Application description  07/2016

Configuration and Commissioning

of SIMIT Virtual Controller in a
PCS 7 Environment
SIMIT SF V8.1 and SIMIT VC 3.0

https://support.industry.siemens.com/cs/ww/en/view/77362399
 Warranty and liability

Warranty and liability

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 Table of contents

Table of contents
Warranty and liability ................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Quality Starts with Engineering ............................................................ 4
1.1.1 Operator training systems with guaranteed performance .................... 4
1.1.2 Ongoing optimization of plant operation ............................................... 4
1.2 The Virtual Controller ........................................................................... 5
2 Virtual Commissioning in Practice ................................................................ 10
2.1 Real plant to virtualized plant ............................................................. 11
2.2 Virtualized plant .................................................................................. 12
2.3 Preparation ......................................................................................... 13
2.4 Configuring the Emulation Manager ................................................... 16
3 Automatic Model Generation .......................................................................... 30
3.1 Creating the device level .................................................................... 31
3.2 Creating the process level .................................................................. 33
3.2.1 Process model of raw material tank RMT1 (“LI111”) with
STANDARD components ................................................................... 33
3.2.2 Process model of Reactor1 with STANDARD components ............... 34
4 Related literature ............................................................................................. 36
5 History............................................................................................................... 36
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 1 Introduction

1 Introduction
1.1 Quality Starts with Engineering
With the SIMIT set of software, an advanced product line for virtual commissioning
of automation systems is already available today. Simulation models that were
created can be connected to a real (hardware-in-the-loop, HiL) or emulated
controller (software-in-the-loop, SiL) without having to make changes to the
automation software. The aim of the recently released Simulation Framework
version 8.1, including the new SIMIT Virtual Controller Software (SIMIT VC), is to
allow integrated virtual commissioning and operator training systems (OTS) with a
uniform simulation environment based on a completely virtual plant. Already during
engineering, the created simulation models can be used for testing to identify and
detect any errors at an early stage. This results in optimized automation concepts.
Virtual commissioning allows you to increase engineering quality and considerably
shorten real commissioning - for example, this significantly reduces the number of
software errors. Project examples from customers prove potential reductions in
commissioning time of up to 90%.

1.1.1 Operator training systems with guaranteed performance

From the perspective of an operator training system, the requirements and the
complexity are significantly higher, particularly if you want to exactly emulate the
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real plant by a virtual plant. On the one hand, it is required to model and calculate
complex processes and, on the other hand, it is necessary to configure distributed
stations. For example, when running the automation programs on emulated
controllers that must communicate with each other via multiple distributed PCs or if
a subfunction for a specific training should run at different speeds. With Virtual
Time Management, SIMIT offers this functionality and, at the same time, ensures
coherence and smooth interaction between the simulation and the automation
process for all virtual controllers. Furthermore, simulation states, including the
controller states, can be saved at any time as snapshots and reloaded at a later
time with all matching values, model states, I/Os and controller programs. And last
but not least: SIMIT allows you to implement a virtual plant system with minimum
space and hardware requirements. Under the name "SIMATIC Virtualization as a
Service" (\5\), complete platforms based on virtual machines are available as an
additional service.

1.1.2 Ongoing optimization of plant operation

When using simulation for virtual commissioning and operator training systems, the
know-how on a plant and its automation is mapped to models. This technology acts
as a reliable basis of experience and decision-making and contributes to promoting
continuous improvements in quality in terms of plant safety, compliance with
standards and productivity over the complete plant life cycle - despite modifications
or changes in staff. With the optimized software offer and the dovetailing of all
tools, SIMIT Simulation Framework is a link between engineering, plant simulation,
virtual and real commissioning, operator training and plant operation. Therefore, it
acts as a multiple lever for quality over the complete life cycle of a plant.

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 1 Introduction

1.2 The Virtual Controller

The Emulation Manager (SIMIT EMU) is an emulation platform that allows you to
virtually commissioning complete plants. The Emulation Manager is used to
generate virtual controllers (SIMIT VCs) that, unlike PLCSIM, can be operated
independently of the engineering station; i.e., the emulated controllers can be
distributed over multiple computers and communicate with OS servers. Therefore,
virtual commissioning on a single station, the engineering station, is no longer
necessary. You can virtualize your complete plant, configure an unlimited number
of virtual AS and virtually adjust your simulation time. For slow processes, you can
accelerate your simulation in synchronization with the emulated AS. Likewise, for
fast processes, you can slow down the complete plant. When the plant is in the
operating point, snapshots allow you to save the state of the complete plant,
including the SIMIT VC image.
A virtual plant consists of the following components:
 ES, engineering system
 OS, OS server(s), OS clients, can be a subnet of a real plant system, but at
least one OS server is required for the visualization
 SIMIT SF, simulation framework
 SIMIT EMU, emulation manager tool that is used to configure the SIMIT VC, an
extension to SIMIT SF
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 SIMIT VC, virtual controller(s)

 SIMATIC NET, Ethernet drivers
The following table lists the options for deployment
Table 1-1
Component Option for deployment
ES Can be part of the virtual plant or shared with the real plant. If shared,
network considerations must be taken into account to create a
thorough separation.
OS OS server (s) and clients (s) dedicated to the virtual plant
SIMIT SF Can be installed on a separate PC or the ES.
SIMIT EMU Emulation manager, MUST reside on the same PC as SIMIT SF
SIMIT VC Virtual controllers run on a PC separate from the OS server PCs.
These can be the ES, the PC where SIMIT SF runs or a separate PC,
the distribution is based on performance requirements.
SIMIT NET The ES, OS and SIMIT VC systems are communicating via SIMATIC
NET Ethernet drivers and therefore SIMATIC NET must be installed on
PCs where any of these components run.

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 1 Introduction

Figure 1-1 shows the basic structure of a virtual plant. It is mandatory that SIMIT
and the Emulation Manager (SIMIT EMU) be installed on the same computer. If
SIMIT is not installed on the computer, the SIMIT VC installer will automatically
install Runtime, which is the case for the SIMIT VC stations. SIMATIC NET must
be additionally installed on the SIMIT VC stations.
Figure 1-1 Basic structure of a virtual plant
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The following table lists the communication interface between the components in
the real plant and the virtual plant:

Table 1-2
Communication Real plant Virtual plant
interface between
ES-AS (SIMIT VC) SIMATIC NET driver, TCP/IP or SIMATIC NET driver, TCP/IP
ISO protocol, PC internal protocol, PG/PC interface
assigned Ethernet card
AS (SIMIT VC) for Ethernet port on the CPU or PC where the SIMIT VC(s)
ES separate CP card with are running, its network
TCP/IP or ISO address interface card (NIC), TCP/IP
downloaded from hardware addresses of the SIMIT
config (Step7) VC(s) are added to the NIC
(Advanced settings of the
TCP/IP address
configuration of the NIC)
AS-AS (SIMIT VC- AS – S7 protocol, TCP/IP or SIMIT VC-Internal protocol,
SIMIT VC) ISO protocol, identified by configured in SIMIT EMU,
connection defined in NetPro defined between virtual
with counter side IDs controllers, uses
communication interface(s)
between PC(s) where the
SIMIT VC(s) are running as
needed

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 1 Introduction

Communication Real plant Virtual plant

interface between
OS-AS (SIMIT VC) SIMATIC NET driver, TCP/IP SIMATIC NET driver,
or ISO protocol, named TCP/IP, named connection
connection configured with that is defined in the PC
NetPro station configuration,
configured in SIMIT EMU,
refers to named connection
name as defined in NetPro
for consistency
AS (SIMIT VC) for Ethernet port on the CPU or Gateway definition and
OS separate CP card with connection(s) in the PC
TCP/IP or ISO address station configuration of the
downloaded from hardware SIMIT VC PC, configured in
config (Step7), configured as SIMIT EMU as the counter
the end point of a named side of the OS-AS named
connection in NetPro connection

The following table lists how communication connections are configured:

Table 1-3
Configured Real Plant Virtual plant
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communication
connections
ES-AS (SIMIT SIMATIC NET driver, TCP/IP SIMATIC NET driver, TCP/IP
VC) or ISO protocol, PC Internal protocol, PG/PC interface
assigned Ethernet card
AS-AS (SIMIT AS – S7 protocol, TCP/IP or SIMIT VC-Internal protocol,
VC- SIMIT VC) ISO protocol, identified by configured in SIMIT EMU,
connection defined in NetPro defined between virtual
with counter side IDs controllers, refers to IDs as
defined in NetPro for
consistency
OS-AS (SIMIT SIMATIC NET driver, TCP/IP SIMATIC NET driver,
VC) or ISO protocol, named TCP/IP, named connection
connection configured with configured in SIMIT EMU,
NetPro refers to named connection
name as defined in NetPro
for consistency

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The following table lists how the communication interface between the components
in the real plant and the virtual plant are deployed:

Table 1-4
Communication Real plant Virtual plant
interface between

ES-AS (SIMIT PC station configuration and PG/PC interface points to

VC) download on the ES the network interface to be
used

AS (SIMIT VC) for Hardware config download Add SIMIT VC(s) their
ES TCP/IP addresses to the NIC
that is used to connect the
PC where the SIMIT VCs are
running to the network

AS-AS (SIMIT NetPro download None, integral part of the

VC- SIMIT VC) SIMIT VC configuration that
gets deployed by SIMIT

OS-AS (SIMIT PC station configuration and .xdb file, generated by

VC) download followed by a SIMIT EMU is used to
NetPro download configure and parameterize
the PC station configuration
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of the PC where the OS will

be running

AS (SIMIT VC) for NetPro download .xdb file, generated by

OS SIMIT EMU is used to
configure and parameterize
the PC station configuration
of the PC where the SIMIT
VC(s) will be running

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 1 Introduction

Figure 1-2 shows the communication relationships. After the plant was configured
using the SIMIT EMU, the generated *.xdb files are distributed to the computers
involved. The *.xdb files must be manually imported into the stations. Then a
coupling to the SIMIT VCs can be created in SIMIT SF.

NOTE Please make sure that the SIMIT project name matches the SIMIT EMU project
name. If this is not the case, there will be no communication between SIMIT VC
and SIMIT SF.

Figure 1-2 Functional relationship between SIMIT SF, SIMIT VC, SIMATIC Manager and
PCS 7 PS
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After you have started the simulation, the SIMIT VCs are started up on the
SIMIT VC stations and a connection between the OS stations is established. Just
like you are used to from PCS 7, the AS program can be downloaded to the
SIMIT VCs using the PLC Download function. The program remains saved even
after exiting the SIMIT VCs and does not have to be downloaded again when
restarting.
If the S7 connections are "Named Connection(s)", it is not necessary to make
changes in WinCC. If the connection is an ISO or TCP/IP connection to WinCC, the
"SIMATIC S7 Protocol Suite" must be customized. For example, an ISO connection
requires that the MAC address of the SIMIT VC station where the emulated
SIMIT VCs run be entered in the "SIMATIC S7 Protocol Suite".

NOTE If the system parameters of the "SIMATIC S7 Protocol Suite" are write-protected,
start the "emuWinCCSetConnPrc.exe" application. It can be found in the
installation location of the SIMIT EMU in the "tools" folder.

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2 Virtual Commissioning in Practice

At the outset, the task is to virtually commission a small plant using SIMIT. The
configuration steps of the SIMIT EMU will be shown and practically performed. The
objective is a running simulation project, as a first step up to the signal level. At this
level, you can manually set or monitor the signals.
The real plant consists of one OS single station, one engineering station and two
automation stations. All PC stations are connected via a bus system, see
Figure 2-1. The redundant AS controls/monitors the plant parts, Plant 1 and Plant
2, via the PROFIBUS DP fieldbus, see Figure 2-2 and Figure 2-3 In the plant parts,
the liquids of the raw material tanks are dosed into the reactors and made into the
product by heating and stirring. Bottling takes place in plant part 3 where the
product is bottled. The automation program for this plant part is run in the single H
station. PROFINET IO is used as the fieldbus, see Figure 2-4. Both AS, i.e. the
redundant one and the single H, are implemented with the CPU 410.

Figure 2-1 Overview of the real bottling plant

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Figure 2-2 Plant part 1 with three raw material tanks

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Figure 2-3 Plant part 2 with two reactors

Figure 2-4 Plant part 3 for bottling the product

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2.1 Real plant to virtualized plant

The virtual plant settings and definitions are based on the configuration of the real
plant. Figure 2-1 shows an example of a real plant configuration. In Figure 2-5 a
possible virtual plant configuration that is capable of the real plant control system is
being shown.

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2.2 Virtualized plant

The real plant is fully virtualized using SIMIT Simulation Framework (SF). The
SIMATIC Manager, SIMIT SF and the SIMIT EMU are installed on the engineering
station (ES). The operator station (OS) is virtualized and runs locally (VC_OSn) on
the ES in VMWare. The virtual controllers (SIMIT VCs) are emulated on the
SIMIT VC station, VC_ASn. The SIMIT VC's runtime environment is installed on
the station. A total of two stations, VC_ASn and VC_OSn, are virtualized on the ES
and can be started with VMWare Player, see Figure 2-5.

Figure 2-5 Virtualized bottling plant

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The virtual stations (client computers) are networked with the host system (ES) via
a "bridged connection". Therefore, all stations are nodes in a network and can
communicate with each other. The Ping command can be used to test this in both
directions, i.e., from the host to the client and vice versa.

Figure 2-6 Testing the connection using ping command

If all nodes in the network are accessible, you can start configuring the virtual
controllers.

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2.3 Preparation
Before configuring, please perform the following steps:
1. Disable the Windows firewall
2. Set the AS IP addresses on the "VC_ASn" SIMIT VC station, see Figure 2-7
Make sure you enter all IP addresses of all the AS you are using (online
interface). In this case, they have already been entered.
For each emulated AS, exactly one IP address must be assigned in the network.
The IP addresses are assigned in the properties of the physical LAN adapter on
the "VC_ASn" SIMIT VC station. Due to this, this physical LAN adapter has not
only one but multiple IP addresses. The main address for the SIMIT VC station and
the sub addresses for the respective emulated AS.

Figure 2-7 Setting the IP addresses on the “VC_ASn” station

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3. Network policies, see Figure 2-8. Make sure that there is an uplink to a
network. Use this dialog box to set the network policies to "Private".

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NOTE The dialog box can be accessed from Start menu, pgedit.msc > Local Computer
Policy > Windows Settings > Security Settings > Network List Manager Policies.

Figure 2-8 Network policies of the virtual controller

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4. Set the access points on the ES, see Figure 2-9.

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This setting parameterizes the online connection from the ES to the SIMIT VC
station. It makes available communications services such as Download AS
program to SIMIT VC station and test mode.

Figure 2-9 Communication settings on the ES for the online connections

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5. The PCS 7 OS project is located on the OS station. The OS station does not
need to be configured. It will be configured later by the SIMIT EMU with the
generated data.

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2.4 Configuring the Emulation Manager

1. Star the Emulation Manager on the ES and create e new project, see
Figure 2-10. The “Launch wizard” guides you though the individual menus of
the SIMIT EMU and should be used – especially at the beginning.

CAUTION If you have already created a SIMIT project, make sure that the name
matches the SIMIT project. Otherwise a connection to the SIMIT VCs
cannot be established.

Figure 2-10 Creating a new SIMIT VC project

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2. Then the system checks whether the appropriate SIMIT license is available. If
a license has been found, the project icon is provided with a green check mark,
see Figure 2-11. Without a valid license, the Emulation Manager remains in
demo mode and the icon starts flashing. In addition, "Demo" is displayed in the
main window.

Figure 2-11 Menu bar when SIMIT license valid

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3. Select "OK" and "Next" to confirm the general information of the wizard. In the
next dialog box, "Computer configuration", define all PC stations involved. To
do this, right-click to open the context menu and open the "Insert" dialog box.

NOTE During this step you will configure the PC station that will be used for the
simulation system. The Number of PC stations depends on the distribution of AS
system(s) and OS system(s) within the simulation system. You can combine one
or more AS systems and the SIMIT and the SIMIT SF on a single PC. The
names of the PC stations in the simulation system can be different from the
names of the PC stations used in the PCS 7 project. If the name of the PC
station in the simulation system that hosts the OS is different from the name
used in the PCS 7 project, then the download path of the OS must to be adapted
to reflect that name

Assign the "role" to the appropriate PC station:

– ESn > “Emulation/simulation”
– SIMASn > “Emulation/simulation”
– SIMOSn > “Operator station (HMI)”
4. Assign the appropriate computer name with the associated IP address, see
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Figure 2-12. You can select the IP address from the drop-down menu. The
MAC address is entered automatically.

Figure 2-12 Configuration dialog box for the engineering station

NOTE All visible PC stations are displayed in the drop-down menu represented by their
IP addresses.

5. To allow the emulation manager to deliver configuration files to the PCs that
are used for the simulation system, a "Share" folder must be defined for the PC
stations, SIMOSn and SIMASn. To do this, use the folders used in Figure 2-13.
The "Update" button (see
Figure 2-12, right hand figure) allows you to make the current share folders
available and select them using the drop-down menu. User name and
password have to be entered as well. Enter a valid user name (in our example
system "WSuser") in the user field and the password for that user in the
password field, see right-hand figure in Figure 2-12.

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NOTE Please make sure that the share folder on the SIMIT EMU computer points to the
same folder path as on the SIMIT VC computer, i. e. “D/Siemens/Emulation”.
When installed to “C:”, the path has to be changed accordingly.

Figure 2-13 Configuring the PC stations

6. Once all PC stations have been configured, select "Next" to continue the
wizard. The next step is to define the AS systems within the simulation system.
This is accomplished by importing the hardware configuration for each AS. The
hardware configuration is exported from PCS 7 as described in Figure 2-14.
Make sure to export the "default values" by selecting this option as shown in
Figure 2-15.

Figure 2-14 Exporting the hardware configuration from PCS 7

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NOTE Since the complete hardware configuration of AS system is exported from the
SIMATIC PCS 7 project and subsequently imported into SIMIT EMU, there is no
need to download hardware to the SIMIT VC soft-controller in a later stage. That
also means that the user must perform an update of the AS as defined in SIMIT
EMU after every modification to the AS in the SIMATIC PCS 7 project.

Figure 2-15 Exporting the hardware configuration

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7. Import the hardware configuration by pointing at the file that was obtained by
performing the export described above, see
Figure 2-16.

Figure 2-16 Hardware configuration dialog box of the SIMIT EMU

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Before the import take place, the next dialog box allows you to specify information
that was not obtained from the hardware configuration file. Confirm the properties
such as "CPU type" and "Order number", see Figure 2-17. In case of the system
being a High Availability controller, in our example for AS1, check the "H-system"
check box. Once you have imported AS1, the next step asks whether you want to
import additional resources, you can repeat the steps until all AS systems have
been imported.

Figure 2-17 Hardware configuration import

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8. In the wizard menu, click "Click here to import new resources" to import the
second AS. Select the hardware configuration of AS2 and proceed as in the
previous step.

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9. SIMIT VC is a soft-controller, several function used in the application program

of the AS are intended to manage hardware related functionality like diagnostic
interrupts. The SIMIT VC controller uses run-time block replacement to replace
these hardware related functions with functions that are suitable for the
soft-controller. The functions that are used as a replacement are known as
“HLL blocks”, they are functions with an identical name and interface definition
as standard (or custom) PCS 7 library function blocks. Since the standard PCS
7 library blocks have different interfaces depending on the version of SIMATIC
PCS 7 that is being used for the PCS 7 project, the user must select the
appropriate version of the HLL blocks to be used as a replacement in the
soft-controller. After importing the AS system(s) you are prompted to import the
"HLL blocks" for each AS, see Figure 2-18. Make sure that the correct PCS 7
Basis Library is selected, in our example that is PCS 7 Basis Library V8.1.

Figure 2-18 Import HLL blocks dialog box

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10. AS systems are imported by selecting hardware configuration export files, OS

(WinCC) (and other runtime components, e. g. a SIMATIC NET OPC server)
must be configured manually. To do so select "Click here to add new resources
manually" to add the OS (WinCC) resource. Right-click to open the context
menu and add a new resource. In "Resource type", select "Runtime
component" and assign it a name such as "WinCC". Select "OK" to confirm the
dialog box.

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11. Once the AS and OS resources have been imported and configured, the AS
resources must identify which (Ethernet TCP/IP capable) communication
processor or on-board interface will be used to download and debug the PCS 7
controller application. This definition is named “Online interface”. Perform these
steps to select the online interfaces. Select each AS resource (in the figure
AS1), than select the CPU or CP card whose interfaces is to be used, than
check the box “Online interface”. Repeat this for every AS (in our example
AS2), see Figure 2-19 and Figure 2-20. Then select "Next" to continue the
wizard.

Figure 2-19 configuring the online interface of AS1

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Figure 2-20 configuring the online interface of AS2

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12. SIMIT SF addresses IO by its symbol name, the user must export the symbol
table of each AS and subsequently import them into SIMIT EMU. This is
performed in the next step, select "Click here to import a symbol table" to
import the symbol tables for resources AS1 and AS2, see Figure 2-21. Select
"Next" to continue the wizard.

NOTE When exporting the symbol table, make sure that is has *.seq format.

Figure 2-21 Symbol import dialog box

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13. After all resources (AS system and OS or other run-time component) have
been defined, the resources must be assigned to the PCs that were configured
in step 1. This process is named “Resource distribution”. In the next dialog box,
distribute the resources to the PC stations, see Figure 2-22.

NOTE The user distributes AS, OS and run-time resources. When AS resources is
being assigned to a PC station the location of the Process model (= SIMIT SF
hosting PC station) must be also selected. The AS relies on SIMIT SF to define
the status of its IO signals.

Figure 2-22 distributing the resources to the respective computers

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14. Continue the wizard until you get to "Resource timing-behavior". Here you can
separately define the individual time slices. In the example, the "default" setting
is retained, see Figure 2-23.

NOTE The purpose of adjusting time behavior is to more efficiently make use of the
available PC performance.

Figure 2-23 Execution cycles of the individual OBs in the VC

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15. Within a Simulation system, communication will occur between the AS

resources and between AS resources and OS and other runtime components.
Within the SIMATIC PCS 7 project, this communication is defined in NETPRO.
There are basically two types of connections that must be defined: AS to AS
connections and AS to OS (or other run-time component) connections.

AS to AS connections are managed within the architecture of the Simulation

system. Therefore these connections use a protocol that is internal to the
Simulation system. The applications refer to these connections by means of an
“ID”, these IDs can be read from the corresponding AS to AS connection in
NETPRO.

AS to OS connections use a SIMATIC NET communication protocol (S7

connection). These connections are typically defined as “Named connections”
They are identified by means of a so named TSAP, hexadecimal number.
These numbers must be unique and can be read from the existing NETPRO
configuration.

Continue the wizard to configure the connections in the next dialog box. Right-
click to insert four new connections and parameterize them as shown in
Figure 2-24.

Figure 2-24 configuring the communications connections

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16. For the "Named Connection" to WinCC, enter the following parameters, in case
of two AS system you will create two connections see Figure 2-25. The easiest
way to do this is to use the local "TSAP" from NetPro (TSAP of the WinCC
application). In both connections, enter "0200" for the TSAP of the remote
partner, WinCC. Generate the second "Named Connection" with the
appropriate parameters.

Figure 2-25 Configuring a Named Connection Emulation Manager

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In the sample project, the two AS communicate with each other. In the SIMIT EMU,
configure AS-AS communication as follows:

Figure 2-26 Configuring AS-AS communication in the SIMIT EMU Manager

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17. For the IDs, also refer to NetPro. When you have configured all four
connections as shown in Figure 2-24, you can select "Next/Finish" to exit the
wizard. In the last step, all required data is generated and distributed to all
stations, i.e. the SIMIT VC station and the OS station. However, the
"Consistency check" dialog box appears first. Select "No" to confirm this dialog
box, see Figure 2-27.

Figure 2-27 Consistory check at the end of the SIMIT EMU project
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18. For connections that rely on SIMATIC NET, the station configuration of
SIMATIC NET must be adapted. This applies to all PC stations of the
Simulation system that support a connection that relies on SIMATIC NET.
Generally these are the PC stations where AS systems will run as a SIMIT VC
and the PC stations where the OS (WinCC) or other runtime resources will run.

SIMIT EMU produces configuration files (so named “.xdb” files) that are used
to configure and parameterize the station configuration of each PC that uses
SIMATIC NET for communication within the Simulation system.

Import the *.xdb files generated by the SIMIT EMU Manager into the "SimOSn"
and "SIMASn" PC stations their station configuration. You can find these files
in the previously defined share folders of each PC station of the Simulation
system, their name indicates which PC station they are intended for.

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NOTE Within SIMATIC NET its station configuration, the “Station name” and the
physical PC name can be different. It is recommended to make both names
identical.

Figure 2-28 Importing the generated *.xdb files into the SIMIT VC station
 Siemens AG 2016 All rights reserved

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 2 Virtual Commissioning in Practice

19. The last step completes configuration and setup of the simulation system PC
stations. The next step is to combine the SIMIT EMU project with the SIMIT SF
project. SIMIT VC controllers are managed as an integral part of the SIMIT SF
project, also if the SIMIT VC controllers reside on other PC stations than the
SIMIT SF installation. To create a SIMIT SF project that integrates the SIMIT
EMU configuration open SIMIT SF on the engineering station and create a new
project with the exact same name as the SIMIT EMU project. Create a new
coupling, "Virtual Controller", see Figure 2-29.

Figure 2-29 creating the SIMIT VC coupling in SIMIT SF

 Siemens AG 2016 All rights reserved

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 2 Virtual Commissioning in Practice

After you have created the coupling, all the AS systems that were configured in
SIMIT EMU, including their signals, are visible in the coupling editor, see
Figure 2-30. Now you can immediately start the simulation and manually test the
signals.

NOTE Since SIMIT VC relies on SIMATIC NET for its communication, it may sometimes
be required to reboot the PC stations where the SIMATIC NET station
configuration has been configured by means of the “.xdb file” import. These
stations include the PC stations that will host the SIMIT VC controllers.

Figure 2-30 Created VC coupling in SIMIT SF

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Now check whether the runtime of the SIMIT VCs runs on the SIMIT VC station
and whether a connection has been established between the PCS 7 OS and the
AS. If the check is successful, you have successfully completed the first step for
virtual commissioning of the complete plant.
The next chapter shows you how to test alarms, warnings and the hysteresis on a
semi-automated basis.

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 3 Automatic Model Generation

3 Automatic Model Generation

In the previous chapter, the AS level was configured using the SIMIT EMU and the
respective coupling to SIMIT was created. SIMIT allows read and write access to
the IO image of the emulated PLCs. When the SIMIT VC sends its control signals,
they are sent to the actuators in the real use case. Then the actuators at the field
level perform an action that changes the process. For example, this can be the
increase of a temperature or the lowering of a mass flow. This change, in turn,
must be detected by sensors at the field level and sent back to the AS, see Figure
3-1.

Figure 3-1 Basic structure of a simulation project using the example of valve control
 Siemens AG 2016 All rights reserved

In the following chapter, you will emulate the process level. You will get to know the
CMT import function provided by SIMIT SF that allows effective engineering. You
will use this to create all device models for the sensors and actuators of the SIMIT
project.

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3.1 Creating the device level

1. Create two new folders: "DeviceLevel" and "ProcessLevel" in the "Charts"
folder. Right-click "Charts", select > "New folder" in the context menu.

Figure 3-2 creating a new folder in SIMIT SF

All process models, for example the ones of the raw
material tank, will later be stored in the "ProecessLevel"
folder. The "DeviceLevel" folder stands for all actuators
and sensors in the plant, for example valves and motors.
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2. Generate a XML file with the plant hierarchy and all control modules (CMs) of
your PCS 7 project.
3. Open the “Plant view” in PCS 7. Use the context menu to navigate to “Export
XML”. “Plant view” > right-click the project > Export XML.

Figure 3-3 CMT export to PCS 7

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 3 Automatic Model Generation

4. Instantiate the SIMIT SF templates with the aid of the generated XML file.
Select the "Charts" folder and right-click to open the "Automatic modeling 
CMT import" function. Select the exported XML file and the Template folder,
see Figure 3-4.

Figure 3-4 CMT import dialog box

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The preview allows you to specifically exclude individual charts from the import. At
the same time, you can control which charts are imported and which symbolic
placeholders are replaced by values in the XML file.
Clicking the "Import" button starts the import process. Now SIMIT SF instantiates
all simulation templates in the folder to a plant hierarchy identical to PCS 7. In the
template, all symbolic placeholders are replaced by values in the XML file. This
step allows you to check, for example, feedback from the valves and motors on a
semi-automated basis. Open, for example, valve "NK111" in WinCC. Does the
valve open and close as expected?
To check warnings, alarm limits and hysteresis, open, for example, simulation chart
“Plant > RMT11 > LI111”. Double-clicking the basic icon of the "…SinusGen"
component opens the operating window, see Figure 3-5. Make sure that the
simulation is running!

NOTE The “…SinusGen” component was created in a previous project using the CTE
tool and is therefore not part of the SIMIT SF basic library.

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Then you can set the amplitude, offset and frequency according to the alarm limits,
warning and hysteresis, e.g. 0…500 for the raw material tank.

Figure 3-5 Testing the alarm limits with the “…SinusGen” component
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3.2 Creating the process level

Up until now, you have used ready-made components to emulate the behavior of
an actuator such as a valve. Modeling processes is a bit more complex. First, it is
recommended to think about how the process to be simulated can be emulated.
The overhead involved in developing the process model must not exceed the
benefits. In many cases, a simple process model is sufficient to test the automation
software. To examine this in greater detail, we will develop and discuss simple
models for the process models RMT1 and Reactor1 in the following exercises.

3.2.1 Process model of raw material tank RMT1 (“LI111”) with STANDARD
components

5. Use drag and drop to insert the following components from the "Basic
components" task card into the "LI111" chart
(…/Charts/Model/LI111):
– From the ”Connectors” folder: 15 “Connector” components
– From the ”Standard/AnalogExtended” folder: 1 “INT” component
– From the ”Standard/AnalogExtended” folder: 2 “Selection” components
– From the ”Standard/AnalogExtended” folder: 2 “MinMax” components
– From the ”Standard/AnlogBasic” folder: 1 “MUL” component.
– From the ”Standard/AnlogBasic” folder: 1 “SUB” component
– From the ”Standard/BinaryExtended” folder: 2 “RS_FF” components.
– From the ”Standard/AnalogExtended” folder: 1 “Compare” component

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 3 Automatic Model Generation

6. In the “LI111” chart, connect the components as shown in Figure 3-6.

Figure 3-6 Simulation model for raw material tank LI111

The integrator is the core component of this model. It is used to simulate the level
in the tank. If the input at the integrator is not equal to zero, the level continuously
rises or drops until it reaches an upper limit of 500l or a lower limit of 0l. Once the
integrator has reached the lower limit of 0, the "selector" switches its output from
100 to 0 and thereby causes the volume flow to drop to zero due to the outflow.
The inflow/outflow is emulated by the subtractor. The volume flow into raw material
tank 1 is defined by a constant value and added to the volume flow out of the raw
 Siemens AG 2016 All rights reserved

material tank. The outflowing volume flow is negatively added and intended to
emulate the outflow.
Mathematically, this can be expressed as follows:
𝑉𝑅̇ = 𝑉𝐼𝑛
̇ − 𝑉𝑂𝑢𝑡
̇
The change of the volume in the reactor equals the inflows minus the outflows. As
a process variable, we want to calculate the reactor height ℎ. To do this, we
replace the reactor volume by 𝑉𝑅̇ = 𝐴 ∙ ℎ(𝑡).
𝑉𝑅̇ = 𝑉𝐼𝑛
̇ − 𝑉𝑂𝑢𝑡
̇
𝑑
̇ − 𝑉𝑂𝑢𝑡
(𝐴 ∙ ℎ(𝑡)) = 𝑉𝐼𝑛 ̇
𝑑𝑡
1
𝑑ℎ = (𝑉𝐼𝑛 ̇ − 𝑉𝑂𝑢𝑡
̇ )𝑑𝑡
𝐴
𝑡
1
ℎ(𝑡) = ∫ (𝑉𝐼𝑛 ̇ − 𝑉𝑂𝑢𝑡
̇ )𝑑𝜏
0 𝐴
The reactor area A can be calculated using the boundary condition of a cylindrical
container and the volume and height.
The volume flow out of the reactor is directly proportional to the opening angle of
the drive. The proportionality constant is 0.1 m³/s and represented by the multiplier.

3.2.2 Process model of Reactor1 with STANDARD components

1. Use drag and drop to insert the following components from the "Basic
components" task card into the "Reactor1" chart
(…Charts/Model/Reac1/LI11x):
– From the “Connectors” folder: 2 “Connector” components
– From the “Standard/AnalogExtended” folder: 1 “INT” component.

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2. Connect the components using the global connectors a shown in Figure 3-7.
Figure 3-7
Model of Reactor1

After you have created the simulation model for the raw material tank and the
reactor, you can fill the raw material tank and start the "RMT1" sequencer. You can
also check the automation program for errors such as motor trip, "NP111".
The previous chapters have introduced you to the basic structure of the three
simulation levels of SIMIT:
 Signal level,
 device level and
 process level
This enables you to implement simple use cases and virtually commission your
 Siemens AG 2016 All rights reserved

plant. An OTS requires more steps, for example modeling the complete process
behavior. How detailed this has to be differs from case to case. For in-depth
information about SIMIT SF and SIMIT VC, visit the SIMIT workshop or send an
email to [email protected].

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 4 Related literature

4 Related literature
Table 4-1
Topic Title / Link
\1\ Siemens Industry http://support.industry.siemens.com
Online Support
\2\ Download page of https://support.industry.siemens.com/cs/ww/en/view/7736239
this entry 9https://support.industry.siemens.com/cs/ww/en/view/77362399

\3\ SIMIT Simulation https://support.industry.siemens.com/cs/ww/en/view/101298066

Framework
(Video)
\4\ SIMIT Simulation http://www.industry.siemens.com/verticals/global/en/chemical-
Framework / industries/products-solutions-systems-services/Pages/simit.aspx
SIMIT Virtual
Controller
\5\ SIMATIC https://support.industry.siemens.com/cs/ww/en/sc/3095
Virtualization as a
Service
\6\ SIMIT Virtual https://support.industry.siemens.com/cs/de/en/view/107196877
Controller
(SIMIT VC) - User
Manual
 Siemens AG 2016 All rights reserved

5 History
Table 5-1
Version Date Modifications
V1.0 10/2015 First version
V1.1 07/2016 Corrections in chapter 2.3 “Preparation”

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