Overview

CaeManager – Engineering from the field device to the visualization object

• The CaeManager is the central tool for creating the entire system configuration – from remote I/O modules, fieldbus connections, and open/closed loop control to the operating and monitoring level.
• Engineering takes place graphically based on IEC 61131-3 using function blocks and hyper macros that are inserted from the APROL standard and customer-specific libraries.
• All engineering data is stored in a central database. Securing and backing up this engineering database is possible in the CaeManager.
• The CaeManager is a configuration tool designed for concurrent engineering, i.e. several project engineers / designers can work together on a project at the same time over a network.
• Projects can be arranged according to S88 structure guidelines, an identification system, or altogether differently than predefined structures; they are displayed in a view similar to that of Windows Explorer.
  
• Different views can be selected by the project engineer / designer:
  - Project view according to the project structure created.
  - Personal work progress of the respective project engineer / designer (all configuration elements)
  - Standardized view of sorted and filtered configuration elements (e.g. to only display process diagrams).

• Each project engineer / designer can save his own bookmarks and working versions for configuration elements and use them for filtering.
• Engineering tips support the project engineer / designer during configuration and prevent incorrect input or faulty configurations.  

Version management system

• The CaeManager contains an automatic version management system. A complete version history is included in the project for each individual configuration element.
• If a change is made e.g. to a process diagram, then the CaeManager generates a new version of it that includes the following information:
  - Time stamp
  - Original version
  - Name of the project engineer / designer
  - Comments about the version.
  - etc.
• The version comment may sometimes be optional, but it's mandatory and can be configured when designing a project that conforms to CFR Part 11 or GAMP4 guidelines.
• Restoring older versions is possible at any time and is logged using the integrated ChangeControl logging feature (21 CFR Part 11, GAMP4).
• The enabled versions of the individual configuration elements can be given a label to make them fixed versions with a separate date and time (21 CFR Part 11, GAMP4).

Security login

• Authorization must be granted during the engineering phase for each project engineer / designer. Rights are assigned using engineering profiles (designer groups) to which project engineers / designers are added. Any number of engineering profiles, project engineers, and designers can be created.
• The project engineer / designer logs into the Engineering system using the designer name and password and receives the specified authorization in the libraries and in the projects.
• In accordance with FDA and GAMP Forum guidelines (21 CFR Part 11 and GAMP4, respectively), access to the individual configuration elements in the libraries and in the projects is differentiated as follows: Read, Write, Activate, Confirm (Enable), Download
• The integrated ChangeControl logging feature (21 CFR Part 11, GAMP4) records all project engineer / designer actions and provides important information (who, what, when, where).

Logging all engineering procedures

• The Change Control logging feature documents all relevant activities in the Engineering system. Following the requirements of the FDA and GAMP forum (21 CFR Part 11 and GAMP4, respectively), the Change Control logging feature records the following actions:
  - Changing configuration elements and saving a new version
  - Enabling and disabling versions
  - Confirming (enabling) versions
  - Generating and downloading individual configuration elements or the entire project
  - Labeling (codifying) versions
  - etc.
• Each entry is logged with the following:
  - Date and time (when)
  - Performed action (what)
  - Project engineer / designer name (who)
  - Location of the action (where)
  - etc.

• The Change Control logging feature is started automatically; no configuration is necessary.
• All data can be imported in Microsoft Office applications (HTML, CSV format), printed out, or saved as a PDF document without needing additional programs.

Concurrent engineering

• Several project engineers / designers can work in a team on the same project without having to worry about access conflicts. The configuration data is stored centrally on the Engineering server.
• The database server coordinates access to the engineering data and the individual configuration elements. If a configuration element is currently being worked on by a project engineer / designer, then all other project engineers / designers only have read access to the configuration element.

Offline engineering  

• Makes swapping and offline engineering of configuration elements on a remote Engineering server possible.
• The selected configuration elements are checked out of the central engineering database and can then be transferred (e.g. over a network) to another Engineering server and worked on there.
• "Outsourced" configuration elements are write-protected in the central engineering database until they are inserted back into the online engineering after the offline engineering. All other areas in the configuration are not affected.
• The version management system in APROL seamlessly traces all changes made offline and documents them using the integrated ChangeControl logging feature (21 CFR Part 11, GAMP4). 

Hardware configuration

• Graphic configuration for the operating and monitoring level and the control computer.
• Graphic configuration for controllers (including fieldbus modules) as well as the centralized and decentralized I/O and fieldbus modules.
• Assignments for I/O cards and I/O channels (MSR number, measurement start and end, device) are stored and maintained at a central location.
• I/O card assignments can also be read over an import interface (ASCII format).
• A project-specific physical view tree shows the actual mounting locations of all hardware components in the process control system.  

Connectivity

• 3rd-party system connections are configured directly for the respective hardware using the GatewayEditor.
• Interfaces (excerpt)
  - OPC
  - XML
  - CSV
  - UCB
  - Python API
  - Profibus DP / PA, Profibus FMS
  - Siemens Industrial Ethernet, Siemens 3964R
  - Modbus, Modbus RTU
  - AB DataHighway, ABDF1
  - DeviceNet
  - CAN, CAN Open
  - Serial RS232, RS422, RS485
  - Ethernet TCP/IP, Ethernet UDP/IP
  - IEC 60870-5104 protocol
  - INET, MININET
  - BacNet, LON, M-Bus, EIB-Bus
• Additional interfaces and the precise scope of the protocols in the releases can be found in the F1 driver documentation for B&R connections.  

Software configuration

• Graphic programming according to the IEC 61131-3 standard by copying and pasting function blocks or hyper macros in a function chart.
• Using lines, the blocks are connected with one another, with I/O channels on the controllers, or with variables on connected 3rd-party systems.
• Assigning the function charts and the blocks to the hardware is done using the project-specific physical view tree.
• The auto-router function optimizes the connections between the blocks.
• High-speed exchange of compatible blocks with or without properties.
• Copying / moving selected objects or chart areas (pins, blocks, connections, texts).
• Extensive plausibility checks prevent incorrect input.
• Comment texts and pages can be placed in the function charts.
• Online debugging  

Creation of process diagrams

• Creating the static process diagram (background picture) without animation using the integrated DisplayEditor.
• Any picture formats (.jpg, .gif, .bmp, .tif, etc.) can be used as the background image.
• Animated display driver function blocks are copied and pasted from the function chart / hyper macro to the static process diagram.
• Display driver function blocks are already connected with the process variables in the function chart / hyper macro, which alleviates the need to assign the graphic to the logic or variables later.
• Images, widgets, and image macros are provided in the system for creating diagrams.
• Process diagrams that span several pages can be created easily and used conveniently using the zooming function. Configurable zoom factor for navigation.  

Operator rights and password management

• The OperatorManager is used to create an individually tailored operator profile in the project for each operator:
  - Login name and password
  - General appearance of the DisplayCenter (menus, toolbars, diagram tree)
  - Access authorization to analysis tools (AlarmReports, TrendViewer, StartManager, ControllerManager, etc.).
  - Access authorization to Audit Trail queries
  - Access authorization to logs
  - Access authorization to logs
  - Access authorization to operating templates (faceplates) on the device (on, off, manual, auto, etc.).
  - Access authorization to messages and alarms (acknowledge, lock).
  - Operator profiles are created in the CaeManager.
  - Operators are managed in the OperatorManager.
  - "As-built" product documentation
• Project statistics with all important generation data.
• Hardware documentation with or without I/O information.
• Function charts with your company logo.
• Process graphics
• Project engineering
• Comments about the version.
• Comment page (can be created for each configuration element).
• Cross-reference list
• Statistics for cross-communication between controllers (controller-controller communication).

Function block libraries

• The CaeManager provides several different B&R standard function block libraries:
  - IEC61131 library (function blocks based on IEC 61131-3).
  - APROL (supplement of the function blocks based on IEC 61131-3).
  - DCS library (hyper macro library – display, motor, controller, etc.).
  - SYSTEM library (system and self-monitoring).
  - ISO 10268 library
• Additional industry or customer-specific function block libraries can be created in the CaeManager.
• These libraries can be protected with a password to prevent unauthorized access by others.
• The following blocks can be created:
  - Functions / function blocks: C editor
  - Image macros / display driver function blocks DisplayEditor
  - UCB function blocks: script language
  - Hyper macro blocks: graphic configuration (see hyper macro concept)
• Newly created blocks can be tested directly in the CaeManager to see if they work.
• Documentation for the block is created automatically as "as-built" documentation during development.
• The automatic version management system in the CaeManager provides a complete version history for each block.
• The enabled versions of the blocks can be given a label to make them fixed versions with a separate date and time (21 CFR Part 11, GAMP4).
• Easy-to-use functions for entering structured as-built block documentation using HTML. This allows description text to be structured clearly and expanded with information such as limitations, notes, links, images, etc. The extended information and the automatically generated block I/O table are listed clearly in the as-built documentation. This guarantees that the block documentation is always current and available.  

The hyper macro concept

• Individual functions (e.g. controller logic, operating hours counter, the visualization, alarms, trends) of a device (motor, valve, or controller) are grouped together in one block (hyper macro).
• Logic blocks
• Animated display driver function blocks
• Alarm configuration
• Message configuration
• Trend configuration
• Blocks connected by logical links
• Hyper macro possible within hyper macro
• Once a hyper macro has been created as a working unit in a library, it can be tested, documented, assigned a version number, and then used in different projects. If any changes are made to the hyper macro, they will automatically be applied in the projects themselves (instances).
• Changes to hyper macro blocks can be completely traced at any time using the integrated version management system.
• Several hyper macros can then be grouped together in another unit and stored as a separate hyper macro (hyper macro within hyper macro). For example, this allows the blocks used for a pump, valve, and flow counter to be grouped into a basic function called "dosing".
• Reusing tested function units in the projects reduces the overall engineering effort, shortens the testing phase, and lowers the error rate.
• Using tested, documented, and qualified hyper macro blocks (black box) that are grouped together in a "sealed" and labeled library validates your system according to FDA and GAMP forum guidelines (21 CFR Part 11 and GAMP4, respectively).  

Distributing engineering data

• The DownloadManager is used to download the project that has been configured in the CaeManager to the operator station, Runtime server, and controllers being used in the APROL process control system.
• Different versions of the project can be selected for the download in the DownloadManager:
  - Current version
  - Labeled (fixed) version
  - Previous download version (if no Engineering server is located on-site, the download can take place from a Runtime server or operator station).
• Several downloads can be started simultaneously, with a job list being used to group together the download lists.
• Each project engineer / designer can save and reload their own download lists.
• The integrated Change Control logging feature (21 CFR Part 11, GAMP4) records all download actions and provides important information (who, what, when, where).
• The rights management system checks whether the operator has the necessary rights to download.
• Operating system updates for controllers can also be handled with the DownloadManager, which compares the operating system version on the controller with the one configured in the project before downloading. In addition, the operating system can be updated as needed. After an operating system update, the controller's module list is updated automatically.

Online documentation

• The entire project, system, and hardware documentation is available to the project engineer / designer in electronic form online and can be accessed with a Web browser.
• The search engine can be used to search the entire documentation for certain texts.
• Documentation for blocks / hyper macros in B&R standard block libraries can be viewed directly when placing a block in a function chart.
• APROL system documentation
• The APROL system documentation additionally includes a documentation DVD for Windows operating systems so that the complete documentation is duplicated in a Windows environment without limitations even before the Linux-based APROL system software is installed.  

Validation

The APROL process control system integrates the following functions with regard to the validation guidelines of the FDA and GAMP forum (21 CFR Part 11 and GAMP4, respectively):

• Integrated engineering rights management
• Automatic revision and modification management
• Change Control logging for the Engineering system
• Tested standard software library
• "As-built" documentation for the process control system
• Several configurable login mechanisms (login name, password, smart cart, biometrics).
• Operator rights and password management (with password revision).
• Long-term data storage and readability of data
• Manipulation-proof data logging (PDF document).
• Access rights management (system-wide).
• Integrated Audit Trail for all operator actions.
• Alarm and trend modules.
• Comprehensive system and self-monitoring.
• Extensive system diagnostic tools.
• Time synchronization across the entire process control system
• B&R certification according to ISO9001.