipe is being paused and must be unpaused manually by the operator to proceed Those two buttons only appears when a recipe is selected or running Red background means Recipe is selected One click on this button starts the recipe Green Background shows a running recipe Pay attention clicking it will deselect and cancel the whole running recipe With this button the operator has the ability to force to remain the device in the actual step even if all conditions are met The green Background shows that this button is activated The step will only advance when all conditions are met and this button is deactivated BeraBrew_User_Manual docx doc Version 0 1 Seite 9 23 Copyright a on AG Munchen All
18. tion and describes the use of common Visualization objects as well as guides the operator through the first steps changing and creating recipes BeraBrew_User_Manual docx doc Version 0 1 Seite 3 23 Copyright a on AG Munchen All rights reserved OS d on d automation 2 First Steps Cfle beraBREW is started during Windows startup or by a shortcut on your Desktop n Now you are seeing the Start screen e r f n Youn Lote OQ Cancel after clicking a button or the plant selection Accesso E As logon credentials a password is being used which limits the function of beraBREW depending on your access level The standard log on for an operator is Pbtrewer With that you can select and start recipes and control the system but you are limited with the Recipe editor and System settings BeraBrew_User_Manual docx doc Version 0 1 Seite 4 23 Copyright a on AG Munchen All rights reserved automation W Gei 3 Navigation 3 1 General The main navigation bar can be seen on every screen Here you are able to do general operations such as navigate through different device screens EIN 0 0n09 Botos A Mt eb 7tzeaags Kus 101 i On the bottom side of the Start screen buttons for closing and minimize beraBREW are available Also Windows and the computer can be shut down from there beraBrew end beraBrew minimize Windows end 3 1 1 Section Se
19. und is a 02FT0001 enn R sum counter The other field is a so called step counter The sum counter is used to keep track of the overall fel 3t0 n SI d value through out many different steps e g lautering Where the step counter is getting resetted in each step to make calculating set points easier e g first sparge 5hl second sparge 7 hl 12hl and not first sparge 5hl second sparge 12hl The mode of the counter manual automatic can be changed by clicking on the hand symbol By clicking on the button with the black dot step counter the operator can activate the counter and it will increase as soon as the flow meter measures flow Each counter can be set to zero by clicking on the button on the right with the R in it BeraBrew_User_Manual docx doc Version 0 1 Seite 13 23 Copyright a on AG Munchen All rights reserved Q Of automation 4 Gei 4 Recipes Each Recipe can run independently There exists no overall Recipe for the whole Brew house Beer is made by several different recipes which are started in each device As beraBREW is a full fledged automation system this process is fully automated This means the operator starts a recipe in the malt department which we will call here very good beer The malt department runs very good beer steps and at a certain point malt department will start an according recipe in the following device mash kettle which we call for easy understandi
20. won t change There are also some visible interlocks which show mostly process errors e g overfilled Vessel in this case the object blinks pink 3 2 4 Errors Errors are shown by a red blinking object 3 2 5 Setpoints Objects like Regulation valves or frequency controlled motors come with an input field near them This fields either in manual or automatic mode shows the value for speed or opening range of this device This is a field in manual mode represented by a green background and a hand beside it It can be switched in automatic by clicking on the hand The operator can control the value directly ooj A In automatic mode the background changes to white and the hand switches to an A The object gets its value from a PID controller now The value cannot be edited anymore BeraBrew_User_Manual docx doc Version 0 1 Seite 12 23 Copyright a on AG Munchen All rights reserved Q Of 0 automation 4 Gei 3 2 6 Two Points ort I I Auto filling Two point controllers are used where a range and not a fix limit is used This is a two point controller from a tank level The button in the middle turns on the automatic operation here filling When the tank level gets below 80hI lower input field the tank will be filled until the tank level reaches 125hl upper input field On Fr 3 2 7 Counters A counter is visualized with a fancy picture and two value fields The field with the yellow backgro

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