Automation and Drives

Welcome

SIMATIC PCS 7
Technology
Customer Welcome
Introduction
Logo to the
Profibus
I/O
Presentation
Controller
F-Engineering of
Communication
Operator System
Engineering System
System Functions
SIMATIC PCS 7
Batch / Route Control Setting a New Standard for Integration !
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 1

 Automation and Drives

Introduction of Speaker

SIMATIC PCS 7
Technology

Introduction
SIMATIC PCS 7
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Demonstration Center for Process Automation
Engineering System
System Functions
Batch / Route Control Dr. Friedhelm Geiger
MIS/MES Integration A&D AS PA PM
Add-ons Tel.: ++49-721-595-2319
Migration
[email protected]
Summary
Karlsruhe facilities

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 2

 Automation and Drives

SIMATIC PCS 7 -
Highlights of the Control System
SIMATIC PCS 7  Based on the robust hardware / software components from
Technology SIMATIC, the global market leader

Introduction  Integrated automation as well as production

and process engineering
Profibus
 Horizontal and vertical integration with TIA, Totally Integrated
I/O
Automation
Controller
 Flexibility due to scalable performance and modular design
F-Engineering
 Consistent engineering throughout the system for all components with a
Communication
shared database; high-performance bulk engineering
Operator System
 Windows-based, hierarchically structured GUI
Engineering System
 High availability of the control system due to redundancy on all levels
System Functions
 Homogeneous integrated safety (certified up to AK6 / SIL 3 by the German
Batch / Route Control
Technical Inspectorate)
MIS/MES Integration
 Decentralization to include PROFIBUS DP/PA components
Add-ons
 Homogeneous integrated batch package (Simatic BATCH) ISA S88 compliant
Migration
 Numerous possibilities for custom solutions (function blocks, faceplates,
Summary
Visual Basic programs, interfaces etc.)
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 3
 Automation and Drives

SIMATIC PCS 7
A Control System for All Sectors and Industries
SIMATIC PCS 7
Technology

Introduction
Profibus Custom add-on's
I/O A control system for all sectors for each industry
 SIMATIC PCS 7 is the automation solution
SIMATIC
Controller BATCH
for all sectors
F-Engineering  Continuous e.g. Polymer, Continuous Sectors Batch Sectors
Communication  Batch e.g. Pharma, F&B
SIMATIC PCS 7
Operator System For primary and secondary processes
Engineering System  SIMATIC PCS 7 can handle not only the tasks for process and production control; it also
controls the total automation of all secondary, upstream and downstream processes
System Functions
Example: An industrial facility for plastic production
Batch / Route Control
Industrial power plant Chemical plant Process water
MIS/MES Integration
SIMATIC PCS 7
Add-ons
Migration  Cost reduction from common hardware, logistics, training
Summary  Increased productivity over entire lifecycle of the plant
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 4
 Automation and Drives

SIMATIC PCS 7
Scalability….from 100 to 100,000 I/O
SIMATIC PCS 7 Plants with multiple production facilities
Technology Production Plants
Labs / Pilot Plants
Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions Scalable
from the PCS 7 Introduction Package (~150 PO) ... ... to a distributed system with client/server
Batch / Route Control architecture (~ 60.000 PO)
MIS/MES Integration
 An integrated control system platform
Add-ons
 Optimal adaptation to the plant size
Migration
 Variety of expansion possibilities
Summary

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 Automation and Drives

SIMATIC PCS 7 BOX

The integrated entry solution for small applications
SIMATIC PCS 7
Technology
6ES7650-2HA06-
Introduction
ES OS
0YX0 ES / OS / AS
Profibus
I/O
Ind. Ethernet
Controller
F-Engineering AS: S7-400
Box PC
Communication
Profibus Profibus
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration Advantages of SIMATIC PCS 7 BOX Includes
 Complete DCS (AS, OS, ES)  SIMATIC Box PC 620
Add-ons  WinAC Slot CPU 416
 Very compact
Migration  Can be extended and integrated  PCS 7 Engineering 250 PO‘s
 Aggressive pricing  PCS 7 OS Runtime Single Station 8000 Var.
Summary

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 Automation and Drives

SIMATIC PCS 7 BOX

The integrated entry solution for small applications
SIMATIC PCS 7
Technology

Introduction
Profibus PCS 7 BOX
I/O SIMATIC ET200M
Controller
F-Engineering
Communication
Operator System
Engineering System Sitrans P SIMATIC PCS 7 OS/ES
System Functions DSIII
Batch / Route Control PROFIBUS DP
PROFIBUS PA
MIS/MES Integration
Add-ons
Migration
Summary

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 Automation and Drives

SIMATIC PCS 7
Based on Components from Totally Integrated Automation
SIMATIC PCS 7
Technology
Totally Integrated Automation
Introduction
Profibus SIMATIC HMI

SIMATIC PCS 7
I/O SIMATIC Software
Controller
SIMATIC Industrial PC
F-Engineering
Communication SIMATIC Controller
Operator System SIMATIC NET
Engineering System
SIMATIC I/O
System Functions
Batch / Route Control
SIMATIC PCS 7 offers in addition to the standard SIMATIC products:
MIS/MES Integration
Add-ons  Integrated system functions (diagnostics, alarms, standard library etc.)

Migration  Add-on packages (F-Engineering, SIMATIC BATCH, Warehouse, etc.)

 Bundles (AS, OS, ES)
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 8

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Process Interfacing with PROFIBUS

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions PROFIBUS
Batch / Route Control - DP
MIS/MES Integration - PA
Add-ons
Migration
Summary

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 Automation and Drives

Process Interfacing with PROFIBUS

Overview
SIMATIC PCS 7
Technology
 DP with over 1,000
Introduction
different devices
Profibus
I/O  DP with over 9,000,000
Die Welt von PROFIBUS is the No. 1 field bus

Controller installed nodes system in the world
F-Engineering PROFIBUS  PROFIBUS DP and PROFIBUS PA
form a coherent unit
Communication  Integrated

Operator System HART technology  Worldwide organization "PROFIBUS

International" with 1,100 members
Engineering System
 Integrated
System Functions
failsafe technology
Batch / Route Control
MIS/MES Integration
 PA with over 150
Add-ons
different devices
Migration
 PA with over 210,000
Summary
installed nodes
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 12
 Automation and Drives

Process Interfacing with PROFIBUS cku

p
Physical Properties Ba

SIMATIC PCS 7
Technology Max. length per
Physical Application
Layer segment/Baud Rate
Introduction
Profibus  Remote I/O  1,000 m at 187.5 kps
PROFIBUS RS 485  Intelligent drives  400 m at 500 kps
I/O DP  Intelligent field devices  200 m at 1.5 mps
Controller  100 m at 12 mps
F-Engineering  Remote I/O Ex
RS 485-IS -"-
Communication  DP/PA Link Ex
Operator System Fiber Optic  Fast transmission
 Wide distance > 10 km at 12 mps
Engineering System
 EMC stability
System Functions
PROFIBUS  Process devices
Batch / Route Control IEC61158-2  Power supply via bus
PA
MIS/MES Integration  Ex applications
 Standardized PA profile 1,900 m at 31.25 kps
Add-ons
Migration
Summary

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 Automation and Drives

Process Interfacing with PROFIBUS

Technical Overview
S7-400
SIMATIC PCS 7  Max. 125 DP slaves per single
Technology
PROFIBUS DP master system
1 > 100km
Introduction OLM  Electrical networks can be extended
2 with repeaters (segments)
Profibus PROFIBUS DP RS485 Fiber optic RS485
 max. 31 DP slaves per segment
I/O  OLM‘s (Optical Link Module) for long
Controller Repeater Max. 1,000 m distances, also provide greater EMC
stability
F-Engineering
 RS485iS coupler for PROFIBUS DP
Communication 3 4 in hazardous areas
Operator System  Copper with RS485 and fiber optic
Coupler RS485iS use the same comm protocol
Engineering System
 PROFIBUS PA provides “power on
System Functions the bus” for smart field devices
5 6
Batch / Route Control DP/PA Link  DP/PA Link takes only one address
on the upstream DP bus
MIS/MES Integration 1,900 m 1,000 m
Non-EX
PROFIBUS PA
Add-ons
Migration 1 2 3 4 .... 31

Summary 1 2 ....

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 Automation and Drives

Process Interfacing with PROFIBUS PA

DP/PA Link
SIMATIC PCS 7 Interface module DP/PA coupler
Technology IM157

PROFIBUS DP
Introduction
PROFIBUS PA (Ex), 110mA
Profibus
I/O PROFIBUS PA, 400mA DP/PA Link

Controller
F-Engineering
Communication DP/PA Link consists of:
 Interface module IM157 to connect to PROFIBUS DP and conversion of the bus
Operator System
transmission rates e.g. 12 Mbps to 31.25 kbps
Engineering System  can be used redundantly – to connected to redundant CPUs (H-System)
System Functions  requires only one PROFIBUS DP address
 max. 244 bytes of I/O data
Batch / Route Control
 max. theoretical limit of 64 subordinate PA devices (Example: 5 bytes per device: 244/5 =
MIS/MES Integration 48 devices)

Add-ons
 DP/PA coupler for electrical isolation of PROFIBUS DP/PA segments and power
supply for the PA segments
Migration  max. 5 coupler per link
Summary  max. 31 devices per DP/PA coupler
 2 models (non-Ex, Ex (ZONE 0,1,2))
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Process Interfacing with PROFIBUS PA cku

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Specifications and Design Ba

SIMATIC PCS 7
FISCO
Technology
 PROFIBUS PA conforms to FISCO (Fieldbus Intrinsically Safe Concept)
Introduction  no need to calculate the inductivity/capacity of the bus segment
Profibus
 devices can be added later without requiring new acceptance

I/O Number of devices

Controller  Typical power consumption of PA field devices:
 Supply through PA bus: approx. 12 mA
F-Engineering
 External supply: approx. 10 mA
Communication  DP/PA coupler current
Operator System  400 mA model for non-Ex: 31 devices
Engineering System
 110 mA model for Ex 9 devices

System Functions Cable Characteristics

Batch / Route Control  9V must be available at the PA device
Fast and easy assembly
MIS/MES Integration  PROFIBUS PA cable: approx. 44  km with split-connect
 DP/PA coupler performance
Add-ons
 Non-Ex coupler: (19 - 9)V/(400mA*44  km) = approx. 560 m (max. 1,900m)
Migration  Ex coupler: (13.5 - 9)V/(110mA*44  km) = approx. 920 m (max. 1,000m)
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 16

 Automation and Drives

Process Interfacing with PROFIBUS cku

p
Cycle Times Ba

SIMATIC PCS 7 Master Class 1 Master Class 2

Technology Cyclic (analog measurement)
(4 bytes measured value + 1 byte status)
Introduction
Acyclic (configuration, diagnostics)
Profibus PROFIBUS DP (parameter reading: 32 Byte)
up to 12Mbps
I/O
max. 1 ms @ 12Mbps
Controller Master Example: Cycle time =
Class 2 3 x 15 ms + 17 ms + 20 ms = 82 ms
F-Engineering DP/PA Link
20 ms

Communication
PROFIBUS PA 31.25 Kbps
Operator System
1 variable 1 variable 1 variable 2 variables
Engineering System Cycle time per device for the
first variable is approx. 15 ms,
System Functions max. 2 ms for each additional
17 ms
variable
Batch / Route Control 15 ms
15 ms 15 ms
MIS/MES Integration
Add-ons
 The bandwidth (Baud Rate) of PROFIBUS PA (31.25 kbps) is sufficient
Migration since the response time of PA field devices typically > 500 ms.
Summary

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 Automation and Drives

Process Interfacing with PROFIBUS PA able

The Barrier Concept v ail 03
A /20
SIMATIC PCS 7 DP/PA coupler 12
PROFIBUS DP non-Ex (400 mA)
Technology  Allows use of the non-Ex DP/PA
couplers (400mA) in Ex applications
Introduction  Barriers for isolating non-Ex and Ex
PROFIBUS PA Backbone zones
Profibus
with increased safety (EEx e)  Outputs are protected from short circuits
I/O 24 VDC ....  Simple to add new field devices
115 VAC
Controller 230 VAC  40mA per output (Eex i)
....
F-Engineering  60mA per output (Eex e)

Communication
 Version with external power supply,
therefore no load on the PA buses
Operator System  Barriers can be cascaded
spur line

Engineering System PROFIBUS PA

 Uses sub-distribution boxes
System Functions instrinsically safe (EEx i)  Operating temperature -40...55°C

Batch / Route Control

MIS/MES Integration Number of devices Length of the
per bus line spur line
Add-ons 1 - 12 120 m
13 - 14 90 m
CEAG “Ex-Hub”
Migration (see add-on catalog)
15 - 18 60 m
19 - 24 30 m
Summary 25 - 32 0m

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 Automation and Drives

Input / Output
I/O Modules
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
I/Omodules
I/O modules
Engineering System
System Functions --ET200M
ET200M
Batch / Route Control --ET200S
ET200S
MIS/MES Integration --ET200iS
ET200iS
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 19

 Automation and Drives

Input / Output
Overview
SIMATIC PCS 7
Technology  Connection of the distributed I/O via PROFIBUS-DP
S7 400 Controller
with S7 400 I/O (also with fiber optics and medium redundant)
Introduction
 Several DP chains allowed for each controller - for
PROFIBUS-DP
Profibus ET 200M
configurations with segregation / distribution requirements
I/O
ET 200M  Comprehensive range of I/O modules
(Failsafe)
Controller - Standard signal modules (low price for each channel)
OLM

F-Engineering ET 200iS - Control system modules (diagnostics, output substitute value for
each channel)
Fiber Optic

Communication
ET 200S - Ex modules (for connecting actuators / sensors in zone 0 / 1)
Operator System - Function modules (e.g. controller, motor starter, weighing module)
OLM

Engineering System - HART modules (for integrating HART field devices)

System Functions DP/AS-I - F modules (for failsafe applications)
- Central modules of S7 400
PROFIBUS-DP

Batch / Route Control DP/EIB

 Hot Swappable modules, change/ expand the I/O configuration
MIS/MES Integration
Serial online during runtime operation
Add-ons (e.g. Modbus)
 AS interface for easy integration of actuators / sensors
Migration
EIB instabus for integration of building automation
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 20

 Automation and Drives

I/O Module ET 200M

Overview
SIMATIC PCS 7  Protection level IP20, operating range 0...60°C (-20...60°C)
Technology
 Redundant connection (for H CPUs) Power supply Interface module
Introduction  I/O Module Redundancy (1 Sensor -> 2 Modules) for Profibus DP
IM153-2
Profibus  Electrical isolation from the backplane bus
I/O  Modularly expandable with plug-in backplane
bus on aluminium rail
Controller
 Max. 8 modules per station
F-Engineering I/O module
 No slot restrictions Expandable
Communication backplane
 20 or 40 pin front-panel connector with screw and
Operator System Aluminium rail
spring construction (1.5mm /0.75mm )
2 2

Engineering System  Economical DI/DO modules without diagnostics (MLFB -0AA0)

System Functions  Diagnostic-capable modules with comprehensive monitoring (MLFB x-0AB0)
Batch / Route Control  Missing sensor power / load voltage
 Short-circuit, wire break
MIS/MES Integration
 Substitute value applied due to automation system failure
Add-ons  Incorrect parameters in module
Migration  Watchdog triggered
 EPROM error
Summary
 RAM error etc.
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 22
 Automation and Drives

I/O Module ET 200M cku

p
Range of Modules Ba

SIMATIC PCS 7 Digital inputs Digital outputs

Technology
 8, 16, 32 channels  8, 16, 32 channels
Introduction  DC 24 V, DC 48-125 V  DC 24V, DC 48-125 V, AC 120/230 V, AC/DC 24-48V
Profibus  AC 120/230V, NAMUR  0,5 / 1 / 2 / 5 A per channel

I/O Analog inputs  Electronic / relay outputs

 2, 4, 8 channels
Controller
 Multifunctional modules for U, I, TC, RTD, resistance
F-Engineering  Specific modules for
Communication  Voltage: e.g.: 0-10V, +/-10V; Current: +/-20mA, 0/4..20mA (2, 4 wire)
Operator System  Thermoelement types B, C, E, J, K, L, N, R, S, T, U (internal linearization)
 Pt 100/200/500/1000, Ni100/120,200/500/1000, Cu10 (2, 3, 4 wire, internal linearization)
Engineering System
 Resistance: 150, 300, 600 Ohm
System Functions
 Variable resolution/accuracy (up to 16 bit, 0.1%)
Batch / Route Control  HART
MIS/MES Integration Analog outputs
Add-ons  2, 4, 8 channels
Migration  Voltage: 0-10V, +/-10V; Current: +/-20mA, 0/4..20mA (2 or 4 wire)
 Variable resolution/accuracy (up to 16 bit, 0,1%)
Summary
 HART
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 23
 Automation and Drives

I/O Module ET200M

Support for Redundant I/O Modules
SIMATIC PCS 7  I/O redundancy for selected modules from  Configuration via browser
Technology
the ET 200M series
Introduction
Profibus
AS 414 H
I/O AS 417 H

Controller
F-Engineering
PROFIBUS DP

Communication I/O Module

Operator System Sensor

Engineering System
I/O module
System Functions redundant

Batch / Route Control

 Redundancy can be configured separately for each module
MIS/MES Integration
 Combination of redundant and non-redundant modules can be used within
Add-ons a single AS
Migration  No special logic in CFC required - channel switching is performed in the
background
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 24

 Automation and Drives

I/O Module ET200M

Redundant I/O‘s – module range
PCS 7 V6.0 SP3
SIMATIC PCS 7
DI
Technology
16xDC 24 V 6ES7 321-1BH02-0AA0
32xDC 24 V 6ES7 321-1BL00-0AA0
Introduction
8xAC 230 V 6ES7 321-1FF01-0AA0
DI with Diagnostics
Additional High End Solution:
Profibus
16xDC 24 V 6ES7 321-7BH01-0AB0 Add FEM (Ordering via A&D SE, Khe)
I/O 16xNamur 6ES7 321-7TH00-0AB0  PROFIBUS DP Slave
4xNamur Ex 6ES7 321-7RD00-0AB0
Controller  Redundancy via Optical Link
24xDC 24 V 6ES7 326-1BK00-0AB0 *)
8xNamur Ex 6ES7 326-1RF00-0AB0 *)
F-Engineering
DO
Communication 32xDC 24 V/0.5 A 6ES7 322-1BL00-0AA0
8xDC 24 V/2 A 6ES7 322-1BF01-0AA0
Operator System 8xAC 230 V/2 A 6ES7 322-1FF01-0AA0
DO with Diagnostics
Engineering System 8xDC 24 V/0,5 A 6ES7 322-8BF00-0AB0

System Functions 16x24 V/10 mA (Ex) 6ES7 322-5SD00-0AB0

10x24 VDC/2A 6ES7 326-2BF00-0AB0 *)
Batch / Route Control AI with Diagnostics
8x12Bit 6ES7 331-7KF02-0AB0
MIS/MES Integration 8x16Bit 6ES7 331-7NF00-0AB0
4x15Bit (Ex) 6ES7 331-7RD00-0AB0
Add-ons
6x13Bit 6ES7 336-1HE00-0AB0 *)
Migration AO with Diagnostics
4x12 Bit 6ES7 332-5HD01-0AB0
Summary 8x12 Bit 6ES7 332-5HF00-0AB0
4x15 Bit (Ex) 6ES7332-5RD00-0AB0 *) F-Baugruppe
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 25
 Automation and Drives

Redundant I/O‘s cku

p
Digital Input Ba

SIMATIC PCS 7
Technology
Assignment of redundant modules
Introduction
Profibus 1)

I/O 2) Discrepancy Analysis in HW-config.

 Time Discrepancy in msec.
Controller  Reaction after discrepancy: AND,
OR, last value
F-Engineering
Communication
Module External Missing Short
Operator System Discrepancy Internal Power Supply Sensor Wire Break Circuit
MLFB analysis Diagnostics *) Missing Supply (Resistor 1) (Resistor 2)
Engineering System Standard Modules
16xDC 24 V 6ES7 321-1BH02-0AA0 x
System Functions 32xDC 24 V 6ES7 321-1BL00-0AA0 x
8xAC 230 V 6ES7 321-1FF01-0AA0 x
Batch / Route Control Modules with Diagnostics
16xDC 24 V 6ES7 321-7BH01-0AB0 x x x x x
MIS/MES Integration 16xNamur 6ES7 321-7TH00-0AB0 x x x x x x

Add-ons 4xNamur Ex ***) 6ES7 321-7RD00-0AB0 x x x x x

24xDC 24 V 6ES7 326-1BK00-0AB0 **) x x x
8xNamur Ex ***) 6ES7 326-1RF00-0AB0 **) x x x x x
Migration
*) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module recommended
Summary **) no discrepancy analysis, always „or“ after discrepancy
**) Calculation of critical parameters for Ex applications necessary – dependant on sensor
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 26
 Automation and Drives

Redundant I/O‘s cku

p
Digital Output Ba

SIMATIC PCS 7
Technology
Assignment of redundant modules
Introduction
( ) ( )
Profibus
I/O
Controller
F-Engineering
Communication Wiring without Module Behaviour on
external Internal Wire No Load Short CPU Stopp
Operator System MLFB diodes Diagnsotics *) Break Voltage Circuit selectable
Modules without Diagnostics
Engineering System 32xDC 24 V/0.5 A 6ES7 322-1BL00-0AA0
8xDC 24 V/2 A 6ES7 322-1BF01-0AA0
System Functions
8xAC 230 V/2 A 6ES7 322-1FF01-0AA0 x
Batch / Route Control Modules with Diagnostics
8xDC 24 V/0,5 A 6ES7 322-8BF00-0AB0 x x x x x x
MIS/MES Integration 16x24 V/10 mA (Ex) **) 6ES7 322-5SD00-0AB0 x x x x x
10x24 VDC/2A 6ES7 326-2BF00-0AB0 x x x x x x
Add-ons
Migration
*) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module recommended
Summary
**) Calculation of critical parameters for Ex applications necessary – dependant on actuator

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 27

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Redundant I/O‘s cku

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Analog Input Ba

SIMATIC PCS 7
Technology
Assignment of redundant modules
Introduction
R
Profibus I
+ -
I/O
Discrepancy Analysis in HW-config.
Controller  Tolerance window (% endvalue)
 Time Discrepancy in msec.
F-Engineering
 Reaction after discrepancy: lower,
higher value
Communication I
+ -
Operator System
Engineering System Module Indirect current Current
Discrepancy Internal measurement measurement with
System Functions MLFB analysis Diagnsotics *) with Resistor external source Wire Break
Modules with Diagnostics
Batch / Route Control
8x12Bit 6ES7 331-7KF02-0AB0 x x x
MIS/MES Integration 8x16Bit 6ES7 331-7NF00-0AB0 x x x x x
4x15Bit (Ex) **) 6ES7 331-7RD00-0AB0 x x x x
Add-ons 6x13Bit 6ES7 336-1HE00-0AB0 ***) x x x

Migration
*) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module
recommended
Summary **) Calculation of critical parameters for Ex applications necessary – dependant on actuator
***) No discrepancy analysis, in case of failure value of faultless module is taken

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Redundant I/O‘s cku

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Analog Output Ba

SIMATIC PCS 7
Technology

Introduction
Assignment of redundant modules
Profibus
I/O
Controller I

F-Engineering
Communication
Operator System
Engineering System
Module Internal External power Wire
MLFB Diagnsotics *) Supply Missing Break
System Functions
Modules with Diagnostics
Batch / Route Control 4x12 Bit 6ES7 332-5HD01-0AB0 x x x
8x12 Bit 6ES7 332-5HF00-0AB0 x x x
MIS/MES Integration 4x15 Bit (Ex) 6ES7 332-5RD00-0AB0 x x x

Add-ons
Migration recommended

Summary
*) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 29

 Automation and Drives

I/O Module ET 200M cku

p
Controller Modules FM355 Ba

SIMATIC PCS 7 Features

Technology
 4 continuous or step controllers per FM355
Introduction  Reduces the load on the Automation System (AS)

Profibus  Back-up function – control even after AS failure

 Integrated within PCS 7 by via function blocks and faceplates
I/O
 Min. cycle time 20msec. (100msec. FM355-2)
Controller
 8 DI, 4 AI, 8 DO (step), 4 AO (cont.)
F-Engineering
Back-up controller FM355
Communication  Temperature control
Operator System  Ride-height control
Engineering System  Liquid level control

System Functions  Pressure control

 Flow control
Batch / Route Control
 Concentration control
MIS/MES Integration
Back-up controller FM355-2
Add-ons
 Special for temperature controls
Migration  Integrated online self-optimization without configuration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 30

 Automation and Drives

I/O Module ET 200M ckup

Serial Communication with CP341 Ba

SIMATIC PCS 7
Technology Features
 1 channel design
Introduction
 Can be inserted anywhere in ET200M chain
Profibus
 3 models for transmission physics:
I/O  RS 232C (V.24)

Controller  20 mA (TTY)
 RS 422/RS 485 (X.27)
F-Engineering
 Protocol types
Communication  ASCII
 3964 (R)

PROFIBUS-DP
Operator System
 RK 512
Engineering System Serial connection
 MODBUS master, slave
e.g. MODBUS
System Functions  Integration in PCS 7 with automatic diagnostics
Batch / Route Control  Custom redundant interfaces

MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 31

 Automation and Drives

I/O Module ET 200M ckup

Counter Module FM350 Ba

SIMATIC PCS 7
Technology Features
Introduction  FM350-1 (40 mm wide)
 1 Channel
Profibus  Counter frequency max. 500 kHz (endless, once, periodical)
I/O  32 Bit
 Latch function
Controller
 FM350-2 (80 mm wide)
F-Engineering  4 independent channels for PCS 7
Communication  Counter frequency max. 20 kHz (endless, once, periodical)
 Frequency
Operator System
 Revolution
Engineering System  Periodic time

PROFIBUS-DP
System Functions  Dosing
FM350-1 FM350-2
 Integration in PCS 7 with function block and automatic diagnostics
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 32

 Automation and Drives

I/O -
Intelligent Field Devices and Drives
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons Intelligent field devices
Migration Intelligent drives
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 37

 Automation and Drives

I/O
Integration of PROFIBUS Devices in SIMATIC PCS 7
SIMATIC PCS 7
Technology

Introduction  PROFIBUS DP devices address the

special requirements of drives and OS ES
Profibus process engineering (motor starter,
I/O frequency converter)
Controller  PROFIBUS PA devices receive power
directly from the bus and can be used
F-Engineering in Ex Areas
Communication  Function blocks for easy configuration

PROFIBUS DP
Operator System in CFC and visualization in the OS via
faceplates
Engineering System
 Configuration using integrated utility
System Functions PDM (Process Device Manager - see
Batch / Route Control Engineering) PROFIBUS PA

MIS/MES Integration
 Integrated control system diagnostics

Add-ons
Migration
 Complete integration of intelligent field devices in PCS 7 enables
Summary simple operation and efficient engineering
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 38
 Automation and Drives

Intelligent Field Devices cku

p
Neutral, multi-vendor integration in PCS 7 Ba

SIMATIC PCS 7
Technology Flexible, open selection of field devices, based on neutral, multi-vendor device
descriptions for parameter assignment and description of the communication
Introduction
Profibus  PROFIBUS PA field devices
I/O (interconnection with EDD,GSE)
Controller  PROFIBUS DP field devices
F-Engineering (interconnection with EDD,GSE)
Communication
 HART field devices
(interconnection with EDD, HCF catalog)
Operator System
 Mixed operation of different devices
Engineering System 4-20 mA, HART, PA, DP
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
GSE: Basic Device Data File, describes the cyclic communication of the device
Migration EDD: Electronic Device Description, describes the acyclic communication of the device

Summary (parameters, diagnostics, device configurations)

HCF: Hart Communication Foundation
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 39
 Automation and Drives

Intelligent Process Devices from SIEMENS

Overview
SIMATIC PCS 7 Temperature Flow Analyser OXYMAT
Controller - SIPART DR

Technology SITRANS F US SITRANS FM

SITRANS T3K ULTRAMAT23

Introduction
Weighing system - SIWAREX
Profibus
I/O Pressure Level
ULTRAMAT SIPAN32

Controller SITRANS P DSIII SITRANS LR 400 SITRANS LC

Motor starter - SIMOCODE

F-Engineering
OXYMAT 61 CALOMAT 6
Communication
Operator System Positioner

Engineering System SIPART PS2 SITRANS LR 300 SITRANS LS

Frequency converter – master drives

200/300
System Functions
Batch / Route Control
Process Devices
MIS/MES Integration PROFIBUS PA
Add-ons
ET200M ET200iS ET200S

Migration Process devices

Distributed I/O
Motor controls
Summary PROFIBUS DP PROFIBUS DP
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 40
 Automation and Drives

Controllers -
the Automation Systems in SIMATIC PCS 7
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Centralsection
Central sectionS7-400
S7-400
Communication
with
with
Operator System
CPU414,
CPU 414,416,
416,417
417
Engineering System
CPU414H,
CPU 414H,417H
417H
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 41

 Automation and Drives

Controllers - v a
ed
nc r e
a
Ad rdw 4
built by SIMATIC, worldwide market leader Ha /200
07
SIMATIC PCS 7
Technology  Robust components from SIMATIC, the worldwide
market leader
Introduction  Fanless operation up to 60°C
Profibus  Hot Swap modules during runtime operation
I/O  Comprehensive configuration
Controller  Convenient, graphical high-level languages (CFC, SFC)

F-Engineering  Standard programming languages (e.g. SCL, Ladder Logic)

Communication  Scalable performance and function

 Standard AS414, AS416, AS417
Operator System
 Failsafe (F) and fault-tolerant (H) AS414H/F, 417H/F
Engineering System
 Changes can be made during runtime operation
System Functions
 User program
Batch / Route Control
 I/O configuration
MIS/MES Integration Typical controller capacity AS 414-3 / AS 417-4 /
AS 416-2 AS 416-3
Add-ons AS 414H AS 417H
(sample project)
Digital-In DI 150 300 850 1500
Migration Digital-Out DO 50 150 315 630
Summary Analog-In AI 50 100 275 500
Analog-Out AO 20 50 130 200
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 42
 Automation and Drives

Contoller – Slot CPU WinAC Slot 416

PLC as a PC Card (in combination with PCS 7 Box)
SIMATIC PCS 7
Technology Memory Card
(RAM/Flash)
Introduction
PROFIBUS DP
Profibus Interface
 2 x 1.6 MB Memory
I/O
 All S7-400 commands
Controller
 2 PROFIBUS DP Interface
F-Engineering  seperate 24 V DC feed in
Communication LED  Only limitation: no CIR
Stop/Run
Operator System Connection to
Back-up battery
Engineering System PROFIBUS DP
Interface
System Functions To external

Batch / Route Control Power Supply 24V DC

MIS/MES Integration
Add-ons Operation independant of PC
 Independant of PC Power - external 24 V DC Supply connection
Migration
 Independant from WINDOWS operating system
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 44

 Automation and Drives

Controllers -
Configuration changes during runtime operation
SIMATIC PCS 7
 Configuration changes during runtime operation (CiR)
Technology
 For all standard automation systems S7-400
Introduction (AS 414-3, 416-2, 416-3, 417-4, 414-4-1H, 417-4-1H)
Profibus  For failsafe systems S7-400F (AS 414F, 417F)

I/O
 Distributed process I/O
Controller - Online changes
F-Engineering  ET 200M

Communication
 Adding new stations (Racks or I/O)
 Adding new I/O modules to a rack
Operator System
 Configuring I/O channel parameters
Engineering System  PROFIBUS DP/PA New
I/O module
System Functions  Adding new field devices
Batch / Route Control  Configuration of intelligent PA devices
 ET 200iS and ET 200S
MIS/MES Integration
 Adding new stations
Add-ons AS
 ET 200iS: configuration using SIMATIC PDM downloa
Migration d

Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 45

 Automation and Drives

Fault-tolerant Controller AS 414H / AS 417H

SIMATIC PCS 7
Technology
 Entry level with CPU 414H
Introduction
 768 kB RAM
Profibus
I/O  High-end with CPU 417H

Controller  up to 20 MB RAM

F-Engineering  Fiber optic connection for synchronization

Communication
 Expandable
Operator System
 Shared rack
Engineering System
System Functions
Batch / Route Control  Separated rack for
distances up to 500 m (to
MIS/MES Integration maximize availability and
Add-ons minimize common-cause
Migration
failure)

Summary
 Scalable even for fault-tolerant controllers
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 46
 Automation and Drives

High-Availability Controller ku
p
c
Synchronization Ba

SIMATIC PCS 7
Without synchronization Cycle synchronization Time synchronization Command synchronization
Technology

Introduction
Profibus

redundant CPU A

redundant CPU B
redundant CPU A

redundant CPU B
I/O

redundant CPU B
redundant CPU A
redundant CPU B
redundant CPU A

Controller
F-Engineering
SIEMENS
Communication patent
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration Guarantees bumpless switchover
Add-ons  Fast switchover time (typically 30ms)
 No loss of information
Migration
 No loss of alarms
Summary  Resumes processing of program where it left off
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 47
 Automation and Drives

High-Availability Controller ku
p
c
Event Synchronization Ba

SIMATIC PCS 7
Technology  Definition:
Event synchronization
Synchronization whenever the two redundant (Siemens patent)
Introduction
CPUs could end up with different results during
Profibus
execution of the program
I/O
Controller
 Automatic operating system function
F-Engineering (Background)

B
Redundant CPU A

Part AG CPU
Communication  Synchronized events:

Redundant B
Operator System  Updating of the process image
Engineering System  Direct access to the I/O
System Functions  Interrupts, alarms
Batch / Route Control  Updating of the timer
MIS/MES Integration  Changes to data through
Add-ons communication functions
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 48

 Automation and Drives

Failsafe Automation
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering Centralsection
Central section
Communication --S7-400F/FH
S7-400F/FH
Operator System I/O
I/O
--ET200M
ET200M
Engineering System
System Functions
--ET200S
ET200S
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 50

 Automation and Drives

Failsafe Automation
Highlights
SIMATIC PCS 7  Uses standard SIMATIC S7 components
Technology
for failsafe applications
Introduction  Flexibility on different
Profibus availability and safety levels:
I/O  Standard (S) systems

Controller  Fault-tolerant (H) systems

F-Engineering  Failsafe (F) systems

 Failsafe and fault-tolerant (FH) systems
Communication
 Safety level SIL 3, AK 6 – can be achieved with use of a single CPU
Operator System
 Secure communication via PROFIBUS with ProfiSafe message
Engineering System
 S and F functions can be combined in the same controller
System Functions
 S and F I/O can be operated on the same PROFIBUS-DP chain
Batch / Route Control
 Configuration of S and F functions with the same engineering tool, CFC
MIS/MES Integration
 F-Tool offers support for acceptance by the technical inspectorate:
Add-ons
 Separation of S and F functions (S and F block library, S and F CFC charts)
Migration
 Checksums via F comparison function
Summary
 Access to F functions protected by password

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 51

 Automation and Drives

Method of Operation - Failsafe System S7-400F

SIMATIC PCS 7 AK1 to AK6 (DIN)
Technology Application S7-400H CPU (F capable)
(S7- 417-4H or 414-4H) SIL1 to SIL3 (IEC)
Introduction Standard
ProfiSafe
program Standard PROFIBUS DP
Profibus communication together with
I/O Shutdown logic failsafe message (ProfiSafe)

Controller F-I/O
Failsafe

PROFIBUS-DP
ET200M
F-Engineering program
I/O
Communication ET200M
Operator System
F-I/O
Engineering System
ET200S
System Functions  Uses standard S7-400 hardware
Batch / Route Control (S7-414/417H) with F software up to SIL3, AK6
MIS/MES Integration  Standard and failsafe program in one controller
 Communication with failsafe I/O modules using Profisafe
Add-ons
 A detected error in the F program does NOT result in AS stop
Migration
 Standard program section continues to run
Summary  Shutdown logic stops the affected F program section (F-STOP)
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 52
 Automation and Drives

F - Engineering
Standard CFC and certified F blocks
SIMATIC PCS 7
Technology

Introduction
Profibus
F block
I/O
library
Controller
F-Engineering
Communication
Operator System TUV-certified
Blocks
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 54

 Automation and Drives

Safety in F - Engineering
Access protection, signature, comparison function
SIMATIC PCS 7 Unique signature of the
Technology F program for validation of
safety program
Introduction
Profibus Comparison function
I/O for two versions of a
program
Controller
F-Engineering
Communication
Operator System Access protection for
Engineering System CFC program

System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration List of all F blocks with
Summary signature and default values

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 55

 Automation and Drives

F - Engineering
Safety Matrix
SIMATIC PCS 7 Effects are the process “response”
Technology

Introduction
Profibus
Causes represent a
I/O process “upset”
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control Beispiel:
Ex: PT_35A exceeding a high limit
forcing the BV_24 to close Intersections associate
MIS/MES Integration a Cause with an Effect
Add-ons
 Easy description of logic in a matrix format
Migration
 Automatic Code Generation without additional user interaction
Summary
 Engineering and Online Visualization on Operator Station
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 56
 Automation and Drives

F - Engineering
Safety Matrix - Advantages
SIMATIC PCS 7  Powerful Programming Language
Technology
 Easy (user friendly) visualization of logic
Introduction  Consistent view for design, documentation, test & monitoring
Profibus  Reduces Development Effort
I/O  Automatic insertion of channel drivers
Controller  Built-in first out alarming
F-Engineering  Automatic visualization support for PCS 7 OS

Communication
 Built-in user interface to safety logic (Bypass, Reset, Override,etc)
 Eliminates Translation Errors
Operator System
 Logic automatically generated from safety design
Engineering System
 Automatic insertion of Safety Matrix CFC logic
System Functions
 Simplifies Documentation
Batch / Route Control
 Creates matrix reports
MIS/MES Integration  Built-in version tracking
Add-ons  Manages & Verifies Configuration Changes (IEC 61511)
Migration  Automatic generation of change documentation
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 57

 Automation and Drives

S7-400F/FH Configuration Alternatives

SIMATIC PCS 7
Technology Single-channel Single-channel Redundant
one-sided I/O switched I/O switched I/O
Introduction
Profibus S7-400F S7-400FH S7-400FH
I/O
Controller ET200M ET200M ET200M
PROFIBUS DP

PROFIBUS DP

PROFIBUS DP
F-Engineering F - I/O F-I/O F-I/O

Communication ET200M redundant

Operator System
F-I/O
Engineering System
 SIL 2, AK4  Redundant S7-400FH  Redundant S7-400FH
System Functions
 SIL 3, AK5 or 6  Redundant PROFIBUS-DP  Redundant PROFIBUS-DP
Batch / Route Control  Redundant IM 153-2  Redundant IM 153-2
 SIL 2, AK4  Redundant failsafe I/O
MIS/MES Integration  
SIL3, AK5 or 6 Discrepancy analysis
Add-ons  SIL 2, AK4
 SIL3, AK5 or 6
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 58

 Automation and Drives

F Engineering: I/O ET200S

SIMATIC PCS 7 4/8 F DI PM-E F PM-D F
Technology ProfiSafe module module PROFIsafe
4 F DO

PROFIBUS DP
Introduction module
Digital input 4/8 F DI Standard DO F motor starter
Profibus
 4 channels SIL3 or 8 channels SIL2
I/O
 DC 24 V
Controller
Digital output 4 F DO
F-Engineering  4 channels SIL3, P and M switching
IM151 HF
Communication  DC 24 V, 2A per channel

Operator System F Power module PM-E F

 2 outputs P and M switching SIL 3 SIL 2
Engineering System
24 VDC, 2A, SIL 3
System Functions  Safe shutdown PM-E DC24V
Batch / Route Control standard module max. 10A, SIL2 AC120/230V

MIS/MES Integration F Motor starter

 Direct starter, reverse starter SIL 3
Add-ons
 7.5 KW (16A)
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 61

 Automation and Drives

F-Engineering: Certificate of the Technical

Inspectorate
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 62

 Automation and Drives

Network Components
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
SIMATIC NET
F-Engineering
Industrial/Fast Ethernet
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 63

 Automation and Drives

Network Components
Fast Ethernet - Network Configuration
SIMATIC PCS 7
Technology
Redundant Optical Ring
Introduction
Profibus
Redundancy Manager
I/O (RM) (= OSM)
Controller
F-Engineering 100 Mbps
10 Mbps
Communication
Operator System
:::
Engineering System
System Functions Optical Switch Module
with 6 connectors (OSM)
Batch / Route Control
MIS/MES Integration
Add-ons Configuration rules
+ Good diagnostics  approx. 50 OSM / ring
Migration  max. 3000 m between two OSM
+ Fast redundancy:
Summary  approx. ring circumference: 150 km
switching of communication paths within 0.3 sec
("long distance" version up to 900 km)
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 65
 Automation and Drives

Network components ku
p
c
Fast Ethernet - Load Optimization and Full Duplex Ba

SIMATIC PCS 7
Technology

Introduction

s
s
Profibus

10

Mbp
bp
0M

s
0M

bp
I/O

100
bp

M
10

0
s

10
Controller L1 Flt DA/STAT SIEMENS L1 Flt DA/STAT SIEMENS
Port
Industrial Ethernet OSM Port Industrial Ethernet OSM
L2 Stby L2 Stby

F-Engineering Port 1 Port 2 Port 3 Port 4 Stand by Port 1 Port 2 Port 3 Port 4 Stand by

Communication
100 Mbps 100 Mbps
Operator System L1+
DC 24 V
Fault
L2+ *
DC 24 V
Port 5 Port 6 L1+
DC 24 V
Fault
L2+ *
DC 24 V
Port 5 Port 6

100 Mbps
Engineering System
System Functions
100 Mbps
Batch / Route Control
MIS/MES Integration Load Optimization: Full Duplex:
Local data traffic Simultaneous sending
Add-ons
remains local and receiving data
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 66

 Automation and Drives

Operator System
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Operator System
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 68

 Automation and Drives

Operator System
Overview
SIMATIC PCS 7
Technology
Alarm System Programming
Introduction
Interfaces
Profibus
Process
I/O
Visualization
Controller
F-Engineering Excel

Communication Standard
Archive System
Operator System
Interfaces
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Report System Data Management
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 69

 Automation and Drives

Operator System
Hardware & Software Components
SIMATIC PCS 7  Custom Operator Stations
Technology
(Bundled hardware + system software)
Introduction - Single-user system (OS single station)
- Client/server system (OS client / OS server)
Profibus - Basis: Standard PC components
I/O Windows 2000
Controller
 System Software for Operator Systems
F-Engineering Configurations System software also available without
Communication Clients hardware (for simulation purposes)
Single-user 1 32
Operator System system
 Packages for Operator Systems
Engineering System Server - Variety of quantities available
System Functions
1 12 - Upgrades via PowerPacks
Opt. redundant server
Batch / Route Control Packages
Number of PO‘s Single-user Server
MIS/MES Integration
250 PO‘s  --
Add-ons System Capacity 2,000 -- " --  
Number of server / server pairs 12 3,000 -- " --  
Migration
Number of clients for each server/pairs 32 5,000 -- " --  
Summary Number of PO‘s for each multiuser system 60.000 8,000 -- " -- -- 

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 70

 Automation and Drives

Operator System
GUI
SIMATIC PCS 7 Alarm line
Technology Overview
section
Introduction
Navigation
Profibus window

I/O
Picture
Controller Faceplate area

F-Engineering
Communication
Operator System
Engineering System
System Functions Button area

Batch / Route Control  Standard user interface (overview and Picture area, buttons, trends, alarms, faceplates)
is provided by the system - no engineering required !
MIS/MES Integration
 Multi-window design with fixed areas - prevents overlap of the overview and button areas
Add-ons
 Easy to operate due to hierarchical structure and simple navigation
Migration
 Well-designed GUI for reliable operation
Summary
of the process – even in critical situations
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 71
 Automation and Drives

Operator System cku

p
GUI  Block Symbols - Faceplates Ba

SIMATIC PCS 7
Technology Plant picture with
block symbol
Introduction
Maintenance view Alarms
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration Faceplate
Limits
Add-ons Trend window

Migration
Summary Faceplate –
Parameter view Batch view extended view
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 74
 Automation and Drives

Operator System
Alarm Management  Screen hierarchy & group displays
SIMATIC PCS 7 Operator prompting through screen hierarchy and group displays:
Technology
 Jump directly from the overview to the picture containing the alarm via a single
Introduction
mouseclick.
Profibus
 Jump directly from the overview to a screen in which all alarms
I/O
from lower levels have been aggregated.
Controller
F-Engineering  The operator decides which alarm is the most important.

Communication A A

 
Operator System
Engineering System
System Functions
Batch / Route Control A A

MIS/MES Integration
Add-ons  
A A
A

Migration
Summary
 Alarm Navigation plus overview of Plant alarm status
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 76
 Automation and Drives

Operator System
Alarm Management  Loop-in alarm
SIMATIC PCS 7  Jump: from the overview alarm line directly to the graphic or faceplate containing the alarm
Technology

Introduction
A

Profibus Loop-in alarm

I/O Alarm with highest priority A

in alarm line (overview)

Controller
F-Engineering A

Communication
Operator System  Jump: from the alarm list directly directly to the graphic or faceplate
Engineering System
A

System Functions
Batch / Route Control
A

MIS/MES Integration Loop-in alarm

Add-ons A

Migration
Summary  Alarm Management by quickly navigating to the source of the fault
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 77
 Automation and Drives

Operator System
Client / Server Architecture & Archive Server
SIMATIC PCS 7  OS client (multi-client)
Technology  Process visualization
 Access to every OS server
Introduction
 Combines process values,
Profibus alarms, etc. from all servers
Central into a single view
I/O archive server OS Client max. 32
 OS server
(process value archive)
Controller  Communication with AS
F-Engineering  12 servers (red.), 32 OS
OS server max. 12
clients
(redundant) Terminal bus
Communication  Archiving of process values,
Operator System alarms
 Archive synchronization
Engineering System .... (for redundant servers)
System bus  Archive configurations
System Functions
 Integrated in every OS server
Batch / Route Control
....  As central archive server (only
process values)
MIS/MES Integration
Add-ons
 Flexible adaptation of the HMI to the plant architecture
Migration  Simultaneous operation of several plant areas with a single OS client
Summary  Optimized communication due to separation of the terminal and plant bus
and true client/server architecture
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 78
 Automation and Drives

Operator System cku

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Trend Displays Ba

SIMATIC PCS 7
Technology
Basic functions of the trend displays
Introduction
Profibus
 Up to 10 tags (pens) for each trend display
I/O  Zoom
Controller  Ruler (with tabular display of value)
 Adjustable time scale (duration
F-Engineering
 Visualization can be stopped
Communication (archive continues to run)
 Scrolling through records (Fwd/Rev)
Operator System
 One Y axis for all values (%) or separate Y axis for each value
Engineering System  Trend displays merge data from
System Functions  Online process values
 Archived (historical) values
Batch / Route Control
MIS/MES Integration
Add-ons  Flexible trend display format maximizes usability
Migration  Fast online viewing of process data

Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 79

 Automation and Drives

Archive System cku

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Performance Ba

SIMATIC PCS 7
Highlights
Technology
 Can be configured online  Process value compression for archiving
Introduction (e.g. acquisition: 2 sec. / archiving: 60 sec.)
 Automatic synchronization for redundant systems
Profibus  Process value acquisition / archiving  Min value
 Cyclic (fastest cycle: 500ms)  Max value
I/O
 Archiving of changes only  Average value
Controller  Last value
F-Engineering  Sum of values (addition)
 Custom function (C script)
Communication
Technical data
Operator System
 Microsoft SQL Server 2000 Acquisition
Engineering System  5,000 process values / sec (archive server)
System Functions  1,000 process values / sec (OS server)
 Up to 30,000 tags can be archived in the database
Batch / Route Control
 10 alarms / sec for each server (steady state)
MIS/MES Integration Archiving
 Alarm buffer with 3,000 alarms in 4 sec
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 80

 Automation and Drives

Archive System V 6. 0 S P3
StoragePlus – integrated Viewer PCS 7

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Alarm Messages
Communication
Curves
Operator System
Engineering System
System Functions
Batch / Route Control
Archived variables in table format
MIS/MES Integration
Add-ons Batch protocols
Migration
StoragePlus with integrated viewer
 Viewing of archived data with standard Internet Explorer
Summary
 easy client - server structures (office) possible
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 82
 Automation and Drives

Operator System
Downloading and Testing Changes Online
SIMATIC PCS 7
Technology ES OS  Simple online change
(also for non-redundant systems)
Introduction
Profibus
I/O New measuring point
(Loop)
Controller
1 2 3 4
F-Engineering  Selective download of redundant
ES servers allows online testing of
Communication changes before complete
system update
Operator System
Engineering System
System Functions  Download server A, clients 1 and 2
A  Test change to ensure that it is OK
OS server
Batch / Route Control B  Download server B, clients 3 and 4

MIS/MES Integration
Add-ons
 Alternative automatic
Migration download with "MAKE" *)
Summary
*) see Engineering System
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 84
 Automation and Drives

Operator System
SFC Visualization
SIMATIC PCS 7  Automatic generation of
Technology displays from the ES
 Navigation window for
Introduction each chart
Profibus  Overview window with
I/O step / transition box
 Several SFC‘s in
Controller
multichart diagram
F-Engineering  Dynamically configured
Communication step and transition boxes
SFC in the Engineering
Operator System  Group displays for operator
input
Engineering System
 Loop-in alarm from operation Detail view with
System Functions prompt  SFC operator input
Overview
Batch / Route Control  Various operator
authorization / privilege
MIS/MES Integration levels SFC online (OS)
Add-ons  Modification & downloading
during runtime operation:
Migration tional
- transitions No addi
Summary - steps gi neer ing !!!
en
without having to stop SFC Single steps with operator input
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 87
 Automation and Drives

Operator System 004

l y2
System Hardware Ju
SIMATIC PCS 7
Technology New preconfigured, turn-key packages
Introduction
Profibus
I/O  Basic SIMATIC Rack PC IL40S
Controller  OS server
 OS client
F-Engineering
 Combination OS / ES station
Communication
Operator System
Engineering System
 Hardware Features
System Functions  CPU: Pentium 4, 2,8 GHz, 800 MHz FSB
Batch / Route Control  RAM: 512/1024 MB RAM (OS client/OS server, ES)
MIS/MES Integration  Hard Disk: 80 Gbyte / 2 x 120 Gbyte RAID controller (OS client/OS server, ES
 CD / DVD R/RW
Add-ons
 Ind. Ethernet (3COM or CP1613)
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 90

 Automation and Drives

Engineering System
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller Engineering System
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 91

 Automation and Drives

Engineering System
Overview of the Tools
Technological function SIMATIC BATCH
SIMATIC PCS 7 blocks with faceplates
OS Engineering
Technology User OS faceplates
and CFC templates for
standard applications
Introduction (e.g. motor, valve, controller)

Profibus
I/O
Controller
F-Engineering
PCS 7 Engineering
Communication
Operator System
Engineering System
SIMATIC Manager
System Functions integrated database

Batch / Route Control

MIS/MES Integration
Add-ons
Engineering for
Migration failsafe Engineering for network/ Programming
SIMATIC PDM
systems communication/hardware of custom user
for field device
Summary function blocks
Automation configuration
engineering
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 92
 Automation and Drives

Engineering System
Views
SIMATIC PCS 7
Technology
Component view
 For configuration of the control system hardware
Introduction (I/O modules, CPU, bus systems etc.)
Profibus
I/O
Controller
F-Engineering
Plant view
 Hierarchical plant architecture according to
Communication
process engineering aspects
Operator System (e.g. plant / process area / unit according to
process model)
Engineering System
System Functions
Batch / Route Control
Process object view
MIS/MES Integration  A centralized development environment for all
Add-ons aspects of a process engineering measuring
Migration
point
 Integrated plant view
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 93

 Automation and Drives

Engineering System
Component View
SIMATIC PCS 7
Technology Hardware configuration
of an AS station with I/O
Introduction
Profibus
I/O Configuration of a
module without
Controller hardware jumpers
F-Engineering
Communication
Operator System
One view of all
Engineering System
hardware components
System Functions (AS, OS, ES, etc.)
and applications
Batch / Route Control (OS, Batch, etc.)
MIS/MES Integration
Add-ons  All components and applications of a plant in a single location
Migration  Hierarchical navigation to configuration of the hardware
Summary  Selection of components from hardware catalog and placement
using Drag and Drop
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 94
 Automation and Drives

Engineering System
Plant View: Hierarchical representation of the plant
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Plants
Communication
Operator System
Engineering System
Process
System Functions Area
Piece of
Batch / Route Control
equipment Control device Integrated in process
MIS/MES Integration (Process Object) object view
Add-ons
Migration
 Good overview provides easy to understand representation of
functional plant architecture in the engineering system
Summary
 Powerful navigation helps to search quickly and “dive in”
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 95
 Automation and Drives

Engineering System
Process Object View...the "Integrated Development Environment”
SIMATIC PCS 7 General
Technology Name, comments, AS assignment etc.
CFC & SFC
Introduction OS cross- parameters /
reference interconnections
Profibus
Block symbols, Alarm Limits,
I/O
I/O fields, settings,
Controller status display Engr range,
high-level
F-Engineering
interconnections
Communication
Operator System
Engineering System Process
System Functions Object
Archives Alarms
Batch / Route Control
Cycles, Message text,
MIS/MES Integration units Alarm priorities
Add-ons
Migration
Summary Hardware configuration
I/O channels, signal names
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 96
 Automation and Drives

Engineering System
Process Object View: EXPLORER-/EXCEL Look & Feel
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O All aspects of the select folder
for measuring point based engineering
Controller Hierarchical
plant view
F-Engineering
Communication Preselection
e.g. plant section
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration  Integrated plant view in EXPLORER – form, allows configuration
of a measuring point (Tag) using EXCEL – Look & Feel
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 97

 Automation and Drives

Engineering System cku

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Process Object View: Comprehensive Filter Functions Ba

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
1 2
2-level filter
Operator System
function
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary
 Selective filtering of relevant parameters allows you to
optimize your configuration activities
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 98
 Automation and Drives

Engineering System cku

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Process Object View: User Friendly Ba

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering Block parameters can be
changed without opening CFC
Communication
Operator System
Project library for storing process tag types
Engineering System and example solutions
System Functions Import and export of process tags and
variations of the example solutions
Batch / Route Control
MIS/MES Integration
Add-ons Collaboration with MS
EXCEL using Copy & Paste
Migration
Summary  Added Efficiency from ability to leverage project data from
MS EXCEL (taglist, alarmlist etc.)
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 99
 Automation and Drives

Engineering System
OS Display Navigation derived from the Controller Configuration
SIMATIC PCS 7 System functions of the plant hierarchy:
Technology  Layout the configuration to represent  Automatic creation of explorer-like
the process structure of the plant navigation windows
Introduction
 Automatic creation of OS areas  Automatic assignment of alarms
Profibus  Automatic generation of the OS (from the PH area) to the OS areas
 Custom user authorizatíon for each plant section
I/O screen hierarchy from the plant
hierarchy of the ES
 Custom alarm filtering for each plant section
Controller  Operators see only those alarms they are
responsible for
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
a d d i ti onal
No
Summary
i n ee r i n g !!!
eng
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 105
 Automation and Drives

Engineering System
Optimal Change Management "Copy & Modify"
SIMATIC PCS 7 Example: How can a plant section be cloned (copied) with minimum effort?
Technology

Introduction
Plant_1 Plant_1
Profibus
Reactor_1 Reactor_1
I/O TIC10 Reactor_2
PIC11 TIC20
Controller
V17 PIC21
F-Engineering V27

Communication Automatic AS-OS synchronization

Operator System
 Copy pictures and charts from Reactor_1 together
Engineering System
System Functions  Easy editing of the copies
 Rename objects (Chart names)
Batch / Route Control  Configure hardware connections of new plant section
MIS/MES Integration
 Compile OS: All references to Reactor_2
Add-ons in the OS are automatically renamed
Migration
 Pictures (including dynamic links)
re u p d ated
 Scripts
o n n ecti o n s a ee ring !!!
Summary  Archive tags O S c al en g i n
h o u t manu
wi t
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 106
 Automation and Drives

Engineering System
Graphical Configuration with CFC Conforming to IEC 1131
SIMATIC PCS 7
Technology

Introduction Place blocks

per Drag and
Profibus
Drop
I/O
Controller
F-Engineering
Communication
Operator System Automatic
connection to other
Engineering System charts and hardware
System Functions signals

Batch / Route Control

MIS/MES Integration
Block libraries with
Add-ons search function
Migration
Summary  Easy engineering of the measuring point logic using
graphical connections of preconfigured blocks
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 107
 Automation and Drives

Engineering System
Libraries
SIMATIC PCS 7
Technology
 Blocks in the PCS 7 library for ES
 Basic blocks and AS
Introduction  Diagnostic / communication blocks
Profibus  Technological blocks

+
I/O  Block symbols
 Faceplates
Controller
 Pre-engineered templates for
F-Engineering
process automation
Communication
Operator System
for OS
 Integrated system response
Engineering System  Diagnostics
System Functions  Alarms
Batch / Route Control  Faceplates
MIS/MES Integration  Online help

Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 108

 Automation and Drives

Engineering System cku

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Function Blocks  Configuration of OS Symbols Ba

SIMATIC PCS 7
 One block type (e.g. motor) can have different symbolic representations in
Technology
the OS station depending upon the application
Introduction  Mixer, pump, motor, compressor etc.
 Alignment of the symbol (left, right, flipped etc.)
Profibus
 The assignment can be made for each instance
I/O  In the CFC (object properties block)
 In the process object view
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
1 block type n symbols in the OS 1 faceplate to the
Migration block type
(e.g. motor)
Summary (e.g. motor)

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 109

 Automation and Drives

Engineering System cku

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Automatic Optimization of the Control Strategy Ba

SIMATIC PCS 7
 The order of the blocks and the sequence groups/charts are automatically
Technology
optimized during compiling based on the data flow through the program (optional)
Introduction  Ensures that interconnected logic is executed in the correct order
 A separate sequence group is automatically created for each new CFC chart
Profibus
(with the same name)
I/O  All blocks of a chart are automatically inserted into the sequence group
Controller
F-Engineering CFCs SFCs
Communication
Operator System
Engineering System Block sequence
System Functions
Batch / Route Control Optimized
by PCS 7
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 110

 Automation and Drives

Engineering System
Editing of Sequence Controls Conforming to IEC 1131 (1)
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary  Powerful and easy-to-use tools for configuring all aspects of
sequential control via “drag and drop” and “fill in the blank”
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 111
 Automation and Drives

Engineering System cku

p
Editing of sequential controls conforming to IEC 1131 (3) Ba
SIMATIC PCS 7  Each SFC supports 16 different states/modes conforming to ISA S88
Technology
Idle - Starting - Run - Completing - Error(Completed) - Completed - Holding - Held -
Introduction Resuming - Error - Held(Error) - Resuming(Error) - Aborting - Aborted - Stopping -Stopped
Profibus  Several sequences can be configured in one SFC chart (max. 8)
I/O  For different operating modes (e.g. heating/cooling)
 For exception handling (e.g. holding, aborting, shutdown)
Controller  Triggering by process events or SFC states
F-Engineering
Heating Cooling Condition for
Communication Shutdown
control strategy
Operator System Heating
Engineering System
Cooling
System Functions

....
Batch / Route Control
MIS/MES Integration
Add-ons
Shutdown
Migration ....
1 2 8
Summary Coordinated automatically by PCS 7
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 112
 Automation and Drives

Engineering System
SFC: Type Instance Concept  Highlights
SIMATIC PCS 7  Chart I/Os can be configured for SFC charts
Technology  Inputs and outputs for controlling and monitoring status of the SFCs are available,
additional inputs and outputs can be configured for SFC types
Introduction
 “Write“ statements in steps to outputs
Profibus  “Read“ transition conditions from inputs
 Configure Interface to SFCs just like standard chart I/Os (e.g. setpoint with limits)
I/O
 The SFC chart can be placed in the CFC chart like a block,
Controller the SFC control block is not needed
F-Engineering
 New object: SFC type in the CFC
 In the SIMATIC Manager or SFC: Chart > New > SFC Type...
Communication  Chart I/Os as described above
Operator System  Real type-instance concept
 Each placement in the CFC chart creates an instance: re-usability
Engineering System  Changing the type changes all instances: central editing
System Functions  Test mode and SFC visualization also for instances
 General display driver block and block symbol for SFC instances are supplied
Batch / Route Control
 Easy integration of SIMATIC BATCH
MIS/MES Integration  No interface blocks required
 SFC Coordination is handled automatically
Add-ons
 Equipment modules are created as SFC types which
Migration  contain the sequential control, operating state logic, control strategies
 are connected directly to the process tags
Summary
 Better specifications and improved performance compared to PCS 7 V5.2
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 113
 Automation and Drives

Engineering System cku

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SFC: Type Instance Concept  Block Interface Ba

SIMATIC PCS 7 SFC Configure chart I/Os

Technology (inputs/outputs/in/outs)
Introduction
CFC
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
SFC operating states can be triggered by
Add-ons interconnections (inputs)
Migration
SFC status can be determined from
Summary interconnections (outputs)
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 114
 Automation and Drives

Engineering System cku

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SFC: Type Instance Concept  Central Editing Ba

SIMATIC PCS 7 Definition of the SFC type SFC instances in the CFC
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Online visualization
Engineering System of SFC Status
System Functions OS faceplate
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary SIMATIC BATCH

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 115

 Automation and Drives

Engineering System
"Make"
SIMATIC PCS 7
Technology  Overview of all configuration changes in
Introduction
the project
 Execution per START command
Profibus
 HW Config (PCS 7 V6.0 SP3)
I/O  CFC
Controller  SFC
F-Engineering
 OS
 SIMATIC BATCH
Communication
 "Smart” compiling and downloading
Operator System of all changes in the correct order!
Engineering System  First make all changes, then compile
System Functions
and download all changes in one step –
Make throughout entire project!
Batch / Route Control
MIS/MES Integration
Add-ons
Migration  Better turnaround times since there is no wait between the
Summary various engineering changes

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 116

 Automation and Drives

Engineering System
Efficient Bulk-Engineering
SIMATIC PCS 7 CAD / CAE  Standardized contol technological libraries with
Technology Typical preassembled, tested blocks and charts (typicals)
Typical
Libraries  Import plant data (e.g. process tag list or I/O list) from
Libraries
Introduction Measurement, the higher-level CAD/CAE world
controller, motor, valve, etc.
Profibus
Import / Export Assistant
I/O
 Automatic generation of
Controller controller configuration based on
TH
F-Engineering the imported process tag list and
the typicals
Communication - Creation of the plant hierarchy
OS Picture Hierarchy
Process - Editing of saved process tag
Operator System charts
Object OS Pictures
Engineering System charts
 Automatic derivation of the OS
picture hierarchy, automatic
System Functions
interconnection of blocks and
Batch / Route Control placement in pictures

MIS/MES Integration Operator

Controller System
Add-ons
 Commissioning of individual Process Objects with the
Migration convenient graphical tools CFC, SFC
Summary  Export of optimized parameters back to CAD/CAE world
during commissioning (documentation of „As-built“)
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 119
 Automation and Drives

Engineering System
Import / Export Assistant
SIMATIC PCS 7  Template chart
 Automatically generates plant
Technology hierarchy and controller
+
 Imported measuring point lists configuration
Introduction
 Automatically configures instance-
Profibus specific parameters and inter-
I/O connects measuring point charts to
I/O, SFCs etc
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Import/Export
Assistant
Batch / Route Control +
PH assign. Chart name PV_LR PV_LR KP TN TV
MIS/MES Integration B17/Reac1 LIC1710 0 100 1.7 2.5 1.3
B17/Reac2 TIC2711 0 500 1.25 3.5 1.0
B17/Reac2 PIC2712 0 10 2.0 1.0 1.0
Add-ons B17/Reac3 FIC3210 0 250 1.5 10 2.0

Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 120

 Automation and Drives

Engineering System
Multiproject Engineering: Concurrent Engineering
SIMATIC PCS 7
Technology Multiproject
Introduction
...  A large plant can be divided into
separate (sub)projects to allow multiple
Profibus
engineers to work on it at the same time
I/O
 Granular to the level of at least 1 AS or
Coordination
Controller 1 OS for each project
with PCS 7 ES
F-Engineering  High performance since the individual
projects are stored and processed
Communication
locally on ES stations
Operator System ...
Engineering System Data AS Data OS Data AS/OS
System Functions local local local

Batch / Route Control

 Parallel processing of projects
MIS/MES Integration
 Local separate processing of projects using branch and merge
Add-ons
 Cross-project functions (AS-AS communication, OS compiling) are supported by
Migration the multiproject
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 121

 Automation and Drives

Engineering System
Version Cross-Checker (VXC) 1
SIMATIC PCS 7
Technology
PCS 7
Introduction VXC
Profibus
+ -
I/O
CFC charts CFC charts
Controller SFC charts SFC charts
F-Engineering Block types Block types
Signals Signals
Communication
Run sequence Run sequence
Operator System Program a Program b

Engineering System
 Tool for comparing and displaying differences between two versions of
System Functions
an AS program
Batch / Route Control  Highlights what is new, missing or different between the two versions
MIS/MES Integration  Results are shown in tree / tabular format
 Fast determination of differences with hierarchical "branching" and color high-
Add-ons lighting of the difference
Migration  A tool that is useful for the smallest applications and for large plants
 Print and/or save the results in CSV format
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 123

 Automation and Drives

Engineering System V6.0 SP1 21 CFR

Part 11
Audit Trail – Downloading to AS complia
nt
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 126

 Automation and Drives

System Functions
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 127

 Automation and Drives

Access Protection with SIMATIC Logon cku

p
Windows 2000 Functions Ba

SIMATIC PCS 7 User administration, security functions

Technology  Central user administration with domains / workgroups on the MS Windows level
 Create, delete, lock, unlock users
Introduction
 Assignment of users to user groups
Profibus  Double token logon (user ID + password)
I/O  Unique logon names within the domain/workgroup
 Define the logon name format (e.g. min. 6 characters, etc.)
Controller
 Double input of password
F-Engineering  Define the re-usablility of the password
 Define the password format (min. length, special characters etc.)
Communication
 Password expiration
Operator System  User can be forced to change his password on first logon attempt
Engineering System  User can be locked out after n failed logon attempts
 MS Windows access rights only for authorized persons
System Functions
 Various access levels
Batch / Route Control  Access settings for each PC
MIS/MES Integration Audit Trail procedures
Event Viewer for audit log entries:
Add-ons  All administrative actions
Migration  All user access actions
(logon, logout, password change by user etc.)
Summary
 Logging of all (failed) logon / logout attempts
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 130
 Automation and Drives

Time Synchronization and Time Stamping

SIMATIC PCS 7 Possibilities of time synchronization
Technology
 External time master "SICLOCK" on the plant bus
Introduction  OS server is time master with
 PC system time
Profibus
 Master Time signal via serial port (GPS / DCF 77 antenna)
I/O  Master Time signal via bus from external PC
Controller
Time stamping
F-Engineering SICLOCK
 Process alarms
Communication  Analog block, e.g. "Analog value high"
 Motor block, e.g. "Motor fault"
Operator System
 Time stamping cyclic in the AS
Engineering System  Precision: AS scan rate, e.g. 500 msec.
System Functions *)
 Error messages of the I/O
Batch / Route Control
 E.g. "wire break"
 Time stamping acyclic in the AS ET200M *)
MIS/MES Integration  Precision : approx. 50 msec.

Add-ons  Digital signals on the input/output station

ET200iS
Migration
 Digital signals via IM153-2 / IM151-2
 Precision : 5 msec.
Summary
Time master/slave
*) ET200M: 16 x DI: 6ES7321-7B/TH0*-0AB0 ET200iS: 4 x DI: 6ES7 131-5RD00-0AB0
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 133
 Automation and Drives

SIMATIC BATCH
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
SIMATIC BATCH
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

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 Automation and Drives

SIMATIC BATCH
Highlights
SIMATIC PCS 7
Technology  High-availability due to redundancy

Introduction  Scalability, from small to very large projects accessing distributed OS

servers and cross-server access to all areas of the plant
Profibus
 Hierarchical recipes conforming to ISA-88.01
I/O
 Flexible control strategies using unit-independent recipes
Controller
 Optimal plant utilization due to assignment of units during runtime
F-Engineering
(dynamic unit allocation)
Communication
 Library for recipe operations (ROP)
Operator System
 Total integration in the PCS 7 Engineering System
Engineering System
 OS faceplates for units, phases and operations
System Functions
 XML-based archiving and reporting systems
Batch / Route Control
 MIS/MES integration - standard interface for SIMATIC IT
MIS/MES Integration
 Open API interface for custom expansion
Add-ons
Migration
 Supports 21 CFR Part 11: FDA-capable user management, electronic
signature, Audit Trail, versioning
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 135

 Automation and Drives

SIMATIC BATCH - Workflow

Plant Configuration Data
SIMATIC PCS 7
Technology SIMATIC
Manager
Introduction
Profibus
I/O
Controller
F-Engineering 5t
27.03.03
Communication
Operator System
Base Contol
Engineering System recipe recipe
St
System Functions
Recipe Batch Batch Batch
Batch / Route Control editor
AF1 AF2
planning control data report
MIS/MES Integration AF3

Add-ons
Migration
Summary
Charge
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 136
 Automation and Drives

SIMATIC BATCH
Scalable, Redundant Architecture
SIMATIC PCS 7
Technology  Scalability, from small to very large projects accessing distributed
OS servers
Introduction  High availability using hot standby redundancy of the batch server
Profibus
I/O
Batch / OS Clients
Controller
F-Engineering
Communication ...
Operator System Terminal bus
Engineering System
OS/Batch Single-user Batch Server
System Functions ...
Batch / Route Control
OS/Batch-Server
OS Server OS Server
MIS/MES Integration Plant bus

Add-ons
Migration
...
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 137

 Automation and Drives

SIMATIC BATCH
Strict adherence to the ISA-88.01 model
SIMATIC PCS 7
Technology

Introduction
Profibus Plant
Plant
Recipe
Recipe
procedure
procedure
I/O
Unit recipe
Sub-plant Unit recipe
Controller Sub-plant procedure
procedure

F-Engineering Technical Recipe

Technical Recipe
operation
equipment
equipment operation
Communication
Single Recipe
Operator System Single
control unit
Recipe
function
control unit function
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration  Hierarchical recipes conforming to ISA-88.01
Summary  All ISA-88.01 hierarchy levels available

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 Automation and Drives

SIMATIC BATCH
Graphical Recipe Editor Tools
SIMATIC PCS 7
 The recipe editor provides tools for easy, intuitive creation of recipes
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions Recipe operation (ROP)
Batch / Route Control Library ROP Parallel branch
MIS/MES Integration
Recipe function Alternative branch
Add-ons
Migration Operator dialog Synch. line Loop
Summary Transition
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 139
 Automation and Drives

SIMATIC BATCH – Unit-Independent Design

SIMATIC PCS 7 Plant Neutral Class Recipe
Technology
Class
Silo
Introduction
Profibus
I/O
Controller Class
F-Engineering Reactor

Communication
Control Recipe
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary  Class concept enables unit-independent recipes
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 140
 Automation and Drives

SIMATIC BATCH
Optimal Assignment of Units and Equipment
SIMATIC PCS 7  Configuration of strategies for dynamic allocation of units
Technology
 Preferred unit
Introduction  Least used unit
 Process parameters
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary  Automatic unit assignment during runtime
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 141
 Automation and Drives

SIMATIC BATCH
Batch Planning
SIMATIC PCS 7
Technology Plant view:
 Assignment of the units
Introduction
 Conflict information
Profibus
I/O
Controller
F-Engineering
Communication
Operator System Order view:
Engineering System
 Batch dispatching
 Batch linking
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 142

 Automation and Drives

SIMATIC BATCH
Batch Planning
SIMATIC PCS 7 Planning tool in the BATCH Control Center
Technology

Introduction
Profibus
I/O
Maximum quantity per unit
Controller
F-Engineering Required quantity
Communication Automatic allocation to
Operator System different batches

Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 143

 Automation and Drives

SIMATIC BATCH
Library for Recipe Operations (ROP)
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration  Central editing
Summary  Facilitates validation
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 144
 Automation and Drives

SIMATIC BATCH
Separation of Formulas and Procedures
SIMATIC PCS 7
Technology
 Association of parameter sets (formulas)
Introduction
with one procedure
Profibus  Simple creation of a variety of basic recipes
I/O  Central editing of recipe procedure

Controller
Formula 1 Formula 2 Formula 3
Formula 1 Formula 2 Formula 3
F-Engineering Qty
Qty
1000 Kg
1000 Kg
500 Kg
500 Kg
900 Kg
900 Kg
Temperature 90 C 80 C 95 C
Temperature 90 C 80 C 95 C
Communication Time 10 min 15 min 12 min
Time 10 min 15 min 12 min
Salt Yes Yes No
Salt Yes Yes No
Operator System Pepper No No Yes
Pepper No No Yes
Sugar 100 g 150 g 50 g
Engineering System Sugar 100 g 150 g 50 g

System Functions Basic

Basicrecipe
recipe#1
#1 Basic
Basicrecipe
recipe#2
#2 Basic
Basicrecipe
recipe#3
#3
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary  Efficient engineering and simplified validation
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 145
 Automation and Drives

SIMATIC BATCH
Online Operation
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System Stop point:
 Block batch processing
System Functions
 Resume after operator
Batch / Route Control input

MIS/MES Integration
Add-ons
Migration
Start Stop after step Stop immediately Resume End Cancel
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 146

 Automation and Drives

SIMATIC BATCH Fulfills 21 CFR Part 11

SIMATIC PCS 7
Technology
 Audit Trail (offline and online)
 Versioning
Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
 Access protection
MIS/MES Integration with SIMATIC Logon
Add-ons
Migration
Summary  Electronic signature

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 147

 Automation and Drives

SIMATIC BATCH
Tightly Integrated into the PCS 7 Engineering System
SIMATIC PCS 7  No project-specific interfaces to OS or AS
Technology
 Data communication in the engineering and during runtime via internal interfaces
Introduction  All engineering data are configured at one place in the ES and made available to
the batch server for the creation of recipes
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
 No double entry of configuration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 148

 Automation and Drives

SIMATIC BATCH cku

p
Reporting system based on XML data structures Ba

SIMATIC PCS 7  Reporting system with integrated browser

Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 149

 Automation and Drives

SIMATIC ROUTE CONTROL SYSTEM (RCS)

SIMATIC PCS 7 CV1304A CV1306A

CV1341 CV1351

CV1326
Destination Source
Technology CV1325
CV1305 CV1307
CV1327
CV1328

CV1340
A A
Introduction MASH TUN B C PRESSURE
B C
MASH TUN
TV 105 COOKER COOKER COOKER
TV 106 TV 107
20-103-1 FT324 20-104 20-103-2
Profibus LT LT
FT313
LT
325 326 STM 327
STM VS
TT TT TT
I/O 105
M
VS
106
M
VS
107
M 316

CV1028 CV1030 CV1032

314 315

Controller

CV1038
CV1037
CV1036
CV1035
CV1031 CV1029 CV1033 FT311
F-Engineering
Main functions CV1034 VS
311 MASH PUMP
Communication 20-105
 engineering/online tool for complex control
Operator System and supervision of transports
 static defined partial routes are combined to a total
Engineering System
route dynamically
System Functions  diagnosis and alarming tool for material routes
Batch / Route Control System environment
 SIMATIC PCS 7
MIS/MES Integration  with and without SIMATIC BATCH
Add-ons Typical applications
Migration  plants with fluid materials
 parts of plants with complex product routes
Summary  tank farms
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 150
 Automation and Drives

SIMATIC ROUTE CONTROL SYSTEM (RCS)

Example: Fermentation
SIMATIC PCS 7
Technology fermentation tank group 1 fermentation tank group 2
switch valves
Introduction
Profibus
I/O water

Controller yeast

F-Engineering CO2

Communication CIP

Operator System
check valves
Engineering System water finishing

System Functions wort 1 fermentation tank group 3/4

Batch / Route Control execute several

wort 2 fermentation tank group 3/4
routes
MIS/MES Integration
CIP

Add-ons
check exclusive allow common use calculate amount of output
Migration occupancy

Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 151

 Automation and Drives

SIMATIC ROUTE CONTROL SYSTEM (RCS) cku

p
Integration in PCS 7 Ba

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O ES OS (Server) OS (Client)
Simatic Manager
Controller
SIMATIC Project
SIMATIC Multiproject
F-Engineering Route Control Server
Route Control Center
(search of routes,
(Visualization, Diagnosis)
Communication SIMATIC Route Control
download list of routes in AS)
Assistent

Operator System

Call
SIMATIC Route Control
Engineering
Engineering System Route Control Faceplate
(Visualization, Diagnosis)
System Functions
SIMATIC RC SIMATIC RC
Engineering-DB Runtime-DB
Batch / Route Control
AS
MIS/MES Integration
Add-ons
Migration
(Control routes and elements and
Summary evaluate its check feedback signals)

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 152

 Automation and Drives

MIS / MES Integration

SIMATIC PCS 7
Technology

Introduction
MIS/MES Integration
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 153

 Automation and Drives

Easy Business and IT Integration Using Standard InterfacesP-2

0 S
OPC V6
.

SIMATIC PCS 7
OPC Clients
Technology

Introduction
OPC Server
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
 PCS 7 System Functions
System Functions
 Access to redundant server
Batch / Route Control  Access to several servers
MIS/MES Integration  Functions
Add-ons  Data Access: reading and writing tags (provided by standard PCS 7)
Migration  Historical Data Access: Read archived tags (optional package: WINCC Connectivity Pac
Summary  Alarm and Events: Alarms, reading alarms (optional package: WINCC Connectivity Pack

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 154

 Automation and Drives

Interface to the IT World with @PCS 7

SIMATIC PCS 7 Process data available through

Technology company with @PCS 7

Introduction
Profibus  Read access to OS data via
Internet/Intranet (process,
I/O archive data, messages)

Controller  Write access to OS data

 Communication with server
F-Engineering applications of @aGlance/ IT
server add-ons
Communication
 Company-wide availability of
Operator System process data; leverages C/S
technology; open for custom
Engineering System C/S applications
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 155

 Automation and Drives

Interface to the IT World with SIMATIC IT

Overview
SIMATIC PCS 7 Information technology (IT), process data management and production planning systems
Technology are playing an increasingly important role in production optimization and cost reduction

Introduction
Profibus Integration & synchronization of all business
processes with the SIMATIC IT technology
I/O platform
Controller
F-Engineering  Links the control level with MIS/MES level
 Comprehensive basic package available
Communication  Integration of manufacturer-neutral IT products
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration  Conforms to standard ISA S95; integration of heterogeneous
Add-ons applications (even 3rd-party)
Migration  Fast response times, better transparency, higher reliability of
Summary
decisions

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 156

 Automation and Drives

Interface to the IT World with SIMATIC IT

Topology and Data Communication
SIMATIC PCS 7
Technology SAP R/3 ERP

Introduction
Profibus Planning level

I/O SIMATIC IT
MES MES
Production Suite MIS
Controller PCS 7 OS Server Client

F-Engineering MIS/
MES
Communication
Operator System Execution level
Engineering System
PCS 7 ES
System Functions
Batch / Route Control Controls
MIS/MES Integration
Add-ons
Control level
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 157

 Automation and Drives

Tasks on the MES Level

SIMATIC PCS 7
Technology

Introduction Production
planning Material
Profibus
Personnel tracking
I/O
/shift
Controller planning
F-Engineering
Communication Performance
Order
Operator System data (KPI)
planning
analysis
Engineering System
System Functions Product
Batch / Route Control
definition

MIS/MES Integration Product data

Add-ons Interface to archiving
control level
Migration (PCS 7)
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 158

 Automation and Drives

SIMATIC IT Product Family (Production Suite)

Based on S95
SIMATIC PCS 7
Technology

Introduction Detailed
PRM: Report Manager
Product Resource
Scheduling
production
Profibus scheduling
Manager Material
Production
I/O tracking
Unilab:
Production POM: Tracking Laboratory
Controller Personnel
resource Production Order and
management Manager Information
F-Engineering Management
System
Communication
Production
Production Production
KPI
Planning
dispatching performance
Operator System Analysis
analysis

Engineering System PPA:

Product PM: Production
System Functions Recipe Mgt
definition
Production Modeler Performance
management
(Base Application) Analyser
Batch / Route Control PrDefMan:
Production Production
KPI
MIS/MES Integration Definition data
Manager BATCH
Production Analysis
collection
Add-ons Historian
Execution
execution

Migration PCS 7 / Batch

Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 159

 Automation and Drives

PCS 7 Add-on Concept kup

c
Ba

SIMATIC PCS 7
Technology
PCS 7 Product Management A&D AS PA PM
Introduction
Profibus Siemens Partner
External Partner
I/O (I&S, A&D, CoC, ZN)

Controller
F-Engineering PCS 7 Compatibility Test Add-on Contract
“Certification”
Communication
Operator System PCS 7 Add-on
Catalog
Engineering System
System Functions
Order directly from partner
Batch / Route Control
MIS/MES Integration
Hotline / Support
Add-ons 1.) Simatic Hotline
2.) Partner Hotline
Migration
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 160

 Automation and Drives

SIMATIC PCS 7 - Add-ons

Examples (1)
SIMATIC PCS 7
Video monitoring
Technology
Motor starter
Introduction Simocode

Profibus
I/O
Controller Frequency converter
Master drives Fingerprint mouse
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary Big screen Ex operating units Cabinet engineering

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 161

 Automation and Drives

Migration –
From the installed basis to SIMATIC PCS 7
SIMATIC PCS 7  Step-by-step transition from the installed base to SIMATIC PCS 7
Technology  Preserves previous investmests (conversion of proven application software; re-use of the I/O)
 Integrated process management using common HMI
Introduction PCS 7 OS Clients PCS 7 ES PCS 7 OS Clients

Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
 Minimal risk, quick transition period, no/minimal production downtime
 Migration products and service from one source
Migration  Migration integrates old plant innovative technologies (e.g. todays EDP infrastructure)
Summary 1 2 3 4 5 6 7
Consulting Offer Logistics Execution IBS Documentation Expansion
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 163
 Automation and Drives

SIMATIC PCS 7 cku

p
Openess on All Levels Ba

SIMATIC PCS 7 SAP R/3

@
  Strict conformance to international industry standards
Technology enables data communication with corporate management
Ethernet Office LAN level
Introduction  Simple and fast integration of additional software packages
Internet/Intranet at plant control level
Profibus @PCS 7 /
OPC-Server  Multi-vendor process data communication of various
I/O Windows applications
Controller  Web capability using interfaces standards such as OPC,
OCX, ODBC
F-Engineering  Interfaces for data import/export with upstream planning tools
Communication from the CAD/CAE world
 Swapping out long-term data in TXT, CSV or XML
Operator System
 Ethernet with TCP/IP communication
Ethernet
Engineering System  S7-SCL (PASCAL-like high-level language conforming to IEC
Serial 61131-3) for creation of custom user blocks
System Functions (e.g. Modbus)
 Serial coupling (e.g. MODBUS) for connecting 3 rd party
Batch / Route Control controls
MIS/MES Integration  Interconnection of intelligent sensor/actuator technology via
HART, PROFIBUS DP/PA (DDBF, EDD)
Add-ons  AS interface for integrating simple actuators/sensors EIB
Migration 
Instabus for integrating
Integration building automation
in existing infrastructure
Summary (EDP topology to sensor technology)

A&D AS PA PM / A&D AS SM MP
 Protects past investments
PCS7_Technical No. 164
 Automation and Drives

SIMATIC PCS 7 cku

p
High Availability  Redundancy at All Levels Ba

SIMATIC PCS 7
OS Clients SIMATIC BATCH Clients
Technology
 Parallel redundancy of OS/Batch clients
Introduction  Redundantly configured OS/Batch server with archive
Profibus OS-LAN Ethernet
synchronization between servers
OS Server Batch Server
I/O (redundant) (redundant)  Double-redundant plant bus in Ethernet
Controller
Ethernet
F-Engineering  Fully redundant configured automation system with
High-availability optical fiber connection between CPUs
Communication automation system
 Max. availability of AS using 2 CPs
AS 414 H / AS 417 H
Operator System ET 200M  Redundant connection of the distributed I/O
Engineering System  Redundant connection of the PROFIBUS PA I/O

Sensor / Aktor
ET 200M

System Functions ~  Redundant connection of non-redundant PROFIBUS DP

ET 200M
Failsafe devices to PROFIBUS DP via Y link
Batch / Route Control DP/PA Link  Redundant I/O with selected modules from the ET200M
PROFIBUS DP

PROFIBUS PA
MIS/MES Integration range (standard and failsafe)
Add-ons Increased availability on all levels
Y Link
Migration  Minimal process down time
Summary COx,
NOx, ...
 Increased productivity
A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 165
 Automation and Drives

SIMATIC PCS 7
System Architecture
SIMATIC PCS 7
@
 SAP R/3
@

Technology
Office LAN Ethernet Office LAN Ethernet

Introduction Internet/ Plant Plant

Intranet Information Maintenance
Profibus
OS Single Engineering BATCH flexible Simatic IT @PCS 7 /
OS Clients
I/O Station Station ES Clients Framework OPC Server
(multi-VGA) Components
Controller SIMATIC PDM
Engineering
F-Engineering Toolset Service
PCS 7 Slot
OS-LAN Fast Ethernet
Communication OS server Batch server
(redundant) (redundant)
Operator System
Industrial Ethernet / Fast Ethernet
Engineering System OS AS 414 F/FH AS 414 H
Box PC AS 417
AS 416 AS 417 F/FH AS 417 H
System Functions
PROFIBUS-DP
AS 414 ET 200M
DP/AS-I Ex-I/O ET 200M ET 200M
Batch / Route Control HART OP failsafe

PROFIBUS-DP

PROFIBUS-DP
PROFIBUS-DP

DP/EIB DP/PA Link

MIS/MES Integration PROFIBUS-PA
ET 200M
PROFIBUS-PA
MODBUS
Add-ons DP/PA Link Y Link
DP/PA Link
PROFIBUS-DP PROFIBUS-PA
Migration ET
200iS COx,
Zone 1
Summary ET ET
Zone 2
NOx,
200X 200S etc.

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 166

 Automation and Drives

SIMATIC PCS 7 Fulfills All Requirements

A Modern Control System
SIMATIC PCS 7 Batch
Technology  Unit-independent recipes
 Hierarchical recipes compliant to S88
Introduction  Scalable from small up to very large plants
 Redundancy
Profibus
 21 CFR Part 11
I/O  Full integration into Engineering System
Engineering
Controller  Plant engineering with central overview HMI components
F-Engineering of all relevant project data  Windows-based intuitive
(Process object view) GUI
Communication  High capacity
 Bulk engineering with import/export functions  Client server architecture
Operator System  Configuration of intelligent field devices  Central archive server
 Redundancy
 Software simulation and testing  Online reconfiguration
Engineering System  Modification tracking
System Functions  Distributed, concurrent engineering

Batch / Route Control Communication

 Fast Ethernet AS, I/O modules, I/O
MIS/MES Integration  Fiber optic switching technology  Online reconfiguration and expansion
 Redundancy (system and field bus)  Redundancy (controller, modules and Profibus)
Add-ons
 Online expansion
 Integrated Safety Engineering
Migration
 Integration of intelligent field devices / drives
Summary  Large range of I/O modules

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 167

 Automation and Drives

SIMATIC PCS 7: worldwide more than 2,445 cku

p
Ba
References
SIMATIC PCS 7 1,896 Installations in Europe 294 Installations
Technology in Asia
Belarus 2 Greece 4 Poland 13
Bulgaria 7 Hungary 1 Portugal 7 Indonesia 5
Introduction Croatia 10 Ireland 14 Romania 4 India 6
Cyprus 2 Latvia 5 Russia 22 Iran 7
Czech Republic 11 Lithuania 4 Slovenia 27 Iraq 1
Profibus Denmark 3 Norway 5 Slovakia 7 Israel 2
Korea 20
I/O Malaysia 8
Finland 61 Oman 1
Pakistan 1
Controller Philippines 7
Sweden 57 Germany 733
Austria 99 Qatar 4
F-Engineering Russia 22 Singapore 7
United Kingdom 87 Taiwan 12
Belgium 115 Netherlands 70 Thailand 16
Communication Uzbekistan 3
France 94
Switzerland 85 Vietnam 2
USA 99
Operator System Italy 124
Spain 164 China 186
Engineering System Turkey 60
Mexico 22

System Functions
185 Installations South Africa 35

Batch / Route Control in America

Argentina 7 48 Installations
MIS/MES Integration Canada 11 Brazil 33
in Africa
Chile 1
Add-ons Colombia 2 Algeria 1
Costa Rica 1 Egypt 3 Australia 22
Ecuador 1 Mauritius 1
Migration Peru 3 Morocco 4 23 Installations
Trinidad 1 Mozambique 1 in Australia
Summary Venezuela 4 Namibia 2
Swaziland 1 New Zealand 1

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 168

 Automation and Drives

Automation made easy !

SIMATIC PCS 7
Technology

Totally
Introduction
Profibus
I/O

Integrated
Controller
F-Engineering
Communication
Operator System
Engineering System Automation
with
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration SIMATIC PCS 7
Summary

A&D AS PA PM / A&D AS SM MP PCS7_Technical No. 169