s

Welcome

For internal use only / © 2007 SIEMENS AG

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Process Control System

SIMATIC PCS 7
Version 7

For internal use only / © 2007 SIEMENS AG

 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Introduction
Engineering System
Advanced Process Control
Chapter Title
Automation System
PC Based Automation
Operator System
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Engineering System
Engineering System
Advanced Process Control Chapter Title
Automation System
Overview
PC Based Automation
Operator System Views
Asset Management CFC
Fieldbus
SFC
Remote IO
Devices Workflow
Process Safety
Multi user
Communication
SIMATIC BATCH PID Tuner

SIMATIC Route Control Version Cross Manager

MIS / MES
Audit Trail
Migration
Add-On SIMATIC PDM
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Advanced Process Control
Engineering System
Advanced Process Control
Chapter Title
Automation System
PC Based Automation
Operator System
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Automation System
Engineering System
Advanced Process Control
Chapter Title
Automation System
PC Based Automation Overview
Operator System Controller Bundles
Asset Management
Fieldbus Loadanalysis (SFC-78)
Remote IO Configuration Change in Run (CiR)
Devices
High Available Controllers
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
PC Based Automation
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System PCS 7 BOX
Asset Management
Fieldbus PCS 7 AS RTX
Remote IO SIMATIC Rack PC
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Operator System
Engineering System
Advanced Process Control Chapter Title
Automation System
Overview
PC Based Automation
Operator System Client / Server Architecture
Asset Management Server Redundancy
Fieldbus
Graphical User Interface
Remote IO
Devices OS Configuration
Process Safety Alarm Mangement
Communication
SFC Visualization
SIMATIC BATCH
SIMATIC Route Control Trend Displays
MIS / MES Archive System
Migration
Web Access
Add-On
Licensing Open PCS 7 System Interfaces
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Asset Management
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System Asset Visualization
Asset Management
Fieldbus Monitoring Levels
Remote IO Views
Devices
Asset Report
Process Safety
Communication Monitoring Process Components
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Fieldbus
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation PROFIBUS
Operator System PROFIBUS PA
Asset Management
Fieldbus FOUNDATION Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Remote IO
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System ET200M
Asset Management
Fieldbus ET200s
Remote IO ET200iSP
Devices
ET200pro
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Devices
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System Process instrumentation
Asset Management
Fieldbus Analytics devices
Remote IO Motor Control
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Process Safety
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System F-Components
Asset Management
Fieldbus Flexible Modular Redundancy (FMR)
Remote IO F-Engineering
Devices
Safety Matrix
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Communication
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System IE Switches (SCALANCE, ESM, OSM)
Asset Management
Fieldbus Ethernet Communication Processors
Remote IO Industrial Wireless LAN
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
SIMATIC BATCH
Engineering System
Advanced Process Control Chapter Title
Automation System Overview
PC Based Automation
S88 Compliance
Operator System
Asset Management Engineering

Fieldbus Recipe System

Remote IO Unit instance independent
Devices
Formulas
Process Safety
Communication Online Operation
SIMATIC BATCH Batch Planning
SIMATIC Route Control
FDA Compliance
MIS / MES
Interplay with SIMATIC Routcontrol
Migration
Add-On Reporting
Licensing Interfaces
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
SIMATIC Route Control
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System Workflow
Asset Management
Fieldbus Benefits
Remote IO Block Library
Devices
Interplay with SIMATIC BATCH
Process Safety
Communication User Defined Process Elements
SIMATIC BATCH
Modes
SIMATIC Route Control
MIS / MES Visualization & Logging
Migration Quantity Structures & Licenses
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
MIS / MES
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System SIMATIC IT Integration
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Migration
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Options
Operator System Siemens DCS systems
Asset Management
Fieldbus 3rd Party DCS Systems
Remote IO Universal Migration Platform
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Add-On
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System Examples
Asset Management
Fieldbus PCS 7 Lab
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Licensing
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Overview
Operator System Engineering Licenses
Asset Management
Fieldbus Examples
Remote IO Frequently Asked Questions
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
System Functions
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation Authentication & Audit Trail
Operator System Versioning
Asset Management
Fieldbus Time Synchronization & Stamping
Remote IO Security
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 s
SIMATIC PCS7
Takes you beyond the limits !

Introduction
Summary
Engineering System
Advanced Process Control Chapter Title
Automation System
PC Based Automation
Operator System
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
SIMATIC Route Control
MIS / MES
Migration
Add-On
Licensing
System Functions
For internal use only / © 2007 SIEMENS AG
Summary
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Introduction

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7
Value Proposition
SIMATIC PCS 7 offer Integration Open System
Central Intelligent Redundancy & Asset
Engineering Instruments on all levels Integration Management
Fieldbus Capability
Migration
Integrated
Integrated Strategies for
Automatic Decentral &
Safety Siemens and
Generation Architecture Redundant
System 3rd-party
BATCH
systems

Siemens is The automation partner for solutions

Siemens relies on its own R&D for the complete development of both the hardware and
software,(Bibliotheken)
LIBRARIES
COMPONENTS
STANDARDS thus offering highly integrated and stable automation solutions

Save time with TIA (Totally Integrated Automation)

TIA offers the highest level of integration between DCS, Safety, PLC and networks,
simplifying and reducing the engineering work for the entire automation project

SIMATIC PCS 7 offers very attractive TCO (Total Cost of Ownership)

Design & Modernization
Financial impact

Operation
Engineering & Upgrade

Installation & Maintenance

Commissioning

For internal use only / © 2007 SIEMENS AG

page 24 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7
The Process Control System for all Industries

One control system for all sectors

SIMATIC PCS 7 is the integrated and homogeneous automation solution for all sectors in
the process industries

For all primary and secondary plants

SIMATIC PCS 7 handles not only process control engineering tasks, but also the complete
automation of all mainstream, upstream and downstream processes at a given production
location

Industry-specific
Add-ons SIMATIC Clear reduction in costs:
BATCH hardware, logistics, training
Conti sectors Batch Sectors

Increase in productivity:
SIMATIC PCS 7 flexibility over the entire life cycle
of the plant
For internal use only / © 2007 SIEMENS AG
page 25 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7
Large Bandwidth of Scalability (1:1000)

Pilot Production Interconnected plants at a

plant plant production location

Scalable ...to the distributed system in client/

From a laboratory system (~100 E/A)... server architecture (~ 100.000 E/A)

… as powerful as you need it to be!

For internal use only / © 2007 SIEMENS AG
page 26 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 BOX

The Integrated Entry Solution for Small Applications

The compact, low-cost process control system for small

applications such as pilot plants, laboratories or package units
Seamless integration into SIMATIC PCS 7
“All inclusive” - all components of a control system united on an industrial PC: automation
system (AS), operator station (OS), engineering system (ES)
Uses standard engineering tools of the SIMATIC PCS 7 process control system

ES / OS / AS
ES OS

Industrial Ethernet
AS: S7-400
Box PC

PROFIBUS PROFIBUS

… 1st step in a Totally Scalable Solution !

For internal use only / © 2007 SIEMENS AG
page 27 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7
Is based on Components from Totally Integrated Automation
SIMATIC PCS 7 comprises:
Industry proven system components selected from the world market leader SIMATIC platform
Integrated system services (diagnostics, alarms, Asset Management...)
Auxiliary packages (libraries, SIMATIC BATCH, Warehouse,...)

SIMATIC HMI
SIMATIC PCS 7

SIMATIC Software

Components
Industrial
SIMATIC Workstation
SIMATIC Controller
SIMATIC NET
PROFIBUS DP

Totally Integrated Automation

For internal use only / © 2007 SIEMENS AG
page 28 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7
Continuous Improvement based on TIA
Alarm hiding
Advanced Plant Asset Manag.
Improved performance in ES
Multiuser engineering
Ease-of-use Advanced process control
Change I/Os, OS on-line Version Cross Manager
Incr. quantity frameworks OpenPCS 7 / OPC
Redundancy at all levels Integrated Route Control
Safety Matrix Innovated S7-400 Control
Improved PCS 7 Box
Improved Engineering
Flexible Modular Redundancy
Higher Performance PROFIBUS PA Redundancy
SIMATIC BATCH FF Integration
Failsafe, high- 21 CFR Part 11 Compl. Security Lab
availability SIMATIC PCS 7 Box
Systems SIMATIC Route Control PCS 7
Multi client/server
Redundancy OS
Fast Ethernet PCS 7 V7.0
~120.000 I/O
Load SW online
PROFIBUS PA PCS 7 V6.x 2006
~120.000 I/O
PCS 7 V5.x
~30.000 I/O 2003
V4.x 2000
~2.000 I/O
1997
TIA
For internal use only / © 2007 SIEMENS AG
page 29 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Engineering Station

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7
Engineering System
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 31 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Overview of the Tools
Automation OS Engineering SIMATIC BATCH
User OS
Engineering faceplates

PCS 7 Engineering
Import/Export CFC/SFC Plant HW Graphics Faceplate SIMATIC SIMATIC S7 SIMATIC
Libraries

Assistant Hierarchy Config Designer Designer BATCH Route Control F-Systems PDM
HEAT MIX

SIMATIC Manager
uniform database

Technological function blocks with

faceplates and CFC templates for
standard applications
(e.g. motor, valve, controller)

Engineering SIMATIC PDM

for for field device
Engineering for network/ configuration
failsafe
communication/hardware
systems
For internal use only / © 2007 SIEMENS AG
page 32 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Views

Component view
For configuration of the control system
hardware
(I/O modules, CPU, bus systems etc.)

Plant view
Hierarchical plant architecture according to
process engineering aspects
(e.g. plant / process area / unit according to
process model)

Process object view

A centralized development environment for
all aspects of a process engineering
measuring point
Integrated plant view

For internal use only / © 2007 SIEMENS AG

page 33 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Component View

Hardware configuration
of an AS station with I/O

Configuration of a
module without
hardware jumpers

One view of all

hardware components
(AS, OS, ES, etc.)
and applications
(OS, Batch, etc.)

All components and applications of a plant in a single location

Hierarchical navigation to configuration of the hardware
Selection of components from hardware catalog and placement using
Drag and Drop
For internal use only / © 2007 SIEMENS AG
page 34 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Plant View: Hierarchical Representation of the Plant

Plants

Process
Area
Piece of
equipment Control device Integrated in process
(Process Object) object view
Good overview provides easy to understand representation of
functional plant architecture in the engineering system
Powerful navigation helps to search quickly and “dive in”
For internal use only / © 2007 SIEMENS AG
page 35 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Comprehensive Processing via Process-Object View

Processing of all aspects such as general information, parameters, signals, messages /

alarms, image objects or archives directly in tabular format General
Name, comment,
OS AS assignment… CFC
Cross- & SFC
reference Parameter/
Connections
Efficient editing of all objects: Block symbols, Limits,
I/O fields, settings,
Block copy / paste (for attributes) status cross-measuring
indicators point
Cooperation with Excel / Access connections
(Copy / Paste) Archives Process Messages
Cycles, units Objects Message texts
Find / replace attributes priorities
Hardware
Browser for convenient Assignment
signal connection I/O channels,
signal names
Import / export of texts
Empty columns for custom attributes
Comprehensive test functions
(e.g. online values, enabling / disabling
of CFC diagrams, I/O simulation)
Improving engineering
productivity
For internal use only / © 2007 SIEMENS AG
page 36 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Process Object View: EXPLORER-/EXCEL Look & Feel

Integrated plant view in EXPLORER – form, allows configuration

of a measuring point (Tag) using EXCEL – Look & Feel
For internal use only / © 2007 SIEMENS AG
page 37 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Process Object View: Comprehensive Filter Functions

1 2-level filter
2
function

Selective filtering of relevant parameters allows you to optimize

your configuration activities
For internal use only / © 2007 SIEMENS AG
page 38 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Process Object View: User Friendly

Block parameters can be

changed without opening CFC

Project library for storing process tag types and

example solutions
Import and export of process tags and variations
of the example solutions

Collaboration with MS EXCEL

using Copy & Paste

Added Efficiency from ability to leverage project data from MS

EXCEL (taglist, alarmlist etc.)
For internal use only / © 2007 SIEMENS AG
page 39 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

CFC: Graphical Configuration of Continuous Automation Functions

Graphical Engineering-Tool CFC (Continuous Function Chart)

Place blocks
by Drag and
Drop

Automatic
connection to
other charts and
hardware signals

Block libraries with

search function

Simple engineering of all measuring points using preconfigured blocks

For internal use only / © 2007 SIEMENS AG
page 40 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

SFC: Editing of Sequence Controls Conforming to IEC 1131 (1)

Graphical engineering tool SFC (Sequential Function Chart)

Standardized elements (step, transition, jump...)
Automatic generation of the operator visualization system
Handling of exceptional states, operating modes...
Link to CFC diagrams by means of simple actions
Type / instance concept for centralized modifications
On-line Modifications

For internal use only / © 2007 SIEMENS AG

page 41 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

SFC: Editing of Sequential Controls Conforming to IEC 1131 (2)

Each SFC supports 16 different states/modes conforming to ISA S88

Idle - Starting - Run - Completing - Error(Completed) - Completed - Holding - Held -

Resuming - Error - Held(Error) - Resuming(Error) - Aborting - Aborted - Stopping -Stopped

Several sequences can be configured in one SFC chart (max. 8)

For different operating modes (e.g. heating/cooling)
For exception handling (e.g. holding, aborting, shutdown)
Triggering by process events or SFC states

Heating Condition for

Cooling Shutdown control strategy

Heating
Cooling

...
.
Shutdown
1 2 .... 8
Coordinated automatically by PCS 7
For internal use only / © 2007 SIEMENS AG
page 42 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

SFC: Type Instance Concept Highlights

Chart I/Os can be configured for SFC charts

- Inputs and outputs for controlling and monitoring status of the SFCs are available, additional inputs and outputs can
be configured for SFC types
- “Write“ statements in steps to outputs
- “Read“ transition conditions from inputs
- Configure Interface to SFCs just like standard chart I/Os (e.g. setpoint with limits)
- The SFC chart can be placed in the CFC chart like a block,
the SFC control block is not needed

New object: SFC type in the CFC

- In the SIMATIC Manager or SFC: Chart > New > SFC Type...
- Chart I/Os as described above
- Real type-instance concept
- Each placement in the CFC chart creates an instance: re-usability
- Changing the type changes all instances: central editing
- Test mode and SFC visualization also for instances
- General display driver block and block symbol for SFC instances are supplied

Easy integration of SIMATIC BATCH

- No interface blocks required
- SFC Coordination is handled automatically
- Equipment modules are created as SFC types which
- contain the sequential control, operating state logic, control strategies
- are connected directly to the process tags
- Better specifications and improved performance compared to PCS 7 V5.2

For internal use only / © 2007 SIEMENS AG

page 43 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

SFC: Type Instance Concept Block Interface
SFC Configure chart I/Os
(inputs/outputs/in/outs)

CFC

SFC operating states can be triggered

by interconnections (inputs)

SFC status can be determined from

interconnections (outputs)

For internal use only / © 2007 SIEMENS AG

page 44 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

SFC: Type Instance Concept Central Editing
Definition of the SFC type SFC instances in the CFC

Online visualization of
SFC Status SIMATIC BATCH
OS faceplate

For internal use only / © 2007 SIEMENS AG

page 45 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

All OS Functions Automatically Generated

Complete plant overview Alarm Summaries, symbols,

for the operator faceplates
Overview (n levels), User-friendly operator navigation
graphic level, key level Jump from group display directly to relevant
graphic
Display hierarchy Loop-in alarm
Hierarchical display organization (jump from alarm directly to graphic)
Acknowledgements from alarms directly in
Messaging and archiving system the graphic

For internal use only / © 2007 SIEMENS AG

page 46 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Downloading and Testing Changes Online

ES OS Simple online change

(also for non-redundant systems)

New measuring point

(Loop)
1 2 3 4 Selective download of redundant
ES servers allows online testing of
changes before complete system
update

Download server A, clients 1 and 2

A Test change to ensure that it is OK
OS server
B Download server B, clients 3 and 4

Alternative automatic download with

"MAKE" *)

*) see Engineering System

For internal use only / © 2007 SIEMENS AG
page 47 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

All OS Functions Automatically Generated

Automatic generation of symbols, faceplates, alarm and process

value archives

1 4

2
Anlage 1
3

Teilanlage 2

Technische
Einrichtung 3

Technische
Funktion 4

For internal use only / © 2007 SIEMENS AG

page 48 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Optimal Change Management "Copy & Modify”

Example: How can a plant section be cloned (copied) with minimum effort?

Plant_1 Plant_1
Reactor_1 Reactor_1
TIC10 Reactor_2
PIC11 TIC20
V17 PIC21
V27

Automatic AS-OS synchronization

Copy pictures and charts from Reactor_1 together
Easy editing of the copies
- Rename objects (Chart names)
- Configure hardware connections of new plant section

Compile OS: All references to Reactor_2

in the OS are automatically renamed
- Pictures (including dynamic links)
- Scripts
- Archive tags

For internal use only / © 2007 SIEMENS AG

page 49 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Libraries

Blocks in the PCS 7 library for ES

Basic blocks and AS
Diagnostic / communication blocks
Technological blocks
Block symbols +
Faceplates
Pre-engineered templates for process
automation
for OS
Integrated system response
Diagnostics
Alarms
Faceplates
Online help

For internal use only / © 2007 SIEMENS AG

page 50 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

Function Blocks Configuration of OS Symbols

One block type (e.g. motor) can have different symbolic representations in the OS station
depending upon the application
Mixer, pump, motor, compressor etc.
Alignment of the symbol (left, right, flipped etc.)
The assignment can be made for each instance
In the CFC (object properties block)
In the process object view

1 block type n symbols in the 1 faceplate to the

(e.g. motor) OS block type
(e.g. motor)
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Engineering System

Automatic Optimization of the Control Strategy

True order of the blocks and the sequence groups/charts are automatically optimized during
compiling based on the data flow through the program (optional)
Ensures that interconnected logic is executed in the correct order
A separate sequence group is automatically created for each new CFC chart
(with the same name)
All blocks of a chart are automatically inserted into the sequence group

CFCs SFCs

Block sequence

Optimized
by PCS 7

For internal use only / © 2007 SIEMENS AG

page 52 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Engineering System

“Make”

Overview of all configuration changes in the project

Execution per START command
HW Config (PCS 7 V6.0 SP3)
CFC
SFC
OS
SIMATIC BATCH
"Smart” compiling and downloading
of all changes in the correct order!
First make all changes, then compile and download all
changes in one step – throughout entire project!

Make

Better turnaround times since there is no wait between

the various engineering changes
For internal use only / © 2007 SIEMENS AG
page 53 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Using a Project Library

Project administrator: Project engineer:

Creates project library Works from one project library
Selects from standard block types / Easy to search for blocks and template
measuring point types or defines custom, charts
project-specific elements Configuration Management by ensuring
that only project standard elements are
Defines attributes of the blocks used in the application
Visible / hidden Makes version control of new block and
Default values template charts easy
Default alarm texts
Hides all other libraries in the GUI

For internal use only / © 2007 SIEMENS AG

page 54 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Faceplate Designer for Creating Custom Faceplates
Library
basic elements Creation and modification
of custom faceplates
Assistant creates the basic frame
Library with basic elements
Easy-to-use (Drag and Drop)
Easy-to-learn (Graphics Designer)
Assistant
Faceplate frame Faceplate

For internal use only / © 2007 SIEMENS AG

page 55 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Efficient Bulk-Engineering

CAD / CAE Standardized contol technological libraries with

Typical
Typical preassembled, tested blocks and charts (typicals)
Libraries
Libraries
Measurement, Import plant data (e.g. process tag list or I/O list)
controller, motor, valve, etc. from the higher-level CAD/CAE world
Import / Export Assistant
Automatic generation of controller
configuration based on the imported
process tag list and the typicals
TH
- Creation of the plant hierarchy
- Editing of saved process tag
OS Picture Hierarchy charts
Process
Object OS Pictures Automatic derivation of the OS picture
charts hierarchy, automatic interconnection of
blocks and placement in pictures

Operator
Controller System
Commissioning of individual Process Objects with the convenient
graphical tools CFC, SFC
Export of optimized parameters back to CAD/CAE world during
commissioning (documentation of „As-built“)
For internal use only / © 2007 SIEMENS AG
page 56 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Import / Export Assistant

Automatically generates plant

Template chart hierarchy and controller configuration
+
Imported measuring point lists Automatically configures instance-
specific parameters and inter-
connects measuring point charts to
I/O, SFCs etc

Import/Export
Assistant
+
PH assign. Chart name PV_LR PV_LR KP TN TV
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
B17/Reac3 FIC3210 0 250 1.5 10 2.0

For internal use only / © 2007 SIEMENS AG

page 57 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Exchange of CAx Data

Improve the Engineering Workflow :

XML Data Exchange

Basic Engineering Detail Engineering

Mapping Object Model (optional)

Import Export Interface

PCS 7 Object model XML

+ IEA functions Im-/
Export

Import Export Command

• Compare • Filter Interface
• Consistency check
• Merge
Plant Hierarchy
Net and Hardware configuration
Signal names
Blocks
CFC/SFC
Libraries
Alarms
For internal use only / © 2007 SIEMENS AG
page 58 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Exchange of CAx Data
WHAT WHERE FORMAT
Tags and Charts Import/Export Assistant CSV

Tag types Import/Export Assistant CSV

Templates Import/Export Assistant CSV

Hardware Configuration HW config CFG (ASCII)

Operation relevant texts SIMATIC Manager TXT or CSV

Tag Types and - Instances VXM & Simatic Manager XML

Technological Hierarchy VXM & Simatic Manager XML

Global Declarations VXM & Simatic Manager XML

For internal use only / © 2007 SIEMENS AG

page 59 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Exchange of CAx Data

Exchange of hardware
information between planning
tool and DCS engineering
Exchange of process object
identifiers
Adoption of tag attributes
Adoption of the plant model
(technological hierarchy)

For internal use only / © 2007 SIEMENS AG

page 60 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Export CAx Data in XML Format (1)

1. Selection of Export Filters CAx

For internal use only / © 2007 SIEMENS AG

page 61 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Export CAx Data in XML Format (2)

2. Start of Export Procedure

For internal use only / © 2007 SIEMENS AG

page 62 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Import CAx Data in XML Format (1)

1. Open the target Project in VXM

For internal use only / © 2007 SIEMENS AG

page 63 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Import CAx Data in XML Format (2)

2. Start Object Import Procedure

For internal use only / © 2007 SIEMENS AG

page 64 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

MultiUser Engineering

Multiproject Concurrent Engineering

for off-line parallel engineering for parallel engineering on-line

...
Coordination
with PCS 7 ES
ES
... ES ES

...
Data AS Data OS Data AS/OS
local local local
Data AS/OS

Multi Project with checking out and checking in for engineering tasks, which must be
done off-line
Concurrent Engineering for on-line parallel working with one central project database
For internal use only / © 2007 SIEMENS AG
page 65 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

MultiUser Engineering

Multiproject A large plant can be divided into separate

(sub)projects to allow multiple engineers to
... work on it at the same time
Granular to the level of at least 1 AS or 1 OS
for each project
Coordination
High performance since the individual projects
with PCS 7 ES
are stored and processed locally on ES
stations

...
Data AS Data OS Data AS/OS
local local local

Parallel processing of projects

Local separate processing of projects using branch and merge
Cross-project functions (AS-AS communication, OS compiling) are supported by the
multiproject
For internal use only / © 2007 SIEMENS AG
page 66 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Allows a Team of Engineers to Work Together Effectively

Engineering Server

Plant (multiproject)

Project 1 Project 3 ... Project n

Engineering Station 1 Engineering Station 2 Engineering Station n

Project 2 in Project 4 in ... Project x in

work work work

For internal use only / © 2007 SIEMENS AG

page 67 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Concurrent Engineering
Concurrent Engineering A Parallel data access is prompted to the user
for parallel engineering on-line Which application
Which workstation
Which user

ES
... ES ES

Data AS/OS
Concurrent working on CFC or SFC charts
One CFC chart can be opened by different user
Project is located on one station and opened via network
System assures data-consistency
Continuous work even during compile and download
For internal use only / © 2007 SIEMENS AG
page 68 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Concurrent Engineering: Licence Handling use case 1
Each workstations has locally own licences

PCS 7 ES
PCS 7 ES licences licencesPCS 7 AS RT floating

For internal use only / © 2007 SIEMENS AG

page 69 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Concurrent Engineering: Licence Handling use case 2
All ES Licences installed on the data server
(access via network)

n x PCS 7 ES floating
1 x PCS 7 AS RT float.

For internal use only / © 2007 SIEMENS AG

page 70 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Concurrent Engineering: Licence Handling use case 3
Each workstation uses a locally installed ES licence
Each workstation has locally installed process objects

PCS 7 ES licences
PCS 7 ES licences
PCS 7 AS RT
PCS 7 AS RT

For internal use only / © 2007 SIEMENS AG

page 71 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

PID – Tuner

Free and integrated component of ES software

Optimization of different controller types

For internal use only / © 2007 SIEMENS AG

page 72 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

PID – Tuner

Comparison of measurement and process model

For internal use only / © 2007 SIEMENS AG

page 73 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

PID – Tuner

„Modellfit“: Value for the quality of the simulated model

Calculated process parameter
Save and read of control parameter

For internal use only / © 2007 SIEMENS AG

page 74 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Version Cross Manager (VXM)

PCS 7
VXM

+ -
CFC charts CFC charts
SFC charts SFC charts
Block types Block types
Signals Signals
Run sequence Run sequence
….. …..
Program a Program b

Tool for comparing and displaying differences between two versions of an AS or ES program
Highlights what is new, missing or different between the two versions
Results are shown in tree / tabular format
Fast determination of differences with hierarchical "branching" and color high-lighting of the difference
A tool that is useful for the smallest applications and for large plants
Print and/or save the results in CSV format

For internal use only / © 2007 SIEMENS AG

page 75 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Version Cross Manager (VXM)

List of changes since last download

Automatic creation of XML comparison file with each download
Presentation of listed changes before download

For internal use only / © 2007 SIEMENS AG

page 76 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Version Cross Manager (VXM)

Comparison of projects or project archives with filter functions for :

Chartfolder
SFC, SFC-Typ, CFC
S7-Program
Project
Library
Symbol-Table
Global Declarations
Data Blocks
Function
Function Blocks
Block Folder Offline
SIMATIC 400- / 300- / H-Station
SIMATIC PC-Station

For internal use only / © 2007 SIEMENS AG

page 77 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Engineering System

Audit Trail – Downloading to AS

For internal use only / © 2007 SIEMENS AG

page 78 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Central Parameterization of Field Devices using PDM

Central parameterization, diagnostics and loop check of intelligent field devices (PROFIBUS DP, PA
or HART) with the tool Process Device Manager (PDM)
More than 1000 field devices from 50 manufacturers pre-integrated in the database
Simple integration of new devices in PDM using Electronic Device Description
(EDD - ASCI file)
Integrated in PCS 7, but can also be used stand-alone (e.g. on the workbench with direct connection
to the field device)

For internal use only / © 2007 SIEMENS AG

page 79 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Connection Points

Engineering Operator Station Maintenance Station

Station ES

Ethernet
.... .... ....
S7- 400H S7- 400 S7- 400 PROFIBUS DP 45,45 kBit/s

PROFIBUS PA

PROFIBUS DP redundant PROFIBUS DP

DP/PA Link ET 200M ET 200iSP HART-Multiplexer /

Interface

PROFIBUS PA

RS232/
RS485

Possible Any device with any

SIMATIC PDM communication type
on the work bench
connecting point
For internal use only / © 2007 SIEMENS AG
page 80 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Integration into the System

GSD files contain the communication parameters

EDD files contain the device parameters and visualization structure and describe the
device behavior
PROFIBUS Field Device
Configurator Parameterization / Diagnostics

ES

SPS

PROFIBUS DP PROFIBUS PA

EDD GSD
For internal use only / © 2007 SIEMENS AG
page 81 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
The EDD - versatile Source of Information
Engineering Commissioning
Configuration of networks, Address
gateways assignment
and remote I/Os Measured value
Export / import of device display
data Simulation
Upload / Download Calibration, adjustment
Parameterization Online parameterization
Comparison of Values Device detection via lifelist
User profiles
For maintenance staff with limited
access to device parameters Operating phase
For specialists with full access to Display device status and diagnostic
device parameters information
Support device replacement
For device-specific user profiles Check device identification
Help and documentation
Overview of:
Variables, dialogs, methods
Ranges of values, default values, units Asset Management
Prepare information for maintenance,
Catalog and E-commerce repair and fault elimination
Ordering data
Process connection
Manufacturer
information

For internal use only / © 2007 SIEMENS AG

page 82 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Simple Device Integration

EDD from CD, DVD or Internet and without PC reboot

textual descriptions (EDD)

operation system-independent
pure import

For internal use only / © 2007 SIEMENS AG

page 83 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Views
Process devices plant view
Hardware configuration
of the plant

Parameter view of
the device

Parameter view
Process devices network view

Example: Sitrans
T3K
LifeList - Autosenses status of all
devices
Online views

For internal use only / © 2007 SIEMENS AG

page 84 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
LifeList

Ideal for commissioning, service and maintenance

Update diagnostic status Profile revision

Detail diagnostics

Diagnostic status

For PROFIBUS (DP/PA) – Networks, including sub-networks

Integrated in PCS 7 for PROFIBUS PA
For HART - modem
Field devices can be parameterized from the LifeList
For internal use only / © 2007 SIEMENS AG
page 85 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Parameter View (Single device)

Online - Dialog

Update diagnostic status

Upload / download of
parameters Only readable

Read- and writeable

Grouping of device
parameters

For internal use only / © 2007 SIEMENS AG

page 86 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Parameter View (Multi View)

PROFIBUS DP Net work

Remote I/O ET 200M
Analog modul (HART)

HART – Field device

DP/PA – Link device

PROFIBUS PA Field
device

Grouping of
device parameters

PROFIBUS DP
Field devices

For internal use only / © 2007 SIEMENS AG

page 87 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Value Comparison

Identification of local changes

Difference to
Project data

Data in the Data in the

Project field device

Comparison of offline data with the online data in the device

For internal use only / © 2007 SIEMENS AG
page 88 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Document Manager

Document Manager – assign all relevant documents to the device

For internal use only / © 2007 SIEMENS AG
page 89 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Import and Export

XML is the universal interface for import and export

Access to office environment
Tool for conversion to csv file
(Excel) is included on the PDM CD
Export with HTML – display
information (View e. g. with MS
Internet Explorer)

It is possible to export:
Lifelist
Projects
Net works
Stations
Field devices (Parameters)
Audit trail protocol
Calibration Protocols (Check
protocol)
For internal use only / © 2007 SIEMENS AG
page 90 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Standard Diagnostic Symbols

Status / diagnostic symbols for each device

Checked Diagnostic information
Communication error - Described in the Electronic Device
Description EDD of the device (provided
Configuration error
by manufacturer)
Error - Encoded in the quality code of the field
Process error devices

Maintenance required
Diagnostic symbols are
Warning: Maintenance required displayed in all views
- Process devices plant view
Simulation Mode
- LifeList
OK
- Process devices network view
Communication OK
- Parameter view of the field devices
Device has no diagnostics
Device passive or not configured

For internal use only / © 2007 SIEMENS AG

page 91 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PDM
Diagnostics Information from the “Quality Code" (Compare PA, HART, I/O)
Alarm text PA Profile HART RIO Conv.
Good X X X X
Good, configuration change in progress X X
Good, active warning X
Good, active alarm X
Good, unknown configuration change X X
Good, unknown warning X
Good, unknown alarm X
Good, device in failsafe position X
Good, maintenance requirement X X
Good, initialization confirmation X
Good, initialization requirement X
Good, incorrect value selected X
Good, local operation X X
Uncertain, not specified X X
Uncertain, last valid value X
Uncertain, replacement value X X
Uncertain, initial value X
Uncertain, measured value formation incorrect X
Uncertain, value outside defined range X
Uncertain, signal source uncertain X
Uncertain, configuration error X
Uncertain, measured value simulated X X
Uncertain, sensor calibration X
Bad, not specified X
Bad, configuration error X
Bad, not connected X
Bad, device error X X
Bad, sensor error X
Bad, no connection – last valid value X
Bad, no connection – no valid value X
Bad, device out of service X X X X

For internal use only / © 2007 SIEMENS AG

page 92 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Advanced Process Control

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7 Library

Advanced Process Control

Embedded multivariable Model Predictive Control

(MPC) in AS for up to 4 process variables

PID gain scheduling (automatic parameter adjustment)

Control Performance Monitoring (Siemens Patent)

For internal use only / © 2007 SIEMENS AG

page 94 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Library

APC Tools embedded in PCS 7
APC OS Faceplates
APC Engineering Tool

OS Clients
Engineering
Station ES
Fast Ethernet

APC Runtime
OS-Server
Function Blocks (redundant)

Automation
System (AS)

Easy to use (no APC experts needed)

Sufficient for many applications
For internal use only / © 2007 SIEMENS AG
page 95 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Library

Model Predictive Control

Design and implementation

Insert new FB into CFC
Plant test
MPC design
Insert model into FB

It is possible without a PhD

For internal use only / © 2007 SIEMENS AG

page 96 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Library

Control Performance Monitoring

Automatic monitoring of control

performance and control deviation

Control Performance Monitoring is

Siemens Patent

Simple to commissioning

Limit view

Standard view

Parameter view

Control view
For internal use only / © 2007 SIEMENS AG
page 97 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Library

Gain Scheduling
e.g. PidConL
Used in non-linear controlled systems
Set the controller parameters variably
Set the controller parameters dependent
on working point.

e.g. PidConL
Parameter view

Standard view

Standard view
For internal use only / © 2007 SIEMENS AG
page 98 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Automation System

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Automation System
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 100 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

Controllers built by SIMATIC, Worldwide Market Leader

Robust components from SIMATIC, the worldwide market leader

Fanless operation up to 60°C
Hot Swap modules during runtime operation
Comprehensive configuration
Convenient, graphical high-level languages (CFC, SFC)
Standard programming languages (e.g. SCL, Ladder Logic)
Scalable performance and function
Standard: AS414, AS416, AS417
Failsafe (F) and fault-tolerant (H): AS412H/F, AS414H/F, 417H/F
Changes can be made during runtime operation
User program
I/O configuration

AS 414-3 AS 416-2 AS 417-4

AS 412H
AS 414H AS 416-3 AS 417H
Digital-Input 50 200 800 2000
Typical controller capacity Digital-Ouput 25 100 300 1000
(sample project) Analog-Input 20 80 250 800
Analog-Output 10 40 110 400
For internal use only / © 2007 SIEMENS AG
page 101 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Automation System

Standard-CPUs

CPU 414
The CPUs for special demands in the mid performance range
Can be used in systems with additional requirements with respect to
program scope and command processing rate
With one slot for IF modules (CPU 414-3, CPU 414-3 PN/DP)

CPU 416
The powerful CPU for the high-end performance range
For installations with the de manding requirements of the high-end performance range
With one slot for IF module(CPU 416-3, CPU 416-3 PN/DP)

CPU 417
The most powerful SIMATIC S7-400 CPU
Can be used in the most soph isticated installations in the upper performance range
With two slots for IF modules

For internal use only / © 2007 SIEMENS AG

page 102 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

Interfaces (Standard-CPUs)
414-3 416-2

Periphery Periphery
2 PROFIBUS DP onboard 2 PROFIBUS DP onboard
1 PROFIBUS DP pluggable

416-3 417-4

Periphery Periphery
2 PROFIBUS DP onboard 2 PROFIBUS DP onboard
1 PROFIBUS DP pluggable 2 PROFIBUS DP pluggable

Support for data record routing

For internal use only / © 2007 SIEMENS AG
page 103 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

Interfaces (PN-CPUs)

414-3PN

Periphery
1 PROFIBUS DP onboard
1 PROFIBUS DP pluggable
Industrial Ethernet
2 ports (switch)
Profinet is not supported by PCS 7
today. The PN interface is used for
416-3PN plant bus connection (Industrial
Ehernet).

Periphery interface
1 PROFIBUS DP onboard
1 PROFIBUS DP pluggable
Industrial Ethernet
2 ports (switch)
Support for data record routing
For internal use only / © 2007 SIEMENS AG
page 104 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

High-Available CPUs

Using of high-available CPUs to

avoid high restart costs following a fault
prevent expensive downtimes
facilitate operation without monitoring or
maintenance personnel

3 different CPU types

With 2 integrated PROFIBUS DP-Master interfaces
With 2 slots for Sync-Module
Can be used with F-runtime lic ense and F-compatible CPU in failsafe
S7-400F/FH systems

CPU 412-3H
CPU 414-4H
CPU 417-4H
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Automation System

Interfaces (High-Available CPUs)
412-3 H/F

* Onboard PROFIBUS DP is
restricted. No subsystem
like PA or HART is possible.
Periphery External DP-CPs supports
1 PROFIBUS DP onboard* data record routing.
Redundancy
2 sync modules

414-4H/F 417-4H/F

Periphery Periphery
2 PROFIBUS DP onboard* 2 PROFIBUS DP onboard*
Redundancy Redundancy
2 sync modules 2 sync modules
For internal use only / © 2007 SIEMENS AG
page 106 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

Memory, Performance, Quantity Framework (Standard CPUs – 1)

CPU 412-1 CPU 412-2 CPU 414-2 CPU 414-3 CPU 414-3
PN/DP

Working memory 2x 144 kB 2x 256 kB 2x 512 kB 2x 1,4 MB

Load memory 512 kB

CPU/processing times min. 0,075 µs min. 0,045 µs

FB / FC 750/750 1.500/1.500 3.000/3.000

DB 1.500 3.000 6.000

Flags/Clock memories 4 kByte 8 kByte

Timers/counters 2.048 2.048

Address areas I/O (Byte) 4 k / 4k 8 k /8 k

Digital channels I/O 32.768 / 32.768 65.536 / 65.536

Analog channels I/O 2048 / 2048 4.096 / 4.096

Number of FMs limited by the number of slots and by the number of connections

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; incl. CP 443-5 Extended and IM 467

Communication interfaces X1: MPI X1: MPI X1: MPI X1: MPI X1: MPI
X2: DP X2: DP X2: DP X3: DP (pluggable)
X3: DP (pluggable) X5: PN (2Ports)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

Memory, Performance, Quantity Framework (Standard CPUs – 2)

CPU 416-2 CPU 416-3 CPU 416-3 PN/DP CPU 417-4

Working memory 2x 2,8 MB 2x 5,6 MB 1x 15 MB

Load memory 1 MB

CPU/processing times 0,03 µs 0,018 µs

FB / FC 5.000/5.000 8.000/8.000

DB 10.000 16.000

Flags/Clock memories 16 kByte 16 kByte

Timers/counters 2.048 2.048

Address areas I/O (Byte) 16 k / 16 k 16 k / 16 k

Digital channels I/O 131.072 131.072

Analog channels I/O 8.192 8.192

Number of FMs limited by the number of slots and by the number of connections

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; incl. CP 443-5 Extended and IM 467

Communication interfaces X1: MPI X1: MPI X1: MPI X1: MPI
X2: DP X2: DP X3: DP (pluggable) X5: X2: DP
X3: DP (pluggable) PN (2 Ports) X3: DP (pluggable) X4:
DP (pluggable)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

Memory, Performance, Quantity Framework (Standard CPUs – 3)

CPU 412-3H CPU 414-4H CPU 417-4H

Working memory 512/256 kB 2x 1,4 MB 2x 15 MB

CPU/processing times min. 0,075 µs min. 0,045 µs 0,018 µs

FB / FC 3000 3000 8000

DB 6000 6000 16000

Flags/Clock memories 8 kByte 8 kByte 16 kByte

Timers/counters 2.048 2.048 2.048

Address areas I/O (Byte) 8 k/8 k 8 k /8 k 16 k / 16 k

Digital channels I/O 65.536 / 65.536 65.536 / 65.536 131.072 / 131.072

Analog channels I/O 4.096 / 4.096 4.096 / 4.096 8.192 / 8.192

Number of FMs limited by the number of slots and by the number of connections

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; inkl. CP 443-5 Extended und IM 467

Communication interfaces X1: MPI X1: MPI X1: MPI

X2: DP X2: DP

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

AS Bundles for Standard Controller

AS bundles – preconfigured, assembled and tested,

CPU CP; Ind.
consisting of: Power supply
opt. redundant Ethernet

Central Processing Units (CPU)

S7 414-3, S7 416-2, S7 416-3, S7 417-4 with integrated Expandable
PROFIBUS-DP Interface storage

Storage capacity 2,8 MB to 30 MB

Variable Scan Rate ( 10 ms up to 5 s)
Up to 1000 PID controllers in a single CPU (Scan rate: 1 s)

Power supply Integrated

Options: 24 VDC, 120 VAC, 230 VAC PROFIBUS DP
interfaces

Communication processor (CP) for Industrial Ethernet

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

Communication Processors (CP)

S7-400 communication Processors are used for data exchange by means of point-to-
point connection, PROFIBUS DP and Industrial Ethernet

PS CPU CP 441-1 CP 443-5 CP 443-1

ext

Industrial Ethernet

PROFIBUS DP

point-to-point connection

Module spectrum:
CP 443-1 CP for connection via Industrial Ethernet
CP 443-5 ext CP for connection via PROFIBUS DP
CP 441-1 CP for point-to-point connection

For internal use only / © 2007 SIEMENS AG

page 111 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

Load Analysis
Controller load analysis
Overview
- total time and spares
- used time for application
For each used task (OB3x, OB8x)
- used time slice
- Spares
- maximum and minimum over a period
Alarm when controller load higher
as configured limit

Enhanced diagnostics
Redundancy state
- for terminal bus
- for plant bus (AS-OS connections)
Redundant I/O on channel basis
“hit list” of asset alarms
Asset comment consistent from asset to HMI

Ease-of-integration of „non-intelligent“ assets into Plant Asset Management System

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Automation System

Configuration Changes during Runtime Operation

Configuration changes during runtime operation (CiR)

For all standard automation systems S7-400
AS 41x
AS 414-3, 416-2, 416-3, 417-4,
AS 412-1H, 414-4-1H, 417-4-1H
For failsafe systems S7-400F ET200M HF
AS 412F, 414F, 417F

PROFIBUS DP
ET200S

Online changes for distributed process I/O

ET 200M and ET200iSP SIMOCODE ET200iSP
Adding new stations (Racks or I/O)
Adding new I/O modules to a rack PROFIBUS PA
Configuring I/O channel parameters
PROFIBUS DP/PA
Adding new field devices
Configuration of intelligent PA devices
ET 200S
Adding new stations
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Automation System

Scalable Availability

Standard System
single power supply double power supply double power supply
single system bus single system bus double system bus
single controller single controller single controller

H System
double power supply quad power supply quad power supply
double system bus double system bus quad system bus
double controller double controller double controller

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

High-Available Controller AS 412H / AS 414H / AS 417H

Entry level with CPU 412H

768 kB RAM
Mid level with CPU 414H
2,8 MB RAM
High-end with CPU 417H
30 MB RAM

Fiber optic connection for

synchronization
Expandable
Shared rack
Separated rack for
distances up to 10 km
(to maximize availability
and minimize common-
cause failure)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

High-Available Controller: Automatic Event Synchronization
Possible Synchronization procedures:
Cycle Time Event Command
synchronization synchronization Synchronization synchronization

CPU B
CPU A
CPU A

CPU B

CPU A

CPU B
CPU B
CPU A

SIMATIC S7-400H
Guarantees bumpless switchover
Fast switchover time (typically 30ms)
No loss of information
No loss of alarms
Resumes processing of program where it left off
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Automation System

High-Available Controller: Automatic Event Synchronization

Definition: (Siemens patent)

Event
Synchronization whenever the two redundant CPUs Synchronization
could end up with different results during execution
of the program.

Automatic operating system function

CPU A

CPU B
Synchronized events:
Updating of the process image
Direct access to the I/O
Interrupts, alarms
Updating of the timer SIMATIC S7-400H
Changes to data through
communication functions
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Automation System

High-Available Controller: Central Controller Configurations

Compact with rack UR2-H

(splitted backplane bus)

Distributed with
two standard racks

10 km

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

High-Available Controllers: Connecting Switched Periphery

Redundant IM 153-2

AS 41x HF

ET200M H/F
Redundant PROFIBUS DP

(Standard & F-Modules)

L+ ET 200M
ET200iSP L+ with active backplane bus
Special bus module (BM)
IM
Y-Link
Active
SIMOCODE backplane bus
IM

PROFIBUS PA

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

High-Available Controllers: FW Update

Improved FW Update for redundant systems:

Error correction during operation

1. CPU Update
Flash Card or
New via Ethernet
2. Switch Over Automatic
New

3. CPU Update Change Over

4. Coupling

As simple as modification during operation

For internal use only / © 2007 SIEMENS AG
page 120 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Automation System

Use Case Optimized Controller

S7 400 H-CPU
- Failsafe applications
- Safety applications
- Redundant communication
- up to large projects

S7 400 Standard-CPU
- Universal applicable -> any project size
- High availability
- High performance

AS RTX
- Highest performance
- Small applications -> many small controller

BOX 416 / BOX RTX

- Compact DCS
- Small isolated applications
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Automation System

Overview AS

Availability Expandability
Modular
Redundancy

Depend on PC Not expandable

Scalability Performance
balanced data Highest performance

Big memory, low periphery High performance

less communication

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Automation System

Overview AS

Availability Expandability
S7 400 CPU – more than 1200 DP-slaves,
S7 400 H-CPU – Redundancy additional interfaces
(modular assembly)
S7 400 Std-CPU – modular assembly,
red. Power supply BOX RTX – up to 250 DP-slaves
(with second CP5613)
BOX 416 PCI – PC independent,
400 based controller BOX 416 – up to 157 DP-salves
(one free slot)
BOX and AS RTX – Controller depends on PC
AS RTX – up to 64 DP-slaves

Scalability Performance
BOX and AS RTX – very fast controller,
S7 400 CPU – balanced memory, periphery depends on PC
and communication
S7 400 Std-CPU – speed graduate controller
BOX 416 PCI – like S7 400 CPU firmware V4 from low to high performance

BOX and AS RTX – big memory, low periphery S7 400 H-CPU – a little bit slower
and less communication than Std-CPU

BOX 416 PCI – like S7 400 CPU firmware V4

For internal use only / © 2007 SIEMENS AG
page 123 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
PC Based Automation

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
PC Based Automation
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 125 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PCS Based Automation

PCS 7 Box and AS RTX
PCS 7 BOX 416
Scalability
Small Entry Price for PCS 7
System Tested
Preinstalled and PCS 7 BOX RTX WinAC Slot CPU (Hardware)
Ready to use

WinAC RTX (Soft-CPU)

SIMATC PCS 7 AS RTX

WinAC RTX (Soft-CPU)

For internal use only / © 2007 SIEMENS AG

page 126 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 Box 416 / RTX
PCS 7 BOX RTX PCS 7 BOX 416

WinAC RTX (Soft-CPU) WinAC Slot CPU (Hardware)

Monitor
PCS 7 BOX 416 or RTX Keyboard OS OS ES

The all inclusive offer ...

Operator-/Engineering-Station ...
Ethernet
Hardware- or Soft-Controller
...
Profibus and Ethernet Interfaces
Same I/O as AS41x
MS-SQL-based Archive system PROFIBUS

SIMATIC BATCH

For internal use only / © 2007 SIEMENS AG

page 127 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 BOX PC 627B Features

High system performance for demanding computing and visualization tasks

- Intel ® processors: Core® 2 Duo
- Intel ® chipset: 945GM Express + ICH7R
- Intel ® graphics media accelerator GMA950
- DDR2 667 memory technology up to 4 GB

Fast and flexible data communication

- SATA hard disks
- 4 high-speed USB 2.0 ports
- 2 LAN 10/100/1000 MBit/s connections (Gigabit LAN)

High system availability and service-friendly device design

- 2 CF drives option
- 2x 7-segment display, 2 signaling LEDs freely programmable

Long-term stable platform (with embedded Intel components)

Integrated in SIMATIC PC-based automation and TIA

- PROFIBUS interface
- SIMATIC HW/SW system-tested

Compact control cabinet PC for high-performance

measuring/control and operating & monitoring tasks
For internal use only / © 2007 SIEMENS AG
page 128 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC WinAC Slot V4.0

BOX 416 based on WinAC Slot CPU 416 V4.0

Performance optimization compared to WinAC
Slot CPU V3.4
Only 1 PCI Slot is needed inside the BOX PC
(Using of Multi Monitor Graphic Card possible)
Configuration in Run (CIR) since PCS 7 V7.0
Controller independent from PC status thanks
to external 24 V power supply
Data retentivity thanks to backup battery
2 PROFIBUS DP interfaces on board

For internal use only / © 2007 SIEMENS AG

page 129 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC PCS 7 BOX 416

BOX 416 based on WinAC Slot CPU 416 V4.0

Performance optimization compared to
WinAC Slot CPU V3.4
Only 1 PCI Slot is needed inside the BOX PC
(Using of Multi Monitor Graphic Card possible)
Configuration in Run (CIR)
since PCS 7 V7.0
Memory 1,6 MB Code
1,6 MB Data
Processing Speed

Bit operations At least 0,04 µs

Word operations At least 0,04 µs
Fixe-point operations At least 0,04 µs
Floating-point operations At least 0,12µs
Times / Counter
S7-Cycles / S7-Counter 2048 / 2048
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 PC Based Automation

SIMATIC WinAC Slot V4.0

Controller is Windows-independent
Controller independent from PC status thanks
to external 24 V power supply
Instruction set and performance equivalent to
those of the powerful S7-400 CPUs
Data retentivity thanks to backup battery
Two DP interfaces on board

For higher availability of the PC solution

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 PC Based Automation

SIMATIC WinAC Slot V4.0

Memory Card slot

(RAM / Flash)
Stop/RUN LED

RUN button

Backup battery for user

memory
MPI/DP Interface
(external)

Profibus-DP
interface External 24 V
power supply
new
24V plug

For internal use only / © 2007 SIEMENS AG

page 132 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC WinAC RTX: CPU Panel and Tuning

BOX RTX based on WinAC RTX Software CPU

Pre Configured RTX CPU for PCS 7
Communication via CP 5613
Very fast program execution
I/O connection using
PROFIBUS-DP modules
CP 5611 and CP 5613
For applications with requirements on
deterministic and real-time behavior
Based on Standard Windows XP/
2000 Pro and Real Time eXtension
from Ardence
Low PC load consumption

For internal use only / © 2007 SIEMENS AG

page 133 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC WinAC RTX: Showing the Diagnostic Buffer

For internal use only / © 2007 SIEMENS AG

page 134 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 Box RTX vs. PCS 7 Box 416

PCS 7 BOX RTX PCS 7 BOX 416

WIN AC RTX (Soft-CPU) WIN AC Slot CPU (Hardware)

Very fast Program execution Higher Availability

Quantity structure like Quantity structure like
414 AS System 416 AS System
Smaller Price as CIR (Configuration in Run)
PCS 7 BOX 416

For internal use only / © 2007 SIEMENS AG

page 135 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 Box RTX vs. PCS 7 Box 416

PCS 7 BOX RTX PCS 7 BOX 416

WIN AC RTX (Soft-CPU) WIN AC Slot CPU (Hardware)

Available in 2 Bundles Available in 4 Bundles

for PCS 7 V7.0 + SP1 2 for PCS 7 V7.0 + SP1 and
1 x SIMATIC PCS 7 BOX RTX 2 for PCS 7 V6.1 + SP1
Complete (Runtime & Engineering) 1 x SIMATIC PCS 7 BOX RTX
1 x SIMATIC PCS 7 BOX RTX Runtime Complete (Runtime & Engineering)
1 x SIMATIC PCS 7 BOX RTX Runtime

For internal use only / © 2007 SIEMENS AG

page 136 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

BOX PC 627B: Based on Intel® Core 2 Duo Technology

SIMATIC Box PC 627B:

Maximum performance
in minimum space -
with the Intel® Core 2 Duo technology

Rugged, compact industrial PC for machine-level applications

Maximum computing power in minimum space
Space-saving realization of fast measuring, open- and closed-loop control and HMI tasks
Maximum computing power (Core 2 Duo Performance)
Integrated GB LAN or PROFIBUS interfaces save slots
Easy migration for existing customers thanks to installation,
interface and function compatibility
The main characteristics “performance” and “compactness” are further
strengthened by new features
For internal use only / © 2007 SIEMENS AG
page 137 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

BOX PC 627B: Performance Improvement
Benchmark tests Sysmark 2004 SE V1.0 (official run under Win XP)

78%
128%

Box PC 627 Box PC 840 V2 Box PC 627B /

827B
For internal use only / © 2007 SIEMENS AG
page 138 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

BOX PC 627 vs. PCS 7 BOX PC 627B

BOX 627 BOX 627B

Motherboard SIEMENS SIEMENS

Chipset Intel 915GM, FSB 533/400 MHz Intel 945GM, FSB 667/533 MHz

Processor Pentium M 760 2.0 GHz, 533 FSB, 2MB L2 Cache Core 2 Duo, T7400 2,16 GHz, 667 MHz FSB,
4MB L2 Cache
RAM Max. 2 GByte, DDR2 533 DDR 2 533 Max. 2 GByte, DDR2 677 SDRAM

Graphic on board, Intel GMA 915 on board, Intel GMA 950

128MB, Dynamic Video Memory 128MB, Dynamic Video Memory
Harddisk 1 x 80 GB SATA 1 x 160 GB SATA

Internal Interfaces 2 x PCI (265/175 mm) 2 x PCI (265/175 mm)

Drives CD-RW/DVD Combo DVD +/- RW

External Interfaces 4 x USB 2.0 4 x USB 2.0

1 x COM /9-pole 1 x COM/9-pole
Monitor DVI-I DVI-I

Ethernet 2 x 10/100 MBit/s, RJ45 2 x 10/100/1000 MBit/s, RJ 45,

VIA VT 6105 Chipset Intel 82573L Chipset

Profibus/MPI Onboard / 5611 Chipset Onboard / CP5611 Chipset

DIAG Monitor V2.2 pre installed in the PCS 7 BOX Systems V3.0 pre installed in the PCS 7 BOX Systems

For internal use only / © 2007 SIEMENS AG

page 139 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC PCS 7 AS RTX

For internal use only / © 2007 SIEMENS AG

page 140 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC PCS 7 AS RTX

Based on the NEW

OS OS ES MICROBOX 427B
...
Positioning as AS System based on
PC Technology with WinAC
PCS 7 AS RTX
... Software CPU
Ethernet
No connecting from Monitor,
Keyboard or Mouse necessary
Pre installed System for using in
PCS 7
PCS 7 BOX Systems
Connection to the PCS 7 Plantbus
PROFIBUS
Download and Configuration from
the ES System
PC Hardware diagnostics via
ASSET Management & DIAG
Monitor
I/O connection via PROFIBUS DP
(12 Mbit/s) over the SIMATIC PC's
integrated PB interface
For internal use only / © 2007 SIEMENS AG
page 141 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 AS RTX: Connection of PROFIBUS I/O
Ardence RTX

WinAC RTX WinAC RTX uses the integrated

PROFIBUS interface for DP IO from the
Microbox 427B:
An Ardence RTX driver used for
the CPs
Exclusive control of the CP by WinAC
CP 5611
RTX
Exclusive assignment to WinAC RTX

CP 5611,
Integrated DP Interface
64 Slaves
DPV0, DPV1
8 S7-connections, of that
> 1 PG
< 8 S7-connections

For internal use only / © 2007 SIEMENS AG

page 142 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 AS RTX: Front Side Overview

Mounting options:
Standard rail mounting Drive:
Portrait assembly with option 2 GB CompactFlash
mounting kit

Service-friendly Interface
full-metal enclosure labeling

Operation 2 x status LED freely

Watchdog
display programmable

For internal use only / © 2007 SIEMENS AG

page 143 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

PCS 7 AS RTX: Rear Side Overview (bottom/top)
Openings for 4 x USB2.0 2 x Ethernet connection
the device‘s interfaces for 10/100/1000 Mbit/s
heat dissipation

DVI-I COM1: serial

connection interface 1

DC power Reset button accessible PROFIBUS: 12Mbit/sec

supply from the outside

CompactFlash
(accessible from
the outside)

For internal use only / © 2007 SIEMENS AG

page 144 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Product Highlights
System availability and High investment protection
service friendliness Long-term available platform with Intel
Zero-maintenance operation Embedded components: marketing of at least
SIMATIC PC CompactFlash 2.5 years
2 x user LED on the front In-house PC development and production
(incl. motherboard and BIOS)
Spare parts availability of 5 years

High industrial functionality

and flexibility
Manifold industrial interfaces
Ultra-compact dimensions High industrial standard
Fast commissioning
Component replacement with Ultra compact, rugged full-metal
the device installed enclosure
Fan-free up to 55°C (with
CompactFlash)
For internal use only / © 2007 SIEMENS AG
page 145 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: High Performance and Maximum
Compactness

Ultra-compactness and high-performance for

machine-level installation through ...

Ultra-compact enclosure volume of 1.7

liters
Pentium M technology 1.4 GHz
DDR2 memory technology, 1 GByte
Industrial power supply already integrated
in the enclosure

Excellent volume/performance ratio for

space- and cost-saving machine-level installation
For internal use only / © 2007 SIEMENS AG
page 146 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Shock and Vibration Resistance

Suitable for high vibration and shock loads during

operation through ...

Full-metal enclosure for high mechanical

ruggedness (image 1)
(vibration/shock: 1 g / 15 g)
Image 1
and EMC compatibility
(CE approval for residential and industrial
applications)

Strain relief, e.g. for USB interface thanks to

enclosed cable clamp (image 2)
Image 2

Reliable 24-h continuous operation under industrial ambient

conditions for maximum operational reliability
For internal use only / © 2007 SIEMENS AG
page 147 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Temperature Application Range up to 55°C

High temperature application range

through ...

Optimum enclosure design

(image 1) for effective air cooling
Operation without fans and CPU throttling
with ambient temperatures of
- 55 °C with derating
- 50 °C with full configuration
Application of tested and high-quality brand Image 1
components with higher MTBF values, e.g.
for industrial power supply or SIMATIC PC
Compact Flash

Full processor power without throttling (possible cause:

operational faults) for stable application execution
For internal use only / © 2007 SIEMENS AG
page 148 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Fast and Space-Optimized Mounting

Ease of mounting through ...

Ultra-compact dimensions for machine-level

applications
Wall mounting brackets (image 1); included
in scope of supply
Equipment for standard rail mounting; included
in scope of supply

Image 1

Space-optimized installation for reduced mounting costs

For internal use only / © 2007 SIEMENS AG
page 149 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Fast Commissioning and Maintenance

Fast commissioning and maintenance

through ...

Pre-installed Microsoft operating system XP

embedded, no time-consuming activation required
Comprehensive operating instructions with detailed Image 1
notes on fast and fault-free commissioning and
maintenance available for free download on the
Internet
Reset button for fast device rest (image 2) during
commissioning accessible from the outside

Image 2

Reduced commissioning times and costs

For internal use only / © 2007 SIEMENS AG
page 150 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Zero Maintenance

Zero-maintenance operation possible

through …

Elimination of mechanical wear parts and

device design without fans and hard disk (opt.)
SIMATIC PC CompactFlash
with 2 GByte (image 1)

Image 1

Minimization of potential failures and maintenance costs

For internal use only / © 2007 SIEMENS AG
page 151 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Local Monitoring and Diagnostics

Monitoring and diagnostic functions

through …

Front-side STATUS LED (image 1) for Image 1

the signaling of critical operating states,
also in headless operation
- Power
- Watchdog
- L1/L2 freely programmable
- L1/L2 additionally as display option for
SIMATIC WinAC RTX (image 2):
green / yellow / red for
run / stop / group fault
Image 2

Detection and elimination of critical operating states in the

industrial PC
For internal use only / © 2007 SIEMENS AG
page 152 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Long-Term Marketing of at least 2.5 Years

Long-term availability through …

In-house developed and produced

motherboards for innovation cycles
of at least 2.5 years (during 6 months
of which the predecessor and successor
models are marketed in parallel),
and spare parts availability of 5 years
Internal enclosure development to ensure
installation compatibility over several
device generations

Industrial standard innovation cycles with maximum

compatibility with the predecessor version for low adjustment
expenditures
For internal use only / © 2007 SIEMENS AG
page 153 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Spare Parts Availability of at least 5 Years

Strategic supplier selection for …

Long-term availability of operating

systems and processors; less laborious
tests and adjustment of customer software
and hardware to new operating systems
and processor platforms
Guaranteed spare parts availability of
at least 5 years

Reduced test and engineering expendigures thanks to long-term

availability of industrial PC hardware and operating system
For internal use only / © 2007 SIEMENS AG
page 154 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: CE-Tests in Certified Test Laboratory

Improved quality through …

CE marking for industrial applications

does away with laborious in-house
tests for quality assurance
UL certification for industrial applications
does away with laborious in-house tests
for export to USA/Canada
WEEE- and RoHS-compliant devices for
environmentally compatible, low-emission
industrial PCs in accordance with the latest
EC directives

No additional time- and cost-consuming qualifications for

markings and certifications
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Accordance with Customer Requirements

Basic customer requirements Technical characteristics

High compactness Dimensions/volume with functionality
EMC-tight full-metal enclosure
High ruggedness EMC
Isolated power supply
Large heat sink to the outside
Temperature directly on processor
Low-voltage CPU/chipset
CompactFlash card
Shock/ vibration
Rugged enclosure

High system availability 24-h continuous operation / 365 days

Without fans
Zero maintenance
Without hard disks

Standard mounting rail

Ease of mounting
Wall

Profibus DP
Upgradeability
4 x USB 2.0

DDR2 RAM
State-of-the-art technology Gbit-LAN (via PCI-Express)
DVI-I
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Technical Data

Basic data
Mounting / Standard rail mounting
installation position Wall mounting
Installation position: horizontal (preference) and vertikal

Processor Intel Pentium M 1.4 GHz, 400 MHz FSB, SLC 2Mb, LV 738

Chipset Intel Alviso 910GML

Main memory 1 GByte DDR2-SDRAM

Graphics Integrated Intel 2D/3D GMA900 graphics accelerator

8 to 128 MB shared graphics memory (dynamically managed)
Resolution CRT: 640*480 pixels up to max. 1600*1200 pixels / true color / 60 to 120
Hz
Resolution DVI-D: 640*480 pixels up to max. 1600*1200 pixels / true color

Power supply 24 V DC; 20.4 ... 28.8 V DC

Isolated

Application conditions Without fan

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Technical Data
Subject to technical changes/improvements.

Drives
SIMATIC PC Replaceable (accessible):
CompactFlash 2 Gbyte
High-performance, industrial-grade CompactFlash

Floppy /CD-ROM drive/ Connectable via USB interface

USB stick Not included in scope of supply

Interfaces
Serial COM1 (RS232)
Graphical DVI-I: DVI and VGA combined
USB 4 x USB V 2.0 / high-speed (480 Mbit/sec)

Ethernet 2 x 10/100/1000 Mbit/sec (RJ 45)

2 independent Intel controllers 82573L (via PCI-Express)
One controller with exclusive, non-shared interrupt
PROFIBUS DP/MPI 12 Mbit/sec (isolated, CP 5611-compatible), optional
With exclusive, non-shared interrupt

Keyboard, mouse Connectable via USB interface

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Technical Data

Subject to technical changes/improvements.

Safety functions
Temperature monitoring Processor and basic board (via PCS 7 ASSET Management and SIMATIC PC
DiagMonitor)
Hour meter (via PCS 7 ASSET Management and SIMATIC PC DiagMonitor)

LED display 4 LEDs for system state display

2 of which are freely programmable by the user
(each two-colored: yellow/green and yellow/red)
Preconfigured for RTX Software CPU
Short-time Up to 5 msec
voltage interruption Then buffering for at least another 10 msec
Network failure signaling through power fail signal
Operating systems
Windows® XP embedded® pre-installed,
no activation required
in connection with
SIMATIC PC CompactFlash 2 Gbyte

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Technical Data
Subject to technical changes/improvements.

Ambient conditions
General In accordance with SIMATIC SPH environment
Degree of protection IP 20 in accordance with EN 60529
Vibration Device without hard disk:
Requirements in accordance with: IEC 61131-2
Testing in accordance with: IEC 60068-2-6, test Fc
5-9 Hz, 3.5 mm deflection, 10x /axis, 1 octave/min
9-150 Hz, 9.8 m/s2, 10x /axis, 1 octave/min

Shock Device without hard disk:

Requirements in accordance with: IEC 61131-2
Testing in accordance with: IEC 60068-2-27, test Ea
Module/rack: 150 m/s2, acceleration,
11 msec shock duration

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Technical Data
Ambient conditions
Electromagnetic compatibility (EMC):

Subject to technical changes/improvements.

Interference emission EN 55022 class B
Interference resistance to transient ± 2 kV (IEC 61000-4-4, burst)
disturbance variables
Interference resistance to ± 1 kV (IEC 61000-4-5, surge symmetrical)
surge voltages
± 2 kV (IEC 61000-4-5, surge asymmetrical)

Interference resistance to electrostatic

± 6 kV, contact discharge (IEC 61000-4-2)
discharge
± 8 kV, air discharge (IEC 61000-4-2)
Interference resistance to
high-frequency irradiation 10 V/m, 80% AM (1 kHz), 80 MHz to 1 GHz (IEC 61000-4-3)
10 V/m, 50% PM, 1.4 GHz to 2 GHz (IEC 61000-4-3)
Interference resistance to
high-frequency power supply 10 V, 80% AM (1kHz), 10 kHz to 80 MHz (IEC 61000-4-6)
on lines
Interference resistance to
magnetic fields 100 A/m effective value, 50/60 Hz (IEC 61000-4-8)

Ambient temperature 0 to 55 ºC with CompactFlash card

during operation (horizontal, with derating)
(depending on installation position) 0 to 50 ºC with CompactFlash card (horizontal)
0 to 45 ºC with CompactFlash card (vertical)
5 to 40 ºC with hard disk (horizontal and vertical)
Humid heat With CompactFlash card: 95%
With hard disk: 80%
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Technical Data
Subject to technical changes/improvements.

Approvals
Safety standards IEC 61131-2
IEC 61010-1
EN 60950-1
Approvals cULus approval in accordance with UL 60950 and UL 508
CE-conformity EC directive 89/336/EEC (EMC directive)
Application in industrial environments:
Interference emission: EN 61000-6-4
Interference resistance: EN 61000-6-2
Application in residential, business and
commercial environments as well as small companies:
Interference emission: EN 61000-6-3
Interference resistance: EN 61000-6-1

Dimensions and weights

Installation dimensions Width x height: 262 x 134 mm
Depth basic device: 47 mm
Depth basic device from
standard mounting rail: 50 mm
Additional depth per extension (1-3): +17 mm each
Weight Approx. 2 kg

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Microbox PC 427B: Further Features

Microbox offers: Benefits:

Reset button Device reset during commissioning without disconnection
of the supply voltage
Little influence on the overall process
No noise development Thanks to the abolishment of fans and hard disk, application also possible in acoustically
sensitive areas
Status LEDs Serve visual support during:
commissioning / operation / servicing
Easy and fast diagnostics without auxiliary tools
Lower power consumption (approx. ≥ 15 Smaller dimensioning of the upstream 24 V power supply possible
W) Compact design thanks to reduced heat development
than standard PCs

Cable clamp for USB plug Compliance with vibration/shock values also without cable clamp
Further improved mechanical design thanks to the cable clamp included in the scope of
supply

Isolated power supply Prevention of potential transfers

Improved system reliability
Support of eased potential/grounding concepts
Application without additional measures
Headless operation Support of system configurations without monitor
Start-up possible without monitor and keyboard
Monitor can be subsequently connected for diagnostic purposes

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

Latest PC Technology

Suitable for highly-performant and IT applications on the control/cell level by …

State-of-the-art technology for maximum performance

- Intel 945G Express chipset

- Intel Pentium CORE 2 Duo processor E6600

- Intel processor technology with 64-bit expansion

Intel Extended- Memory-64 Technology for future 64-bit applications

- DDR2 677 SDRAM memory technology with dual channel support

Memory expandable up to 4 GByte

- Intel GMA950 graphics controller

with dynamic Video Memory Technology integrated in chipset

- Intel Matrix Storage Technology

RAID controller integrated in ICH7R chipset
no PCI slot for RAID controller required

- Powerful 250 GByte Serial ATA hard disks (SATA)

with NCQ technology

- PCI-Express slots for expansions

- Gigabit Ethernet integrated

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

Industrial Standard

Suitable for use in industrial environments thanks to…

Robust all-metal housing for

- high mechanical robustness
- high EMC compatibility

Reliable retaining card holder for

- impact and vibration protection of the
PC modules

Guaranteed positive pressure ventilation with temperature-controlled fan

and exchangeable filter for
- dust protection and a consequential increase of the service life of all
internal components

Active cooling concept and an optimum component arrangement for

- 24h continuous operation with full configuration, with total processor
performance through avoidance of automatic processor throttling in the
temperature application range up to 400C

International certifications for

- industrial areas (CE, cULus)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Rack PC 547B: Product Highlights

Latest PC technology Industrial standard

State-of-the-Art Intel CORE 2 Duo Dust protection
technology Service friendliness
High performance and scalability CE mark industry and office
PCI and PCI Express slots Transportation lock for expansion
Gigabit Ethernet cards

Investment protection
Guaranteed spare parts
availability of at least 3 years

High system availability

Monitoring and diagnostic functions
RAID1 configuration (mirror disks),
ASSET Management diagnostics

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Rack PC 547B: Improvements
IL 43 547B

Chassis: no Changes
Design: Changed Frontprinting on Rack PC 547B

D2156-S1 D2156-S2
Motherboard: no changes on the technical properties (Chipset)
Support from the NEW Intel Core 2 Duo Processor

Replacement from Pentium 4 Processor by Core 2 Duo

For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 PC Based Automation

SIMATIC Rack PC 547B: Bundles for PCS 7 V7.0 + SP1

7 x RACK PC 547 Bundles

PCS 7 ES/OS RACK PC 547B BCE = Windows XP Professional
PCS 7 ES/OS RACK PC 547B IE = Windows XP Professional
PCS 7 OS Server RACK PC 547B BCE = Windows Server 2003
PCS 7 OS Server RACK PC 547B IE = Windows Server 2003
PCS 7 OS Client RACK PC 547B = Windows XP Professional
(without Multi VGA)
(2 Client Bundles with preinstalled Multi VGA
Graphic Card)
PCS 7 OS Client RACK PC 547B = Windows XP Professional
(2 Screen Multi VGA)
PCS 7 OS Client RACK PC 547B = Windows XP Professional
(4 Screen Multi VGA)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

SIMATIC Rack PC 547B: Bundles for PCS 7 V7.0 + SP1

In a second Step (December 2007) the Rack PC 547B is also for PCS 7
V6.1 + SP1 available.
Pre installed with PCS 7 V6.1 + SP1
Restore DVD A1 and A2
5 x Windows XP / Server 2003 and
3 x Windows 2000 Professional / Server
Bundles for PCS 7 V6.1 + SP1

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

RACK PC IL43 vs. RACK PC 547B

IL 43 RACK PC 547B
Motherboard FSC OEM D2156-S1 FSC OEM D2656-S2

Chipset Intel 945G, FSB 1066/800/533 MHz Intel 945G, FSB 1066/800/533 MHz

Processor Pentium 4, 3,4 GHz, 800 FSB, HT Core 2 Duo, E6600 2,4 GHz, 1066 FSB

RAM Max. 4 GByte, DDR2 533 SDRAM Max. 4 GByte, DDR2 677 SDRAM
2 GB (2x1024) in OS Server and ES Station 2 GB (2x1024) in OS Server and ES Station
1GB (2x512) in OS Client 1GB (2x512) in OS Client

Graphic on board, Intel 945G on board, Intel 945G

Dynamic Video Memory Dynamic Video Memory

Harddisk 2 x 120GB RAID 1 inside the OS Server and ES 3,5” SATA (7200 RPM, 8MB Cache, NCQ)
Stations 2 x 250GB RAID 1 inside the OS Server and ES Station

1 x 120GB OS Client 1 x 250GB OS Client

Internal Interfaces 4x PCI, 1x PCIe x16, 2x PCIe x1 4x PCI, 1x PCIe x16, 2x PCIe x1

Drives 1,44MB Floppy Disk 1,44MB Floppy Disk

DVD ROM in OS Server and OS Client DVD ROM in OS Server and OS Client
DVD+/- RW in ES Station DVD+/- RW in ES Station

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 PC Based Automation

RACK PC IL43 vs. RACK PC 547B

IL 43 RACK PC 547B
External Interfaces

Ethernet Onboard, 10/100/1000 Mbit/s, RJ 45 Onboard, 10/100/1000 Mbit/s, RJ 45

USB 6 x USB 2.0 6 x USB 2.0

(4x back side, 2x in front) (4x back side, 2x in front)

Monitor 1x VGA 1x VGA

Sound Realtek ALC260 Audio Realtek ALC260 Audio

- Mic in - Mic in
- Line in - Line in
- Line out - Line out
Parallel Yes, 25-pole Yes, 25-pole

Seriell COM1; V.24, 9-pole; COM1; V.24, 9-pole;

COM2 in OS Server only COM2 in OS Server only

PS2 2 x for Mouse and Keybord 2 x for Mouse and Keybord

DIAG Monitor V3.0 pre installed V3.1 pre installed

For internal use only / © 2007 SIEMENS AG

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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Operator System

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Operator System
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Overview
User
Management
Alarm System Web access
Process
Visualization
Excel
Programming
Interfaces
Archive
System

Standard

Report System Interfaces

Data Management

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Hardware & Software Components

Custom Operator Stations

(Bundled hardware + system software)
- Single-user system (OS single station)
- Client/server system (OS client / server)
- Basis: Standard PC components
Windows Server 2003 / XP Prof.
System Software for Operator Systems
Configurations System software also available without hardware (for
Clients simulation purposes)
Single-user 1 2 3 32 Packages for Operator Systems
system
- Variety of quantities available
Server - Upgrades via PowerPacks
1 12 Packages
# PO Single user Client/Server
Optional
redundant server 250 X X

System capacity 1.000 X X

2.000 X X
Number of servers / server pairs 12

Number of clients (screens) 32 3.000 X X

Number of PO‘s per multiuser system 12 * 8.500 5.000 X X

Number of AS per server/ pair of server 64 8.500 - X

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Client / Server Architecture

OS client
Process visualization
Access to every OS server
Combines process values,
Max. 32 OS Client alarms, etc. from all servers into
Central Archive a single view
OS server
Max. 12 OS server Communication with AS
(redundant) Terminal bus
12 servers (red.), 32 OS clients
Archiving of process values,
.... alarms
Archive synchronization
System bus
(for redundant servers)
Archive configurations
.... Integrated in every OS server
Flexible adaptation of the HMI to the plant architecture (short term)
Simultaneous operation of several plant areas with a single OS client Central Archive Server
Optimized communication due to separation of the terminal and plant (long term)
bus and true client/server architecture
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Redundancy

Initial state:
Client Client Client Client Client Client Distribution of the clients
A A A B B B
between redundant servers
(preferred server for each Client)

Automatic client switchover in

Server Server the event of server failure
A B (e.g. ClB server A)

Generate Control system alarm

due to server failure
(e.g. server A reports failure B)

Server recovery: automatic

reconnection to the process and
automatic archive
synchronization
(e.g. server A server B)

Automatic client switching after

server recovery
High availability of the operator control level (back to initial state/preferred
server)
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Graphical User Interface (GUI)

Alarm line Overview

section
Navigation
window

Picture
Faceplate area

Button
area
Standard user interface (overview and Picture area, buttons, trends, alarms, faceplates)
is provided by the system - no engineering required !
Multi-window design with fixed areas - prevents overlap of the overview and button areas
Easy to operate due to hierarchical structure and simple navigation
Well-designed GUI for reliable operation of the process – even in critical
situations
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

GUI: Buttons for fast and easy Access
Operator controls in the overview area located at the top of the screen:

Alarm system Acknowledge alarm

Loop in alarm Print

Operator controls located at the button bar at bottom of the screen:

Switching between the Navigation buttons Switching between the
button sets button sets
Password Previous screen Language setting

Alarm system Store / retrieve picture Batch Control Center

Reports Screen composition Route Control Center

Trend list Plant configuration SFC Visualization

Picture selection via process Picture information User Administration

tag
Picture list Acknowledge horn Exit runtime

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

GUI: Standard Faceplates

Digital value

Analog Indicator Dosing / Totalizing Operating time counter Interlock

Motor - Reversing Motor Motor Motorized Valve Valve

right/left direction slow/fast two feedback signals One Feedback

One-button
operation
Analog output One-out-of-three Digital output
with limit digital value operation

Counter for Ratio controller: PID controller Step controller

switching operations V = U1 * U2 + BIAS For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

GUI: Examples for Standard Block symbols

One-button Picture selection

PID controller Valve Motor
operation

Dosing / Totalizing Valve Motor Step controller

Analog Indicator

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

GUI: Block Symbols - Faceplates

Plant picture with

block symbol
Maintenance view Alarms

Limits Trend window

Faceplate Faceplate –
Parameter view Batch view
extended view
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

GUI: Multi-Screen

Multi-Screen Technology
One control device (mouse/keyboard) for
multiple monitors (1...4)
Provides ease-of-use functions
(e.g. store screen composition/layout)
No additional configuration required

Configuration of monitor layout

Project Editor
Max. 4 Monitor (each max. 1600 x 1200)

Comprehensive overview of the process (information at your fingertips)

Simple operation using multiscreen technology
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

OS Configuration using Project Editor
Project Editor
Simple, menu-operated configuration of GUI
Screen resolution
OS client monitor configuration
(1, 2, 4 monitors)
Arrangement / separation of overview
(max. 64 areas)
Faceplate settings
(size and position)

Adaptation of the overview areas

e.g. 6 areas

e.g. 20 areas

Simple and convenient to optimize operator’s standard view

For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Alarm Management
Preconfigured alarm lists
- New list (all unacknowledged alarms)
- Old list (all active, acknowledged alarms)
- Went out list (all unacknowledged, cleared)
- Operator input list (all operator messages)
- Control system list (all control system alarms)
- Log list (all alarms in chronological order)
Alarm classes
- A Alarm (high / low)
- W Warning (high / low)
- S Control system
- O Operator input prompt
Alarm priorities
Alarm system functions
- Priority 0 (lowest) ... Priority 16 (highest)
- Loop-in alarm
Quote: "A warning from the main reactor is
(jump from alarm directly to process screen) more important than an alarm from an auxiliary tank"
- Acknowledgement - Highest priority alarms in alarm line (overview)
(single, via page, via faceplate, for entire picture)
Alarm selections
- Chatter suppression (in AS) Criteria: e.g. date, time, area, class, priority
(alarms reannunciated only after
acknowledgement)

Comprehensive system support for alarm analysis

For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Alarm Management: Screen Hierarchy & Group Displays

Operator prompting through screen hierarchy and group displays:

1. Jump directly from the overview to the picture containing the alarm via a single mouseclick.
2. Jump directly from the overview to a screen in which all alarms
from lower levels have been aggregated.
3. The operator decides which alarm is the most important.
A A

A A

A A
A

Alarm Navigation plus overview of Plant alarm status

For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Alarm Management: Loop in Alarm

Jump: from the overview alarm line directly to the picture / faceplate containing the alarm

Loop-in alarm
Alarm with highest priority A

in alarm line (overview)

Jump: from the alarm list directly to the picture / faceplate

Loop-in alarm
A

Alarm Management by quickly navigating to the source of the fault

For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Alarm Management: Alarm Hiding
OS Client
The OS Client only presents “non hidden alarms” –
the operator concentrates only on relevant alarms
and messages.
OS Client
OS Server
The OS server decides, based on configured rules
OS Server
(ES), whether an alarm will be hidden (only sent to
archive) or presented to the user (and written to the
archive)
Unit State Alarming AS
Generator
An user definable logic (state generator block)
AS combines the process states and triggers a PCS7
state

state representation block

This block sends the states up to the OS servers.

Process Process
The state of any part of the process changes, e. g.
startup / run / shutdown / maintenance etc.

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Alarm Management: Alarm Hiding

Engineering
Assign function blocks to alarm groups

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Alarm Management: Alarm Hiding

Engineering
… than define „hiding rules“

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

SFC Visualization
SFC Engineering SFC Runtime

Single Steps
with operator
input

Detailed view
with operator
Automatic generation of
input
displays from the ES
Automatic generation of displays Dynamically configured Various operator
from the ES step and transition boxes authorization / privilege
Navigation window for each chart Group displays for levels
Overview window with step / operator input Modification & downloading
transition box during runtime operation:
Loop-in alarm from
Several SFC‘s in multichart operation prompt SFC - transitions
diagram - steps
without having to stop SFC
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Trend Displays

Engineering
Minimum, maximum and unit of measurement is
automatically transferred from engineering to runtime
during download.
These three parameters are used for the scale of a
trend.

Features
Flexible trend display format maximizes usability
Fast online viewing of process data

Basic functionality of the trend displays:

Up to 10 tags (pens) for each trend display
Zoom in / out
Ruler (with tabular display of value)
Adjustable time scale (duration)
Visualization can be stopped (archive continues to run)
Scrolling through records (Fwd/Rev)
One Y axis for all values (%) or separate Y axis for each value
Trend displays merge data from: Online process values / Archived (historical) values
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Trend Displays

Print all trends without Show online and archived

Show y axis separately
additional configuration values in same trend view

Export trend values into

csv file

Bring trend to front via

double click or script

Color of X axis
configurable

Dock legend table to trend User scaling

chart window (readable range names)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Archiving System / Overview

Key features

High-performance archiving system based on

Microsoft SQL Server 2005
Cyclic Archives for process values and
messages/alarms on OS-Server
Long-term archiving on Central Archive Server
Adjustable cycle time
CAS in single or redundant configuration
available
Long-term archiving of OS- and Batch reports
Backup archiving on DVD with third party
software (e.g. nero)
High performance Premium Server available

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 System Functions

Archiving: Central Archive Server

OS Client

Online ....
Archive
OS Server OS Server Batch Server Long Term
Archive
CAS

Archived Data:
Operator messages
Alarm Logging
Trends
Batch reports
Audit trails
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Operator System

Storage Plus Viewer

Storage Plus viewer is unified with

DataView
Preconfigurable settings
(predefined views)
Show alarms as table / hit list of
alarms / alarm filters
Process values as table or chart
Export of alarms and trends
Show WinCC or Batch reports
Advantages of both viewers have
been combined
StoragePlus viewer is part of CAS
and StoragePlus

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Operator System

Storage Plus Viewer

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Operator System

Archive System Performance Trend
Technical data Highlights
Parameter OS CAS Can be configured online
Number of archive tags 10,000 120,000 Automatic synchronization
Number of message def. 150,000 n.a. for redundant systems
Tags / s 1,000 10,000 Process value acquisition / archiving
Messages / s 10 Cyclic (fastest cycle: 500ms)
Message burst 3,000 / 4s Archiving of changes only

Process value compression for archiving

(e.g. acquisition: 2 sec. / archiving: 60 sec.)
Acquisition
Min value
Max value
Average value
Actual value
Sum of values (addition)
Archiving Custom function (C script)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Operator System

Archive System Packages
Additional
OS local
archive tags via
power packs (short term) archives
512 archive tags / OS OS OS OS
OS free if CAS
not used 10,000
5,000
1,500
512

OS Basic Package X X X

CAS Additional
archive tags via
power packs 120,000
OS OS OS OS 80,000
30,000
1,500 archive 10,000
tags free if 5,000
CAS is used
*) 1,500

CAS Basic package X X X X X

*) The number of included archive tags is calculated per PCS 7 project (1-32 OS + 1-2 CAS)
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Archive System

License Rules

Common rules
Short term archive tags are stored on an OS
Long term archive tags are stored on a CAS
There is only one type of archive tag license
License cost rules
Short term tags are counted as 1 for one OS and 2 for redundant OS
Long term tags are counted as 1 for one CAS and 2 for redundant CAS
Installation rules
If no CAS is included, the license is installed on the OS
If one CAS is included, the license is installed (only) on the CAS
If two CAS are included, the licenses are installed on both CAS
Upgrade rules
Upgrade OS software from V6.1 to V7
Install upgrade license OS server V6.1 to V7
Transfer archive licenses from OS manually to CAS (disk or file share)
Free license rules
If no CAS is included, each OS provides 512 „free“ archive tags
If a CAS is included, only the CAS provides 1,500 „free“ archive tags

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SIMATIC PCS 7 Archive System

Benefits

Only one type of archive tags, no difference between counting and handling of
short and long term archive tags from the license point of view.
Easier license counting and handling
The new licenses are „countable“ , therefore combinations are possible:
10.000 + 5.000 or 30.000 + 2x 5.000 (see available power packages).
More flexibility, reduced number of „not used archive tags license“
„Forwarding“ long term archive tags by the OS is „free of charge“. Only the
long term archive tags on the CAS are „charged“.
Reduce costs of archive licenses
Therefore, a long term archive tag on the CAS is „charged“ only once and no
longer twice because of the redundant OS (as in PCS 7 V6.1 SP1)
Reduce costs of archive licenses
The CAS provides 1,500 archive tags „free of charge“ in the CAS base
package
Free archive tags for up to 3 OS are covered by the CAS base package

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SIMATIC PCS 7 Archive System

Benefits

If a CAS is configured in the PCS 7 engineering project, the OS archive tags

are licensed remotely on the CAS, where the licenses have been installed.
This means, we provide a „license server“ the first time also for archive tags.
„archive tag license server“ easier handling, reduced installation effort
DataMonitor-Viewer unified with StoragePlus Viewer
Extended functionality / export of data / alarms / trends
Transparent access from OS client to OS / CAS process values (trend data)
Transparent access from OS client to OS / CAS alarm messages
Reduced engineering effort
Better handling / usability for operators
CAS uses the same internal archive mechanism as the OS (WinCC)
CAS may be down for a while, segments are incorporated later on
More performance
CAS now available as a redundant CAS configuration. Automatic data
synchronization of alarm, trend and report archive data
Higher availability of archived data

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SIMATIC PCS 7 Archive System

Benefits

CAS is decoupled from the process. After CAS was down and is up again, the
system automatically synchronizes the archived data
Consistent archives
CAS may be down as long as the size of the OS archive, even days!
Batch reports are located on the master CAS
Process data, alarms, WinCC and Batch reports at the same place
CAS provides up to 120,000 archive tags
Higher quantity structure in V7
Get more information out of the process
Licenses are installed on the OS in a non-CAS configuration and on the CAS,
if CAS is included
In a configuration with CAS, licenses are installed centrally
Easier handling

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Archive System

Web Access

Features
Transparent access to all OS servers
WinCC pictures are published
no additional engineering for web pages required
Typical configurations
Web standard server and client or
Web diagnostic server and diagnostic client
Both can be used in client / server or single station projects
Preferred solution is the standard web configuration
Operating system
For this use case with a web server running on the OS client, the OS Client is released
on a Windows 2003 Server
Requirements for Web Client
Operating systems Windows server 2003 or XP Professional
Software Internet Explorer
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Archive System

Standard Web Server
Web Standard
Client / Server Application
Web clients Up to 50 web clients are connected to the same
PCS 7 project via internet or intranet
The web clients are connected to the same
Internet / Intranet
PCS 7 web server normally.

OS Client
Licensing
Web Server
The web clients doesn‘t need any license being
installed
ES OS Server
The web server is licensed for the number of
web clients that can connect to the web server:
Web Server packages

AS ≤ 3 web clients ≤ 25 web clients

≤ 10 web clients ≤ 50 web clients

Web Server power packages

3 10 web clients

10 25 web clients

25 50 web clients

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Archive System

Web Diagnose Server

Web Diagnose Application

Web diagnose One or more but only a few web diagnose
client
clients are connected for diagnose
reasons from time to time to one of the
projects (via web server)
Internet / Intranet
Web diagnose Clients are used for control,
remote control and diagnostics
Typically the connected systems are
Single Station Client/Server smaller ones, e. g. some single stations,
+ Web Diag + Web Diag. but client / server projects are also
Server Server
possible.
A B C
Licensing
Each web diagnose client requires its own
Web diagnostic licenses client diagnose license
Web Diagnose Client The web diagnose server requires a web
Web Diagnose Server diagnose server license

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 System Interfaces

OpenPCS 7

OPC clients

OS Clients

… OpenPCS 7
station

OS-
OS-Server OS-
OS-Server OS Server Archive Server

Central access to the whole system

Transparent access in aspect of location
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 System Interfaces

OpenPCS 7

Interfaces
OPC DA – Data access version 3.0
OPC HDA – Historical data access version 1.2
OPC A&E – Version 1.1 Alarms and events (incl. historical A&E !)

Features
Transparent data access in aspect of
time (OS-CAS)
location (OS1, OS2 … Osn)
redundancy (OS1, OS1red)
Standard interfaces of OPC
Support of full quantity structure of PCS 7
Hierarchical access on objects and conditions (A&E)
Hierarchical access to A&E alarm and message data is the preferred solution for PCS 7 projects

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 System Interfaces

OpenPCS 7
1 # OPC PCS 7 Description

First level where the

1 OPC Server n.a. OPC clients
connects to
2

List of OS servers of
2 OPC area OS Servers
one PCS 7 project

3 One OS server of the

3 OPC area OS Server
PCS 7 project

4 One area of the OS

4 OPC area PCS 7 area
server

One process object

5 OPC source Process object
inside one OS server
5
6 PCS 7 alarm /
OPC Conditions the OPC
6 tolerance
condition client can advise on
mesages
Sub conditions*
OPC sub • Alarm high/low
7 High / low
condition • Warning high/low
• Tolerance high/low
*) The sub conditions are not shown in the tree
view here
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 System Interfaces

OpenPCS 7

Data OS
Time frame CAS OPC OLE-DB
Type Server

Process DA
Actual X n.a. -
Values (Read / Write)

Process HDA X
Historical X X
Values (Read only) (Read only)

Alarms & A&E

Actual X X*** (Read / -
Events Acknowledge)

Alarms & A&E* X**

Historical X* X*
Events (Read only) (Read only)

*) Extention of the OPC A&E interface

**) Currently non transparent access, switchover has to be managed by OLE-DB client
***) Only messages created by the CAS itself
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Operator System

Additional Features

Signal module
(alarm horn for Centralized time
Language setting synchronization
visual and
at runtime with DCF 77 or
audible signals)
GPS receiver

Smartcard reader Customizable user

Video overlay right settings
for simple and in process
secure user (functions, plant
screens sections, etc.)
identification

For internal use only / © 2007 SIEMENS AG

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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Asset Management

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Asset Management
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Asset Management is an Integrated Part of PCS 7

Automation Maintenance

Enterprise Resource
Planning
(ERP - level)

Management level
One project
(MES - level)
for
Control Process control
and
Field
Asset Management

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Plant Asset Management System (PAMS)

Plant Asset Management System Plant Asset Management

in SIMATIC PCS 7 provides
Performance Monitor.
online, real time functions:
high
Monitoring of the components Process

Customer benefit
Message at status change
Display of
diagnostic information
Plant
Creation of Components
maintenance request
Automation
Tracking of maintenance Components,
activities DCS, Network, …
Single
devices
Main benefits of the implementation in SIMATIC PCS 7: low Effort and Complexity high

Homogenous integration into SIMATIC PCS 7

Maintenance Station integrated into Operator Station or as dedicated station
Common visualization (symbols, faceplates) all assets (unified assets)
Automatic generation of all Asset Management diagnostic pictures
Consequent implementation of NAMUR recommendations NA 64 & NE 91

Enhanced Asset Management functionality to increase availability of the process

control system and of the plant
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Asset Management

Separation of Process and Maintenance Information

Operator Diagnostics
control OS MS
& Maintenance
& Monitoring Request

Process event Diagnostic event

OS: Operator Station MS: Maintenance Station

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Free Choice of Field Devices (all suppliers)

It depends on the „intelligence“ of the device,

how the integration into the Asset Management
System (MS) works
The manufacturer of the device determines the
amount of information for his device
Only the manufacturer knows the asset
management capabilities Profile, e.g. DP/PA + EDD
MS
of the device
Compliance with international standards
and specs determines
the integration effort

PB – PROFIBUS
EDD – Electronic Device Description
MS – Maintenance Station
RIO – Remote I/O
PA – Process Automation

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform Visualization of all Assets

Applicable to all components within SIMATIC PCS 7 projects

Standards for representing status in SIMATIC PCS 7

Maintenance request Maintenance not in

Good progress
(low)
Maintenance demand
Simulation (medium) Maintenance is requested

local Maintenance alert Maintenance in

operation (high) progress

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Generating the MS Runtime

Asset Part is automatically configured with “Zero Engineering”

Plant View PCS 7 OS MS

Transfer of the folder

„Diagnostics“ to Maintenance
Station

Diagnostic / Asset- Project

Generated automatically
by the Engineering system

Automation- Project

Individually adaptable
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Asset Management

Monitoring Levels

PC Level

Ethernet Level
User Area

AS Level

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Source for uniform visualization of process value state
PROFIBUS PA – profile /
FF – status definition On Maintenance station
xx Function check / local override

xx O.K.
OK
xx Update event
xx Function check
xx Maintenance required Maintenance alarm
x Uncertain, Process related

HART - status Maintenance demand

xx Malfunction
xx O.K.
Maintenance request
xx Update event
xx More status available Siemens specific definition
xx e.t.c. Local function /
Specific - status Simulation
xx Wire break
xx O.K.
xx Low range limited Out of specification
xx Short current process related
x Channel error

Failure
process related

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Source for uniform visualization of all field device state
PROFIBUS PA – profile /
FF – status definition On maintenance station
xx Function check / local
override
xx O.K. Good device status
xx Update event
xx Function check Maintenance alarm
xx Maintenance required
x Uncertain, Process related

HART - status Maintemance demand

xx Malfunction
xx O.K.
Maintenance request
xx Update event
xx More status available Siemens specific definition
xx e.t.c. Simulation
Specific - status
xx Wire break Out of service
xx O.K.
xx Low range limited
xx Short current
Passivated
x Channel error
Local operation
EDD – condition status
xx Simulation Update event
xx Good.
xx Maintenance demand Device status unknown
xx Maintenance request
x Configuration change For internal use only / © 2007 SIEMENS AG
page 222 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Asset Management

Hierarchical Structure

Fast and easy-to-use operation guidance through complete hierarchy

by unified symbols

SIMATIC S7-400
and PROFIBUS
Network

status and selection of

underlaying hierarchy
ET 200M
diagnostic symbol
Station
of the component

Clear hierarchical structure PROFIBUS

devices
Plant overview
Overview all controllers
Controller (with sub-hierarchy)
PROFIBUS Assets
DP station (e.g. ET 200M) Faceplates
for intelligent
Intelligent field device devices

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Description of Information
Green Wrench:
Order Parts
Order Replacements

Yellow Wrench
Schedule Craft Labor
Schedule Contact Service
Expedite Parts

For internal use only / © 2007 SIEMENS AG

page 224 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s
Beschreibung der Informationen

SIMATIC PCS 7 Asset Management

Description of Information
Before Red Wrench

Schedule repair before serious problem

Schedule to minimize lost production
Assure all Personnel, Tools and Parts are available.

For internal use only / © 2007 SIEMENS AG

page 225 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Asset Management

Uniform View: Identification

Uniform view for all assets according to their information capability

Diagnostic Direct callup of

Request status SIMATIC PDM
status Maintenance status
Direct callup of
HW Config

acyclic asset data, e.g.

cyclic information from
application
via PDM

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform View: Log Display

contains all
diagnostics and error messages
operator logs
maintenance requests
Request Status

Diagnostic Status

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform View: Special Diagnostic via PDM

Manufacturer described diagnostic via EDD

SIMATIC PDM interpreted diagnostic information
Different language possible in dependence from manufacturer of the asset
Request Status
Maintenance Status

Diagnostic Status

Communication

Status

Detailed
Description
Status diagnostic

Repair

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform View: Parameter View for Field Devices

View of the field device parameter

For intelligent field devices
Information generated by SIMATIC PDM
Request Status
Maintenance Status

Diagnostic
Status

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform View: Audit Trail via PDM

Audit trail
System Performance of SIMATIC PDM
Display in Form of HTLM - Sites
Request Status Start SIMATIC PDM
Maintenance Status Start HW – Conf.

Diagnostic Status

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform View: CPU

Präventive Meldung bei hoher CPU Last

Performancedaten – Wahl der geeigneten CPU
Verbesserte Diagnoseinformationen durch Meldungen und
Darstellung in Bildbaustein
Neuer Notbetrieb – Bedienbarkeit der Anlage bleibt erhalten

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Asset Management

Uniform View: CPU

Utilization of controller
Overview screen per controller
Display of alarm limits
Display of average values over
a time interval

Determination of cycle times for

OB3x, OB8x and OB1 (SFC 78 )
Display of cycle time utilization
Applies to a defined period of time

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Uniform View: Industrial PC (IPC)

View of the current value

Information about temperature, operating hours
Information transfer by OPC SNMP
Request Status
Maintenance Status

Diagnostic
Status

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Decision Support

The system generates a maintenance proposal (request)

The service staff confirms or changes
Request Status
Maintenance Status

Diagnostic Status

Request status set by

the user

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Asset Report

All important information concentrated

The same structure for all Assets

Asset – Status

Identity

Maintenance -
Status

Detailed diagnostic

Current massages

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Asset Management

Asset Report as XML

All important information concentrated

The same structure for all Assets

Document Info

Maintenance -
Status

Current massages

Identity

For internal use only / © 2007 SIEMENS AG

page 236 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
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SIMATIC PCS 7 Asset Management

User Diagnostic – Monitoring process components
Valves
Equipment: Motors
Major Equipment;
• Reactors
• Heat Exchangers
• Vessels
• Filters
• Scrubbers…

KPIs: Service intervals

Gradient monitoring
Quality values
Logic monitoring
Efficiency
etc.

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Asset Management

User Diagnostic - Hierarchy

Overview
Integrated „Plant Asset Management“
Plant Overview and Detailed View

Faceplate
“ASSETMON”

Detailed view

For internal use only / © 2007 SIEMENS AG

page 238 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Asset Management

Integration of Plant components

CFC Function Block

Interface to PCS 7 Maintenance
Station
Monitoring Value 1
for all uses case
based on standard functionality Monitoring Value 2
Functions
Monitoring of 3 process values, Monitoring Value 3
each with
Message Triggering
Maintenance request
Maintenance demand
Maintenance alarm
Detailed Diagnostics
Message triggering for
3 x Maintenance status
4 x Device status
16 Diagnostic States
“ASSETMON”
For internal use only / © 2007 SIEMENS AG
page 239 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Asset Management

Application Monitoring

Faceplates
Identification
- Object designation
- Type label
Monitoring
- Process value display
- Monitoring
Diagnostics
- 16 Radio buttons
- 16 Detailed diagnostic
texts
Message display
Maintenance

For internal use only / © 2007 SIEMENS AG

page 240 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Asset Management

“ASSETMON" configuration in CFC and PDM

Call PDM from

Faceplate

Engineering of
values, texts und
messages

Link to PDM
via PLT-ID
For internal use only / © 2007 SIEMENS AG
page 241 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Asset Management

“Intelligence” of Plant Components
Logic (KPI) Monitoring
Plant components mostly
have no „Intelligence“
(Communication- and
Diagnostic capability).

Determination of KPI by
combination of existing
information and application
logic

Monitoring of KPI in User

Diagnostic

Assetmon

For internal use only / © 2007 SIEMENS AG

page 242 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Fieldbus Components

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Fieldbus Components
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

Process Interfacing with PROFIBUS

PROFIBUS is the No. 1 field bus system in the world

PROFIBUS DP and PROFIBUS PA are one unit Now more than 20 Million
installed nodes !!!

PROFIBUS supports:
- HART communication
- Fail-safe technology (PROFIsafe)
- Drive integration (PROFIdrive)
- Device profiles
- And much more

For internal use only / © 2007 SIEMENS AG

page 245 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / PROFIBUS

SIEMENS PROFIBUS Devices

Process Instrumentation and Analytics Controller

Pressure Flow Analytics Positioning High end

Temperature Level Mid range

Distributed I/O Panels Motion Control

Intrinsically Drives
safe

Modular

Bit-
modular

Failsafe MCC

For internal use only / © 2007 SIEMENS AG

page 246 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / PROFIBUS

Technical Overview
S7-400
Max. 124 DP slaves per PROFIBUS DP
1 master system
15 km
OLM 2 Electrical networks can be extended
RS485 Fiber optic RS485
with repeaters (segments)
PROFIBUS DP

(Diagnose) - max. 31 DP slaves per segment

Repeater Max. 1,200 m
OLM‘s (Optical Link Module) for long
distances, also provide greater EMC
3 4 stability
RS485iS coupler for PROFIBUS DP in
Coupler RS485iS hazardous areas
Max. 1,200 m 6 Copper with RS485 and fiber optic use
DP/PA Link 5 the same communication protocol
RS485iS
1,900 m PROFIBUS PA provides “power on the
PROFIBUS PA bus” for smart field devices
DP/PA Link takes only one address on
the upstream DP bus
1 2 3 4 .... 31
For internal use only / © 2007 SIEMENS AG
page 247 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / PROFIBUS

Physical Properties

Physical- max. segment length

Application
Layer @ transmission rate
1200 m @ <93,75 kBit/s
Remote I/O 1000 m @ 187,5 kBit/s
PROFIBUS
RS 485 Intelligent drives 400 m @ 500 kBit/s
DP Intelligent field devices 200 m @ 1,5 kBit/s
100 m @ up to 12 MBit/s
1,200m @ <93.75 kBit/s
1,000m @ 187.5 kBit/s
RS 485iS Remote I/O Ex
400m @ 500 kBit/s
200m @ 1.5 MBit/s
Fast Transmission
Up to 15,000m @ 12 MBit/s between
Fiber Optic Wide distance
two OLMs
EMC stability

MBP Field devices 1,900m @ 31.25 kBit/s (non Ex)

PROFIBUS (Manchester 1,000m @ 31.25 kBit/s (Ex)
Power supply via bus
PA Coded Bus
Powered) Ex Applications

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

Central Access to all Connected Devices

Faceplate
Application (CFC)

M
OS ES

Process picture
SIMATIC PDM

PROFIBUS DP

PROFIBUS PA

z. B. Simocode pro

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

Fast Cycle Times

Engineering
Station Two separated cycles on
ES PROFIBUS DP and PROFIBUS PA

PROFIBUS DP up to 12 MBit/s 2 msec

0,3ms 0,5ms 0,5ms

0,5ms

DP/PA Link acyclic read cyclic

20ms
acyclic
PROFIBUS PA 31,25 kBit/s

80 msec

10ms 15ms
15ms
10ms 10ms

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

DP/PA-Link

PROFIBUS DP 124 devices

DP/PA Link 64 devices

PROFIBUS PA (Ex) 9 devices

PROFIBUS PA 31 devices

DP Interface module IM153-2 (max. 12 MBit/s to 31.25 kBit/s)

- Slave on PROFIBUS DP (one address), Master on PROFIBUS PA
- Can be used redundant (H-System) DP/PA Coupler
- Max.. 244 bytes of I/O data (1 AI Value = 5 Byte) Interface module
- Up to 64 PA devices
IM153-2
DP/PA coupler for PROFIBUS PA segment
- Two types of DP/PA Coupler available:
• Non-Ex with 1,000 mA
• Ex [EEx ia] with 110 mA
- Up to 31 (9 Ex) PA devices
- Max. 5 DP/PA Couplers per link
DP/PA Link
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Plug and Play in the Hazardous Area

Goal: Eliminate safety related calculations

Strategy: Definition of max. values (U/I) for a segment

Only prerequisite: All devices must fulfill the guideline

For PROFIBUS DP: PNO Guideline 2.262
DP/PA Link
For PROFIBUS PA: FISCO
(Fieldbus Intrinsically Safe Concept) PROFIBUS PA
intrinsically safe

DP/PA Coupler
Ex Version
(I.S. Output 110 mA)

Benefit: Devices replacement or system expansion without re-analysis

(Plug & Play in the Hazardous Area)
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: The Barrier Concept

Safe Area
Barrier for isolating non-Ex (safe
DP/PA Coupler area) and Ex (hazardous area) zones
PROFIBUS DP non-Ex (1000 mA)

Non-Ex DP/PA coupler (1000mA) can

PROFIBUS PA Backbone be used in Ex applications
with increased safety (EEx e)
.... Outputs are short-circuit proof

Simple to add new field devices

Field Barriers
(refer to add-on catalog) 40mA per output (EEx i)
PROFIBUS PA
instrinsically safe (EEx i) Barriers can be cascaded

Hazardous Area Operation in Zone 1

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Redundancy Prevents Major Potential Faults

AS 41x H

PROFIBUS PA Trunk
Bus termination

PROFIBUS DP

Spur

Failure Effect
DP/PA Coupler Breakdown of up to 31 devices

Short-circuit / wire break on Trunk Line Breakdown of up to 31 devices

Short-circuit / wire break on Spur Line Breakdown of typ. 1-4 devices

Missing bus termination Disturbance of communiaction

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Redundant Configuration Options
PROFIBUS DP Coupler Redundancy
Coupler Redundancy
M DP/PA Coupler,
redundant (M =
master)

IM 153, redundant Active Field Splitter

PROFIBUS PA

Bus termination
Automatic bus termination

PA Ring Redundancy
PROFIBUS DP

Coupler Redundancy
MM
DP/PA Coupler, Media redundancy based on a ring topology
redundant (M = Master)
Active Field Distributor

IM 153, redundant

PROFIBUS PA
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: High Availability with Ring Redundancy

M DP/PA-Link
redundant PRFOBUS DP connection
PROFIBUS DP

PA coupler redundancy
PA media redundancy

PROFIBUS PA

Short-
Short-circuit or
wire break on trunk line

AFD AFD AFD

Automatic bus termination

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Safe Device Installation using Active Field Distributor (AFD)

Active Field Distributor (AFD)

Automatic partial segment isolation

Automatic bus termination
Short-circuit proof spurs (4x 60 mA)
Diagnostics by LEDs

IP66 case, PG connectors Devices connected to

Temp. range: -20°… 70° spur 2 and 3
(blinks on short-circuit) No device on spur
Installation up to Ex zone 2 3 and 4
Termination Termination
enabled disabled

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Changing Hardware in Run

Add new devices

Expand line
Bus termination
Automatic bus termination
M
Expand ring

PROFIBUS PA

AFD AFD AFD AFD AFD

Mixed operation of single and redundant

DP/PA Couplers in one DP/PA Link possible

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Enhanced Diagnostics

DP/PA Coupler as PROFIBUS diagnostic slave

Identification and Maintenance
(I&M) Data
Redundancy state
Current value
Voltage value
Short-circuit und wire break
Signal level
Local life list
Diagnostics by LEDs
Short-circuit or wire break
Support in determination of failure locations

For internal use only / © 2007 SIEMENS AG

page 259 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Diagnostics with PDM

Standard Device specific

diagnostics detailed diagnostics

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Diagnostics with PCS 7 Asset Management

Detailed diagnostics
via PDM

Available views:

Identification
Alarms
Diagnostics
Parameters
Change Report
Maintenance

FDC 157-0 DP/PA coupler is fully integrated in the PCS 7 Asset Management
For internal use only / © 2007 SIEMENS AG
page 261 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Increase of Accuracy …

Conventional 4…20mA technology

0...10 bar A
0...50 bar D 8.9
A D
D µP A 4…20mA 0...10 bar

PROFIBUS technology

0...50 bar 8.928

A PA- 8.928
D µP Interface

PROFIBUS PA

turns into a dramatic increase of process control

Less drift, faster conversion
32 bit resolution, digital transmission
No application specific measuring ranges
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Multi Variable Process Instruments

Conventional 4…20mA technology

3 conventional
4…20mA
4…20mA transmitters
Logic in controller
(total flow, direction)

PROFIBUS technology

PROFIBUS PA One single device

Actual flow
Total flow (forward, reverse, reset)
Temperature

Less devices, wiring, controller logic

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFIBUS PA: Bidirectional Communication

Conventional 4…20mA / 24 VDC technology

Analog 4…20mA
Analog 4…20mA
Set point
Readback actual value
Digital
Digital 24 VDC
Position (closed, opened, failsafe)

PROFIBUS technology
PROFIBUS PA
One single wire

Less wiring, I/O cards . . .

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS PA

Customer Benefits

Easy installation because of

bus powering (incl. I.S.) and
automatic bus termination

Prevention of unscheduled
plant downtimes due to
scalable redundancy concept

Early fault recognition and preventive maintenance due to enhanced

diagnostics and Asset Management support

Cost saving alternative for conventional technologies

(4…20mA, HART, etc.)

Hardware configuration change (including modifications on trunk line) in run

without production downtimes

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

Failsafe Applications

F-Master
Standard-Master

Standard-I/O F-I/O

PROFIBUS DP
Coexistence of standard and failsafe communication Repeater

DP/PA

Standard-I/O

F-Field-
Device

PROFIsafe on PROFIBUS DP implemented since 1999

PROFIsafe on PROFIBUS PA implemented since 2006
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFISafe

F_PA_DI

F_PA_AI

4…20 mA

PROFIsafe on PROFIBUS DP (SIL3) PROFIsafe on PROFIBUS DP and PA (SIL3)

IEC 61508/11:
The whole communication path to the field device is failsafe now!
Cost savings:
No F-I/Os required, less cabling
Simplified periodic testing
Seamless integrated in PCS 7 Engineering and Maintenance

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

PROFISafe: Conventional Fault Tolerant and Failsafe Applications

Yesterday’s Architecture Failsafe fault tolerant

measurement (2oo3)
S7-400FH

2oo3
PROFIBUS DP

ET200M (F)

Safe communication to the I/O card

Safety and fault tolerance requires multiple I/O cards

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / PROFIBUS

PROFISafe: Cost Saving Architecture Fault Tolerant and Failsafe Applications

Today’s Architecture Failsafe fault tolerant

S7-400FH
measurement (2oo3)
PROFIBUS DP

DP/PA Coupler, redundant

Safe communication down 2oo3

to the field device

Safety and fault tolerance

on one segment
1oo2

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / PROFIBUS

The Fieldbus Network Motivation

Up to 70% space saving + 40% cost saving

Cabinet Cabinet

Terminal blocks

Terminal blocks PROFIBUS

Safety barrier
Terminla blocks

Drive Distributed I/O´

I/O´s Measurement
Drive
Measurement
For internal use only / © 2007 SIEMENS AG
page 270 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / PROFIBUS

The Process Fieldbus

Field proven technology

Huge installed base
Huge range of available device types
Open standard ensures optimal interchange- and interoperability

Integrates all automation tasks

High Speed
Bus powered (PROFIBUS PA and FOUNDATION fieldbus)
HART
Operation in hazardous areas
Safety

Lower installation, commissioning and maintenance costs

Central configuration and parameterization
Plug & play for hazardous areas
Optimal interchangeability and interoperability

Prevention of plant downtimes

Seamless integrated and scalable redundancy concept
Enhanced diagnostic / Asset Management
Hardware configuration change in run

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / DP/FF-Link

Optimal Architecture based on Customer's Requirements

ES OS MS PDM

Industrial Fast Ethernet

AS

PROFIBUS DP

FOUNDATION Fieldbus
Remote
PROFIBUS PA
PROFIBUS PA

I/O
Drives
redundancy

H1

For internal use only / © 2007 SIEMENS AG

page 272 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / DP/FF-Link

Features

DP/FF-Link Bundle (6DL4400-1AA) consists out of: Key Features

Central engineering
PROFIBUS DP Uplink „Anybus DP-Link“ (HMS) Cyclic and acyclic data exchange
Fieldbus interface Module „FIM3420“ (EMERSON)
Detailed diagnostics
MS Integration in PCS 7 Asset
ES Management
„Control In The Field“
Anybus DP-Link FIM 3420
Industrial Fast Ethernet
41x

DP/FF-Link
PROFIBUS DP

FF-H1

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / DP/FF-Link

Quantity Structure

41x(H)

max. 10 external DP lines

PROFIBUS DP

per CPU

Y-Link
1 DP/FF-Link per Y-Link
DP/FF-Link
max. 64
FF-H1 FF-Devices
4 FF-H1 Segments per
per DP/FF-Link DP/FF Link

DP/FF-Link max. 16 FF-Devices

per FF-H1 Segment
FF-H1

Max. 64 FF-H1-Field devices per DP/FF-Link with:

8 binary outputs
8 binary inputs
32 analog inputs
16 analog outputs

For internal use only / © 2007 SIEMENS AG

page 274 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS7 / DP/FF-Link

Configuration in HW Config (1)

Inserting AnyBus DP-Link from the “PROFIBUS DP / Additional Field Devices / Gateway” directory
on the DP master system
I/O slots of the AnyBus DP-Link have already been correctly assigned

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / DP/FF-Link

Configuration in HW Config (2)

Definition of the symbols for the symbolic interconnections of the FF driver blocks
Address assignment for process value and status according to the later MODBUS
mapping of the FIM3420
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / DP/FF-Link

Driver Blocks for FF-H1 Devices

FF_A_AO

FF_A_AI

FF_A_DO

FF_A_DI

Drivers for FF-H1 devices are included in the “PCS 7 Library V7.0”

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / DP/FF-Link

Configuration in CFC

FF driver blocks are symbolically interconnected with the I/O address and connected to
the diagnostics drivers and the status information by the driver generator
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / DP/FF-Link

Configuration of the FF-H1 Field Devices

Importing EDDs for the devices to be configured

The FIM 3420 permanently polls all connected field devices and automatically detects
the currently accessible field devices.
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / DP/FF-Link

Mapping FF-H1 Tags to Process Image

Example for the assignment of an analog

input value of a FF field device

Register assignment: Status value

1. Assign register 2. Assign value

Register assignment: Process value

FIM 3420 web interface

The values and associated quality codes of the FF devices are mapped to MODBUS registers
Each MODBUS register comprises 2 bytes. Analogue values require 2 registers (4 bytes), status and
digital values require 1 register (2 bytes)
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS7 / DP/FF-Link

FF-H1 Devices on PCS 7 Maintenance Station

ASSETMON
represents FF device

Diagnostics status of the FF device is visualized via ASSETMON

Further information on the device can be called via SIMATIC PDM

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / DP/FF-Link

FF-H1 Segment Diagnostics via Web-Interface of the 3420 (1)

Detailed diagnostics possible via the FIM3420 web interface

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS7 / DP/FF-Link

FF-H1 Segment Diagnostics via Web-Interface of the 3420 (2)

Diagnostics status of the FF field devices available via the FIM3420 web interface

For internal use only / © 2007 SIEMENS AG

page 283 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Remote IO

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Remote IO
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 285 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

Overview

Connection of the distributed I/O via PROFIBUS-DP:

S7 400 electrical, with fiber optics, single or redundant
Controller
with S7 400 I/O Several DP chains allowed for each controller: up to 10 via
PROFIBUS-DP

ET 200M external CPs and up to 4 via internal DP interfaces

Comprehensive range of I/O modules
ET 200M
(Failsafe)
- Standard signal modules (low price for each channel)
- Control system modules (diagnostics, output substitute
OLM

ET 200iSP value for each channel)

- Intrinsically safe (Ex) modules for connecting
Fiber Optic

actuators/sensors in zone 0/1

ET 200S
- Function modules (e.g. closed loop controller, motor
starter, weighing module, counter module)
OLM

- HART modules (for integrating HART field devices)

DP/AS-I
- Safety modules (for failsafe applications)
- S7 400 I/O modules for CPU main rack
PROFIBUS-DP

DP/EIB
Hot Swappable modules, I/O configuration changeable
during runtime operation
Serial
(e.g. Modbus) AS interface for easy integration of actuators / sensors
EIB instabus for integration of building automation

For internal use only / © 2007 SIEMENS AG

page 286 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

Flexible Solutions for Signals from Hazardous Areas

ET 200M

PROFIBUS DP
DP/PA Link
PROFIBUS PA

Zone 0
RS485iS Coupler

ET
200iSP Zone 1
ET 200S
Zone 2

ET 200M, ET 200S, DP/PA link/coupler can be located in i.S. zone 2 (Class I Div 2)
ET 200iSP modules for connection to signals from zone 1
ET 200iSP for operation directly in zone 1 (Class I Div 2), for connection to signals from
zone 0 (Class I Div 1)
PROFIBUS PA for signals from zone 1 and zone 0

For internal use only / © 2007 SIEMENS AG

page 287 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

ET 200M

Protection level IP20, operating range 0...60°C (-2 0...60°C) Power supply Interface module
Redundant connection (for H CPUs) for Profibus DP
IM153-2
I/O Module Redundancy (1 Sensor -> 2 Modules)
Electrical isolation from the backplane bus
Modularly expandable with hot swap backplane bus
on aluminium rail
Max. 12 I/O modules per station
I/O module
No slot restrictions Expandable
20 or 40 pin front connector in screw, spring-loaded backplane
or fast connect type (1.5mm2/0.75mm2) Aluminium rail
I/O Modules with comprehensive diagnostics
Missing sensor power / load voltage
Short-circuit, wire break detection
Substitution value applied due to Controller or Bus failure
Invalid parameters in module
Watchdog triggered
EPROM error
RAM error etc.

For internal use only / © 2007 SIEMENS AG

page 288 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

ET 200M: Range of Modules

Digital inputs Digital outputs

8, 16, 32 channels 8, 16, 32 channels
DC 24 V, DC 48-125 V DC 24V, DC 48-125 V, AC 120/230 V, AC/DC 24-48V
AC 120/230V, NAMUR 0,5 / 1 / 2 / 5 A per channel
Electronic / relay outputs
Analog inputs
2, 4, 8 channels
Multifunctional modules for U, I, TC, RTD, resistance
Specific modules for
Voltage: e.g.: 0-10V, +/-10V; Current: +/-20mA, 0/4..20mA (2, 4 wire)
Thermocouple 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)
Resistance: 150, 300, 600, 750 Ohm
Variable resolution/accuracy (up to 16 bit, 0.1%)
HART including HART IEEE Values
Analog outputs
2, 4, 8 channels
Voltage: 0-10V, +/-10V; Current: +/-20mA, 0/4..20mA (2 or 4 wire)
Variable resolution/accuracy (up to 16 bit, 0,1%)
HART including HART IEEE Values
For internal use only / © 2007 SIEMENS AG
page 289 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

ET 200M: New 8-Channel HART Modules

Additional input range +/- 20mA at the AI module

Improvement of the resolution to 16 bit for both the 8AI and the 8AO;
independent of used noise suppression
Improvement of the accuracy to +/-0,15% (8AI) and +/-0,2% (8AO)
respectively, independent of used noise suppression
Enhanced cable length to 800m
Enhancement of load resistance to 750Ohm for the 8AO
I/O Redundancy
FW Update in RUN
HART IEEE Value support (4 per channel / 8 per module)
Time stamped Diagnostic buffer

For internal use only / © 2007 SIEMENS AG

page 290 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

ET 200M: Support for Redundant IO Modules

I/O redundancy for selected modules Configuration via browser

from the ET 200M series

AS 412 H
AS 414 H
AS 417 H
PROFIBUS DP

I/O Module
Sensor

I/O module
redundant

Redundancy can be configured separately for each module

Combination of redundant and non-redundant modules can be used within a single AS
No special logic
For internal use only / © 2007 SIEMENS AG
page 291 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

ET 200M: Module Range for Redundant IO with channel redundancy

PCS 7 V7.0 SP1 Redundancy type

DI
16xDC 24 V 6ES7 321-7BH01-0AB0 channel
24xDC 24 V 6ES7 326-1BK00-0AB0 *) module
8xNamur Ex 6ES7 326-1RF00-0AB0 *) module
DO
10x24 VDC/2A 6ES7 326-2BF00-0AB0 *) channel
16x DC DC 24 V/0.5 A 6ES7 322-8BH01-0AB0 channel
AI
8x16Bit 6ES7 331-7NF00-0AB0 channel
6x13Bit 6ES7 336-1HE00-0AB0 *) channel
8x16Bit HART 6ES7 331-7TF01-0AB0 channel
AO
8x12 Bit 6ES7 332-5HF00-0AB0 channel
8x16 Bit HART 6ES7 332-8TF01-0AB0 channel

*) F-Module in Standard Mode

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

SIMATIC PCS 7 Terminal Modules (MTAs)

MTA

fast and easy connection of the field level to ET200M I/O modules
prevent wiring faults
provide wiring and installation effort/costs reduction.
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Remote IO

SIMATIC PCS 7 Terminal Modules (MTA‘s)
Redundant ET200M Single ET200M

MTA MTA

Preconditioned
cable incl.
connectors
+ - + - + -

MTAs provide fast and easy connection of the field level to ET200M I/O modules
SUB D plugs for connection to preconditioned cables
1:1 screw terminals to the field level
channel fuses with LED indication
redundant power feeder including power monitor board for diagnostics (Option)
redundancy support for ET200M modules
For internal use only / © 2007 SIEMENS AG
page 294 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Remote IO

MTA: Product Overview

I/O Range Associated ET200M Redundant I/O

Description MLFB Number Interconnecting Cable
per channel I/O Module MLFB Support

Std-8-chan, 1-5 V 6ES7922-3BD00-0AS0 (3 m)

6ES7650-1AA51-2XX0 6ES7 331-7NF00-0AB0 YES
Analog Input MTA 0/4-20 mA 6ES7922-3BJ00-0AS0 (8 m)

Std-8-chan, 6ES7922-3BD00-0AS0 (3 m)
4-20 mA 6ES7650-1AB51-2XX0 6ES7 332-5HF00-0AB0 YES
Analog Output MTA 6ES7922-3BJ00-0AS0 (8 m)

Std-8-chan, Thermocouple 6ES7 331-7PF10-0AB0 6ES7922-3BD00-0AS0 (3 m)

TC 6ES7650-1AF51-2XX0 NO
MTA 6ES7 331-7PF11-0AB0 6ES7922-3BJ00-0AS0 (8 m)

Std-8-chan, 6ES7 331-7PF00-0AB0 6ES7922-3BD00-0AS0 (3 m)

RTD 6ES7650-1AG51-2XX0 NO
RTD MTA 6ES7 331-7PF01-0AB0 6ES7922-3BJ00-0AS0 (8 m)

Std-16-chan, Discrete 6ES7922-3BD00-0AT0 (3 m)

24 VDC 6ES7650-1AD10-2XX0 6ES7 322-8BH01-0AB0 YES
Output MTA (10/2007) 6ES7922-3BJ00-0AT0 (8m)

Std-16-chan, Discrete Input 6ES7922-3BD00-0AN0 (3 m)

24 VDC 6ES7650-1AC11-3XX0 6ES7 321-7BH01-0AB YES
Input MTA 6ES7922-3BJ00-0AN0 (8 m)

Failsafe 24-chan, Discrete 24 6ES7 326-1BK00-0AB0 6ES7 326- 6ES7922-3BD00-0AS0 (3 m)

24 VDC 6ES7650-1AK11-7XX0 YES
VDC Input MTA 1BK01-0AB0 6ES7922-3BJ00-0AS0 (8 m)

Failsafe 10-chan,Discrte 24 6ES7922-3BD00-0AN0 (3 m)

24 VDC 2A 6ES7650-1AL11-6XX0 6ES7 326-2BF01-0AB0 YES
VDC Output MTA 6ES7922-3BJ00-0AN0 (8 m)

Failsafe 6-chan, 6ES7922-3BD00-0AS0 (3 m)

4-20 mA 6ES7650-1AH51-5XX0 6ES7 336-1HE00-0AB0 YES
Analog Input MTA 6ES7922-3BJ00-0AS0 (8 m)

Failsafe 10-chan, 110-220VAC 5A 6ES7922-3BD00-0AS0 (3 m)

6ES7650-1AM30-6XX0 6ES7 326-2BF01-0AB0 YES
Relay Output MTA 24VDC 5A 6ES7922-3BJ00-0AS0 (8 m)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200M: Serial Communication with CP341

Features
1 channel design
Can be inserted anywhere in ET200M chain
3 models for transmission physics:
RS 232C (V.24)
20 mA (TTY)
RS 422/RS 485 (X.27)
Protocol types
ASCII

PROFIBUS-DP
3964 (R)
RK 512 Serial connection
e.g. MODBUS
MODBUS master, slave
Integration in PCS 7 with automatic diagnostics
Custom redundant interfaces

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200M: Controller Modules FM355

Features
4 continuous or step controllers per FM355
Reduces the load in the Automation System (AS)
Back-up function – control even after AS failure
Integrated within PCS 7 by via function blocks and faceplates
Min. conversion time 20msec. (100msec with FM355-2)
8 DI, 4 AI, 8 DO (step), 4 AO (cont.)
Back-up controller FM355
Temperature control
Ride-height control
Liquid level control
Pressure control
Flow control
Concentration control
Back-up controller FM355-2
Special for temperature controls
Integrated online self-optimization without configuration

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200M: Counter Module FM350

Features
FM350-1 (40 mm wide)
1 Channel
Counter frequency max. 500 kHz (endless, once, periodical)
32 Bit
Latch function
FM350-2 (80 mm wide)
4 independent channels for PCS 7
Counter frequency max. 20 kHz (endless, once, periodical)
Frequency
Revolution

PROFIBUS-DP
Periodic time
FM350-1 FM350-2
Dosing
Integration in PCS 7 with function block and automatic
diagnostics

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200S: Overview

Power modules
Protection level IP20 Interface module
for PROFIBUS
Operating range 0...60°C DP IM151 HF
Comprehensive series
Rail
DI, DO, AI, AO
Motor starters (Standard and Failsafe) Electronic module
DI, DO Failsafe Modules
Terminal module
Permanent wiring enables easy module replacement
Comprehensive diagnostics (wire break, short-circuit, Terminal module
module error etc.) with integrated
energy bus Motor
Integration into PCS 7 using the standard driver concept starter
“Hot swapable” during operation
Max. 64 modules per station
Certified for Ex zone 2 (electronic module only)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200S: IO Modules

Digital input Digital output

2, 4, 8 channels 2, 4 channels
DC 24 V, AC/DC 24-48 V DC 24 V, AC 120/230 V, AC/DC 24-230 V
AC 120/230V 0,5 / 1 / 2 / 5 A per channel
Electronic / relay outputs
Analog input
2 channels
Voltage: 0-5V, +/-10V, +/-5V
Current: +/-20mA, 4..20mA (2, 4 wire)
Thermocouple type E, N, J, K, L, S, R, B, T, C (internal linearization)
Pt 100/200/500/1000, Ni100/1000, (2, 3, 4 wire, internal linearization)
Resistance: 150, 300, 600 Ohm
Variable resolution/ accuracy (up to 15 bit, 0.1%)
Analog output
2 channels
Voltage: 0-5V, +/-10V; Current: +/-20mA, 4..20mA
Variable resolution/accuracy (up to 16 bit, 0.05%)

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200S: Integrated Motor Starter

Up to 80% less wiring

Drastically reduced costs for configuration
and documentation
50% reduction in required cabinet space
Substantially reduced testing costs
Easy to Wire

energy bus
(does not require industry-specific know how)
Rangierverteiler
Permanent wiring
Increased availability due to replacement
under load in a few seconds without tools Leistungsschalter

Energiezuleitung
Integrated voltage busses
with up to 40A current capacity Schütze
Power range up to 7.5 kW
0.3-16 A; 500VAC (IEC)
Terminals
0.3-16 A; 600VAC (UL, CSA)
Direct (soft) starter, reversing starter
Failsafe Motor Starter up to SIL 3
Diagnostics functions (e.g. short-circuit, overload) M M M

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200iSP

ET 200iSP is a remote I/O series

for connection of intrinsically safe signals (Ex i)

Direct installation in zone 1 (21), zone 2 (22)

with gas (dust) atmosphere
and in non-hazardous areas

Connected sensors and actuators

can be installed directly in zones up to 0 (20)

Explosion protection in compliance with CENELEC: II2 G(1) GD Eex de ib [ia]

IIC T4

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200iSP: Product Features

Intrinsically safe
Installation up to Compact
Zone 1 and flexible

Optimal integration
in PCS 7 and others
Full redundancy
(diagnostic, …)

HART-
SIMATIC transparent
integrated
parameterization
(TIA) Counter +
Frequency
measurement
Hot swapping +
Configuration in Run
Optimized connection
of valves
For internal use only / © 2007 SIEMENS AG
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SIMATIC PCS 7 Remote IO

ET 200iSP: Product Features

Modularity
Function and cost-optimized station design
Expansion capability
16 modules can be plugged regardless of type, expandable to up to 32
modules per ET 200iSP station with configuration rules adhered to

Permanent wiring
Easy connection method as with terminal block
Faster installation through prewired terminal modules
Fast wiring testing without imposing a risk on electronic components
Hot swapping - module exchange during operation
Increased availability due to fast module exchange

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200iSP: Product Features

Reliable design
Robust design for hostile industrial environments (5g vibration strength)
Spring-loaded terminals or screw terminals for terminal modules
Operation at temperatures between -20 °C and +70 °C for horizontal
installation
Self-coding of the interface and electronics modules
Redundancy
Higher plant availability due to the redundant design of the power supply
and/or of the PROFIBUS connection of ET200iSP

For internal use only / © 2007 SIEMENS AG

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SIMATIC PCS 7 Remote IO

ET 200iSP: Product Features

Configuration in Run (CiR)

Adding / removing stations
Adding / removing new modules
Changing parameters of modules during operation

System integration
Integration into PCS 7, PDM and Asset Management
CFC driver integrated into PCS7:
Automatic generation of all required system function blocks, interconnections and
messages
Full Integration in PCS 7 Asset Management
New blocks: MOD_HA, CH_CNT1
Firmware upgrade possible via bus

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200iSP: Product Features

HART support
Connection of HART devices possible
Full HART functionality
Direct access via PROFIBUS DP, no service bus required (e.g. diagnosis)
Central data management possible in control system, no HART handheld
required
Access to all HART devices possible via PDM
All HART field devices can be used like “normal” digital I/Os
Use of HART IEEE variables possible (secondary values)
Additional measured values, temperatur for example

Counting and frequency measurement

Up to two inputs of the DI module can be used for counting or for measuring
frequencies
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Remote IO

ET 200iSP: HART Devices and Digital Devices

PCS 7
SIMATIC HW config Engineering Station Ethernet

S7-400
Controller

diagnostics &
commissioning
PROFIBUS DP max. 1,5 MBit/s
Ex-Coupler
RS 485iS
PROFIBUS DP
RS 485iS
Drive max. 1,5 MBit/s
Motor Starter Positioner DP/PA Link

PROFIBUS-PA 31,25 Kbit/s ET 200iSP

Classic
I/O
& HART
Positioner Level Temperature Flow Pressure

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200iSP: Product Structure

Power supply Terminal module Interface module

Ex protected, for power supply
Termination
Sand enclosure,
module
explosion-proof
Electronic module EEx ib

Connection terminals EEx

Equipotential Connection of ia/ib
grounding 24V DC PROFIBUS DP Ex
ib
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Remote IO

ET 200iSP: Module Range
Power supply (redundancy option available)
IM 152 interface module (redundancy option available)
Watchdog module (life beat monitoring and intrinsically safe power supply)
Digital modules
digital input 8 DI NAMUR
digital output 4 DO, DC23,1V/20mA
digital output 4 DO, DC17,4V/27mA
digital output 4 DO, DC17,4V/40mA
all DO modules available with external high or low shut-down:
capability to switch the off output signals via external H or L signal
Analog modules
analog input 8 AI I 0..20/4..20mA/HART 4..20mA (2 wire and 4 wire)
analog input 4 AI RTD and TC (temperature)
analog output 8 AO HART
Reserve module (for further expansion)
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Remote IO

ET 200iSP: Integrated Valve Block by BÜRKERT

BÜRKERT – AirLINE Ex Type 8650

Integrated solution for electrical and pneumatic
signals for applications up to Ex zone 1 / 21
(housing with IP30)

Digital outputs for integrated pilot valves

Up to 32 electronic / pneumatic modules

Up to 48 pilot valves for 11mm-valves

(QNN = 300l/min typical in Process Industries)
or up to 32 pilot valves for 16.5mm-valves
Detailed information at:
3/2-way + 5/2-way valves

Pressure range: 2,5 - 8 bar (optional 1 – 8 bar)

http://www.Burkert.com
Temperature range: 0 – 55°C

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200pro: Distributed System Solution in IP65/67
No additional enclosure necessary
Extremely resistant to vibrations
-> Direct machine mounting even with heavy loads
Metal version of connection modules
-> Rugged and optimum shield connection
Application up to -25º C !
-> Usage in refrigerated warehouse etc.
Optional expansion with 16 expansion modules
Station width up to 1 meter
Optional expansion with 16 expansion modules

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200pro: Design – modular and well thought-out

Connection module Interface module IM

CM IM
Bus module
Mounting rail
narrow

Electronic module EM Bus termination

module
Connection module CM

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200pro: Interface Module
CM IM DP ECOFAST: CM IM DP Direct:
IM 154-2 DP High Feature only one hybrid cable (Bus + L1 + Cable gland -
L2) up to 16 A and 2,5 mm2
Integrated Power module for load
power supply L2+ (various load
groups in one station)
Maximum address range:
244 Input- and 244 Output bytes
Providing failsafe modules
Connection via PROFIBUS DP:
Running as DPV0- or DPV1-Slave
(Diagnostics- and Process alarms
possible)
CM IM DP
3 types of connection modules:
M12 / 7/8“:
CM IM DP ECOFAST, CM IM DP M12, 7/8‘‘ –
Direct, CM IM DP M12 / 7/8” widely used

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Remote IO

ET 200pro: PCS 7 Integrated Module Range

Digital High Feature Modules:

- 8-channel DI
- 4-channel DO

Analogue High Feature Modules:

- 3 different 4-channel AI
- 2 different 4-channel AO

Failsafe Digital Modules:

- 16/8-channel F-DI
- 8/4-channel F-DI + 4-channel DO

For internal use only / © 2007 SIEMENS AG

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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Field Devices & Drives

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Field Devices & Drives
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 317 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 / Field Devices & Drives

Neutral, Multi-Vendor Integration in PCS 7

Flexible, open selection of field devices, based on neutral, multi-vendor device

descriptions for parameter assignment and description of the communication

PROFIBUS DP field devices

HART field devices
PROFIBUS PA field devices
FOUNDATION Fieldbus H1 devices
Mixed operation of different devices
4-20 mA, HART, PA, DP

For internal use only / © 2007 SIEMENS AG

page 318 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 / Field Devices & Drives

Process Sensors

Level Flow Temperature

Capacitance Ultrasonic Radar Ultrasonic Rack Head
Coriolis 2-wire

PA
Clamp On
MID

Field HART

Pressure Positioners Panel Instruments Weighing

Electro Process Controllers SIWAREX
pneumatic Components

Weigh Belt
Feeders Scales

Pneumatic Process Recorder

For internal use only / © 2007 SIEMENS AG
page 319 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 / Field Devices & Drives

Process Analytics

Gas Analytics Spectrometry

Series 6 Rack Mass Spec
Fidamat

Calomat
Series 6 Field
Oxymat

Laser
Ultramat 23
Spectrometry

Gas Chromatography Exhaustgas Analytics

Maxum edition II SIBENCH E-BOX

MicroSam

For internal use only / © 2007 SIEMENS AG

page 320 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 / Field Devices & Drives

Motor Control

Motor Control Management PCS 7 SIMOCODE pro – Library (V7.0)

In HW-Config.: Insert „SIMOCODE pro V (PDM)“
(e.g.) below „Switching Devices“ in the Standard
Library

Frequency Inverters

SIMOCODE
PRO

MICROMASTER
Drive ES PCS 7 DRVPCS7 – Library (V6.1)
In HW-Config.: Insert „MICROMASTER 4
lite“ below „Frequency converter“ in the
Standard Library
For internal use only / © 2007 SIEMENS AG
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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Process Safety

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Process Safety
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 323 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Objective of Safety Engineering

To avoid accidents and damage when a fault

occurs and to ensure maximum safety for

Environment/
People Process
nature

For internal use only / © 2007 SIEMENS AG

page 324 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Cause of Faults in Automation Systems

Operation & Changes after

maintenance commissioning
21%
15%
Installation &
commissioning 6%

15% 44%
Planning &
implementation Specification

* Health and Safety Executive

For internal use only / © 2007 SIEMENS AG

page 325 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

International Safety Standards

IEC61508
IEC 61508 serves as the basic standard and basis for safety standardization.
It covers all areas where electrical, electronic or PLC systems are used to realize safety-related
protection functions.

IEC61511
There are sector-specific standards based on IEC 61508, such as IEC 61511
for the process industry or IEC 61513 for the nuclear industry
These sector standards are important for planners and operators of
corresponding plants.
For internal use only / © 2007 SIEMENS AG
page 326 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Evaluation of Risk to define the SIL Risk Chart

W3 W1 Effect
W2
Ca Minor injury
Ca X1 a Cb Major, irreversible injury
or death of one person
Cc Death of several persons
Pa X2
Fa 1 a Cd Death of very many
persons
Cb Pb
X3 2 1 a
Fb Pa Frequency and duration
Fa Seldom to often
Pb
Cc Fa X4 Fb Frequent to constant
Pa 3 2 1
Fb
Pb Danger prevention
Cd Fa X5
Pa 4 3 2 Pa Possible under
Fb cert. circum.
Pb X6 Pb Nearly impossible
b 4 3
Probability of occurrence
Safety Integrity W1 Very low
Levels SIL W2 Low
a = no special safety requirements W3 Relatively high
b = individual safety system insufficient
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Process Safety

Target Safety Integrity Levels

Probability of failure on
Safety Integrity demand (PFD) Risk Reduction Factor
Level per year = 1/PFD
(Demand mode of operation)

SIL 4 >=10-5 to <10-4 100000 to 10000

SIL 3 >=10-4 to <10-3 10000 to 1000

SIL 2 >=10-3 to <10-2 1000 to 100

SIL 1 >=10-2 to <10-1 100 to 10

SIL: A performance criteria of a SIS, among other things, describes the

probability of failure on demand.
For internal use only / © 2007 SIEMENS AG
page 328 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Risk Analysis and Minimization

Risk for a technical facility

Changed process
layout
Other measures for risk
minimization

Risk Safety systems

Acceptable risk
“Zero risk” is not feasible
For internal use only / © 2007 SIEMENS AG
page 329 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Safety Concept for a Plant

Disaster Disaster protection

protection

Collection
basin Passive protection

Overpressure
valve, rupture Active protection
disc

Safety system Safety Safety Instrumented

(automatic) System (SIS)
shutdown

Plant
personnel
intervenes Process alarm
Process control
system
Basic
Process
automation value Normal activity

For internal use only / © 2007 SIEMENS AG

page 330 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Safety Instrumented System (SIS)

SIS: A combination of sensors, logic units (e.g. controllers) and actuators which
detect abnormal operating conditions and AUTOMATICALLY switch the plant to
a safe state.

Safety Instrumented Basic Process Control

System (SIS) System (BPCS)
Inputs Outputs Inputs Outputs

PT PT
1A 1B

I/P

FT

Reactor

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Process Safety Applications

Safety applications in the Process Industry

Emergency and Process Shutdown Systems (ESD/PSD)

According to IEC 61508, IEC 61511 and ISA S84

Burner Management Systems (BMS)

According to NFPA 85

Fire & Gas Applications (F & G), Fire Detection and Fire Alarm Systems
According to EN 54, NFPA 72

For internal use only / © 2007 SIEMENS AG

page 332 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Process Safety with Safety Integrated

For internal use only / © 2007 SIEMENS AG

page 333 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

SIMATIC Safety Integrated

Integrated Control & Safety

Totally Integration into SIMATIC PCS 7
One User-Interface for Engineering, Operation, Diagnosis and HMI
One platform for safety and none-safety applications

Flexible Modular Redundancy

Provides scalable, cost effective solutions for your application

Integrated Safety-Fieldbus Technology

Failsafe and fault-tolerant communication between CPUs, distributed IOs and safety
field devices

Safety Lifecycle Engineering

Easy programming with CFC and Safety Matrix
Safety Matrix as Lifecycle Management Tool

For internal use only / © 2007 SIEMENS AG

page 334 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

The “Right” Level of Integration

ENG HMI ENG

INTERFACED
DCS Gateway SIS

ENG HMI

INTEGRATED
DCS SIS

ENG HMI

COMMON

DCS SIS

For internal use only / © 2007 SIEMENS AG

page 335 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

The “Right” Level of Integration

ENG HMI SIMATIC S7-400FH ENG

INTERFACED Gateway
DCS Gateway SIS

SIMATIC PCS 7
ENGES & OS HMI SIMATIC S7-400FH

INTEGRATED
DCS SIS

SIMATIC PCS ENG

7 HMI
SIMATIC S7-400FH
ES & OS
COMMON

DCS SIS
Std. I/O

For internal use only / © 2007 SIEMENS AG

page 336 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Integrated Control and Safety

Common controller platform for process control and process safety

One hardware for all

One engineering system for process control and process safety application
Reduces training and uses the available knowledge

User-friendly display of process safety information in PCS 7

Automatic integration of process safety diagnostics into the operator interface

Direct communication between DCS and SIS

Less engineering work

For internal use only / © 2007 SIEMENS AG

page 337 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

SIMATIC Safety Integrated

Process Safety Distributed Safety

Controller Controller
CPU 412H for PROFIBUS
CPU 414H ET 200S F-CPU
CPU 417H CPU 315F/317F-2DP
CPU 416F-2
for PROFINET
CPU 315/317F-2PN/DP
Engineering
CFC CPU 416F/CP443-1ADV
Safety Matrix Engineering
FBD, LAD

PROFINET with
PROFIBUS with PROFIsafe-Profile
PROFIsafe-Profile
Actors ET 200M ET 200ecoET 200S ET 200pro ET 200S ET 200pro
Sensors

For internal use only / © 2007 SIEMENS AG

page 338 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Scalable, Distributed Architecture

S7-417-4H
Redundant Systems 30MB

S7-414-4H
2.8MB

S7-412-3H
768kB

All certified to SIL 3 For internal use only / © 2007 SIEMENS AG

page 339 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Innovated and New H/F-Controller

414-4H 417-4H

today

1,4 MB/60ns 20 MB/30ns

412-3FH 414-4FH 417-4FH

V7.0 SP1

768KB/75ns 2,8MB/45ns 30MB/18ns

more Memory & Speed same Price

FW-Update via Ethernet
capable for FW Update in RUN
CPU Load Analysis
improved Diagnostic Capabilities

For internal use only / © 2007 SIEMENS AG

page 340 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Safety Mechanisms: CPU-Software Architecture

F-User Program
Standard- F-User Blocks F-Control
User Blocks
Program F-Standard- F-System-
blocks blocks

Program Program
execution execution

Communications Self tests

Safety-relevant sections of the operating system

Standard-
Operating System F-Access protection Safety-relevant Safety-relevant
System Func. Calls Self tests

For internal use only / © 2007 SIEMENS AG

page 341 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Safety Mechanisms: Coded Processing

Time redundancy and multiple channels instead of structural redundancy

A, B C
Operators Operation Output
AND

Coding Comparison Stop

by D ≠ /C
OR
Multi-
Multi-
Multi-
Multi-channel Multi-
Multi-channel
channel
operators /A, /B operation D = /C output

Time redundancy
Time

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

SIMATIC Failsafe I/Os

SIMATIC PROFIsafe modules

Parameterization via STEP 7 EN 954 (up to Category 4)
UL-listed NFPA 79 – 2002,
IEC 61508 (up to SIL 3) NFPA 85
TÜV-certified
and IEC 61511

I/O DI DO AI Motor starter Features

The modular I/O for high-channel

ET 200M X X X -- applications with up to 24 channels per
module

ET 200S The bit modular I/O with up to eight

X X -- X
channels per module

The low-cost block I/O with high degree

ET 200eco X -- -- -- of protection IP 65/67

ET 200pro X X -- -- High degree of protection IP 65/67

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Process Safety

SIMATIC ET200M Failsafe I/Os

Redundant, Distributed IO-System, SIL3

Redundant PROFIBUS communications capability

F-DI 24
SIL2, SIL 3 configurable on channel level
Configurable short circuit monitoring

Sequence Of Events
F-DI 24 with new IM153-2 HF (2BA02)
Sequence of Event (SOE) recording
Full Integration in the PCS 7 Alarm & Event
Management

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Flexible Modular Redundancy (FMR)

DO

DO
DI
AI
AI

Simplex Dual
1oo1 LS
DO

DO
DI
AI
AI

Triple
AI

1oo2 Valves 2oo3 PT

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Process Safety

Flexible Modular Redundancy (FMR)

Redundant S7-400FH Redundant S7-400FH Redundant S7-400FH

Redundant PROFIBUS DP Redundant PROFIBUS DP Redundant PROFIBUS DP
Switched I/O – Redundant I/O – Redundant, switched I/O –
ET 200M ET 200M ET 200M

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Flexible Modular Redundancy (FMR)

Multiple Fault Tolerant

Fieldbus architecture allows system to tolerate multiple faults
without interruption
I/O redundancy independent of CPU redundancy
All components rated for SIL3
No degraded mode
Safety not dependent on redundancy
DO

DO
DI
AI
AI

DO

DO
DI
AI
AI
AI

1oo2 Valves For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Flexible Modular Redundancy (FMR)

Safety Integrity Level up to SIL 3 with one controller

Highest Safety Integrity Level

Highest Flexibility
Separate or combine safety and standard application in one CPU
Use redundancy for safety only where it is needed
Parallel use of PROFIsafe on PROFIBUS

Highest Availability through Multiple Fault Tolerance

Architecture allows system to tolerate multiple faults
IO redundancy independent of CPU redundancy
IO and device redundancy can be matched to maximize availability

Cost reducing
Use redundancy only where you need it for safety or availability
Parallel use of PROFIsafe on PROFIBUS

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Safety Integrated with PROFIsafe

PROFIsafe is an application layer (profile) that describes the communications between fail-
safe devices
Originally published in 1999; current version (V1.30) published in June 2004

Supports safe communication over open standard buses PROFIBUS

(DP, PA) and PROFINET
Standard message frame

S S S S S S
TÜV Certified
IEC 61508 SIL 3
EN 954-1 Cat 4
F I/O data Status / Sequence CRC Standard
control byte number I/O data

Sender- across
80,000 devices installed based F-data
counter and
11,000 systems F-parameter
Max. 12 / 122 bytes 1 byte 1 byte 2/4 bytes *) (240/238 - F-data)
At least 12 different suppliers Max. 244 bytes DP data
*) 2 bytes for a max. of 12 bytes F I/O data
4 bytes for a max. of 122 bytes F I/O data

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Integrated Safety Fieldbus

PROFIBUS
Well known Fieldbus Solution
Open Standard
First Fieldbus with Safety Instruments

PROFIsafe on Profibus
FMR, high flexibility of choosing the redundancy levels for safety and availability
One PROFIBUS cable for standard and safety-related communication PROFIsafe is
possible
Fast system setup and commissioning, due to use existing PROFIBUS

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

F-Systems

Multi-Driver Concept for PROFIsafe DP and PA Devices

Enhanced Diagnostics
F-STOP Concept and Improved Visualization
Voter Block‘s
F_2oo3_DI
F_1oo2_AI
F_2oo3_AI
Blocks for QUADLOG migration
Compare and Select (EQ, NE, GT, GE, LT, LE, F_MUX16R)
Move and Timing (F_REPCYC, F_ROT)
F-Communication Blocks to Distributed Safety
Concurrent Engineering Support

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Safety Data Write

Modifying F-Parameters in OS Safety program.

Modification is effected via a safety protocol

Modification process (transaction) is effected because of a specific operation
sequence
In a specific time

Type of users
Transaction can be effected by one user
As well as by two users (Initiator, Confirmer)

Safety requirements class SIL3 according to IEC 61508 are fulfilled.

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Configuration

Function Blocks with Corresponding Block Icons in the OS

With corresponding Faceplate

Changes are logged in

the OS operations list

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

Safety Lifecycle Engineering

SIMATIC S7-400FH with S7 F-Systems

Is used for configuring the hardware and safety related process applications acc. to
IEC 61511
Enhances S7-400FH Controller with safety functionality
Simplifies the creation of safety programs by using of a F-Library
with TÜV-certified function blocks acc. to SIL 3 IEC 61508
Simplifies the documentation of the safety programs, e.g. by administration of
signatures
The configuration of the safety programs can be done on the one hand with CFC or
on the other hand with Safety Matrix

Optional F-Library for Burner Management acc. to IEC 61508 SIL 3 for gas-,
oil burner

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

The IEC 61511 (ISA S84) Safety Lifecycle

Risk Analysis and Protection Layer Design

Sub-clause 8

Allocation of Safety Functions to Safety Instrumented Systems

or other means of risk reduction
Sub-clause 9
Verification
Safety Lifecycle
Management of Structure and
Functional Safety Planning Safety Requirements Specification for the Safety
and Functional Instrumented System
Safety Assessment Sub-clause 10

Design and Development of Safety Design and Development of other means of Risk
Instrumented System Reduction
Sub-clause 11 Sub-clause 9

Installation, Commissioning and Validation

Sub-clause 14

Sub-clause 5 Operation and Maintenance

Sub-clause 6.2
Sub-clause 15
Sub-clause 7, 12.7

Modification
Sub-clause 15.4

Decommissioning
Sub-clause 16

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

The IEC 61511 (ISA S84) Safety Lifecycle

The different phases of the safety lifecycle

Analysis Phase
Identification of Hazards and Risks
Development of the Safety Requirement Specification for the Safety Instrumented System
Allocation of Safety Function to Protective Layers

Realization Phase
Design and Engineering of Safety Instrumented System
Design and Development of other Means of Risk Reduction
Installation, Commissioning & Validation

Operation Phase
Operation & Maintenance
Modification
Decommissioning

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

The Realization Phase with Safety Matrix

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

The Realization Phase with Safety Matrix

The Realization Phase

The SIMATIC Safety Matrix as Engineering Tool

Configuration of the Safety Functions with the Cause & Effects Method

Automatic TÜV-certified Creation of the Safety Logic from the Cause & Effect matrix

Easy Configuration without special Programming Knowledge

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Process Safety

The Operation Phase with Safety Matrix

For internal use only / © 2007 SIEMENS AG

page 359 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

The Safety Matrix

Engineering and Design

Easy Use due Cause & Effect matrix
Automatic generation of the safety CFC program for the controller

Operation and Maintenance

Online View, integrated into PCS 7
Support Operation functions like Bypass, Reset and Override
Sequence of Event Recording
First Alarm Display

Safety Lifecycle Management Tool

Integrated Version Tracking
Integrated Documentation of Operator Manipulations
Integrated Documentation of Changes

For internal use only / © 2007 SIEMENS AG

page 360 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Process Safety

Process Safety and Totally Integrated Automation

Integrated Control & Safety

Best Integration into the distributed control system PCS 7
Less training and easy handling due using same tools
Less hardware due using same CPU for standard and safety

Flexible Modular Redundancy

Save money by mix and match to meet the goals of the application
Highest availability due the multiple fault tolerance

Integrated Safety Fieldbus

Less wiring due PROFIsafe on PROFIBUS, one cable for the communication safe and
non-safe
Prepared for safety fieldbus instruments

Safety Lifecycle Engineering

Safety Matrix supports the phases of the Safety Lifecyle
For internal use only / © 2007 SIEMENS AG
page 361 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Communication

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
Communication
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
Communication

Advantages
Redundant
Gigabit rings for high-
availability & high-
performance
communication in the
SIMATIC PCS7 process
control system

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
Redundant Terminal and Plant Bus (maximum availability)

Terminal bus
Gigabit ring
Redundant double ring (Standby
redundancy)
Redundant Terminal Bus Adapter
Package consisting of 2 Intel PCI
network cards

Plant bus
Gigabit ring
Redundant double ring (Standby
redundancy)
CP 1613 A2
S7-Redconnect

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
SCALANCE X Switch Family

SCALANCE X-400 modular

- Modular high-performance switch
- Gigabit Ethernet
- For use in high-performance plant networks

SCALANCE X-300 managed plus

- Compact high-performance switch
- Economical, compact variant for use in high
performance plant networks (Gigabit Ethernet)

SCALANCE X-200 managed

- Convenient management
- Up to 24 ports and remote diagnostics

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
Managed Switches SCALANCE X-200

SCALANCE X204-2, X206-1LD, X208,

X212-2, X212-2, X216 and X224

Rugged metal housing with S7-300 format, IP30

degree of protection
Redundant 24 V DC supply
C-PLUG can be used
Integrated redundancy manager for
High Speed Redundancy (HSR,
reconfiguration time < 300 ms with up to 50 switches)
Transmission path lengths up to 26 km
(long distance) over single-mode FOC
Temperature range
-10°… +60°C for optical variants SCALANCE
-20°… +70°C for electrical variants X-200

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
Managed Switches SCALANCE X-200 IRT

SCALANCE X200-4 IRT, X201-3P IRT and

X202-2 IRT

Integrated redundancy manager for

High Speed Redundancy (HSR,
reconfiguration time < 300 ms with up to 50 switches)
Standby function < 300 ms for
redundant coupling of network segments
Various device variants for glass, PCF, POF or copper
interfaces
Temperature range SCALANCE
-10°… +60°C for optical variants
X-200IRT
-20°… +70°C for electrical variants

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
Managed Plus Switches SCALANCE X-300

SCALANCE X310, X308-2 and X308-2LD

Up to 3 Gigabit Ethernet ports

SCALANCE
Comprehensive local displays and opportunities for remote
X-300
diagnostics
Integrated redundancy manager for
High Speed Redundancy (HSR), reconfiguration time < 300
ms with 50 switches)
Standby function < 300 ms for the redundant coupling of
network segments
Temperature range 0°… +60°C
Support of office IT standards

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
Modular Switches SCALANCE X-400

SCALANCE X414-3E and X408-2

Up to 22 TP ports or up to 14 FO ports with extender

and/or media modules Gigabit and Fast Ethernet media
SCALANCE
modules)
X-400
Up to 4 Gigabit Ethernet ports in X408-2
Modular switches with IP20 degree of protection for
installation in control cabinets
Integrated redundancy manager for
High Speed Redundancy
Standby function < 300 ms for
redundant coupling of network segments
Temperature range 0°… +60°C
Support of office IT standards and router functionality

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7
IE Communications Processors

CP 443-1 communications processor

CP for connecting SIMATIC S7-400 to Industrial Ethernet

CP 1613 A2 and CP1623 communications processor

CP for connecting IPC to Industrial Ethernet

Desktop adapter network card (Intel) for connection of OS & ES

to Industrial Ethernet (10/100/1000 Mbit/s) + Redundant
Terminal Adapter Package (Server- and desktop adapter for
redundant terminal bus)

CP 7515 communications processor *)

PC card for connecting Notebooks & PG
to IWLAN

*) Product cancelled - only available as spare part! For internal use only / © 2007 SIEMENS AG
page 371 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7
Industrial Wireless LAN (IWLAN)

Wireless connection of additional

remote OS clients (max. 2)

Wireless linking of Web clients to

a SIMATIC PCS 7 Web server
(max. 2)

Wireless remote access to ES

via NetMeeting or Remote
Desktop

Important Note:
IWLAN is not released as terminal bus or plant bus of SIMATIC PCS 7!
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7
Industrial Wireless LAN (IWLAN)

Access Points:

SCALANCE W788-1PRO and SCALANCE

788-2PRO access points

Client Modules:

SCALANCE W746-1PRO and SCALANCE

744 1PRO Ethernet client module

IWLAN PC Card:

CP 7515 *) communications processor

e.g. for Field PG and Notebooks

*) Product cancelled - only available as spare part!

For internal use only / © 2007 SIEMENS AG
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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
SIMATIC BATCH

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
SIMATIC BATCH
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 375 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Basic Functionality

Create Recipes

Engineer Process
Model
Plan Batches

Start / Monitor /
Control Batches

Document
Report
Batches

For internal use only / © 2007 SIEMENS AG

page 376 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Workflow

Plant Engineering Data

SIMATIC
Manager

5t
27.03.03

Master Control
Recipe Recipe
St St

Recipe Batch Batch Batch

AF1 AF2 AF1 AF2
Editor Planning Control Reports
AF3 AF3

Batch
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC BATCH
Architecture

Scalable from small to very large projects with access to distributed

OS Servers
Batch / OS Clients

Terminal Bus

Batch- /
Batch PCS 7 OS OS-
Server Server Single
Station

Process Bus

For internal use only / © 2007 SIEMENS AG

page 378 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
S88.01 Model: Hierarchical Recipes

Hierarchical Recipes according ISA S88.01

Process Recipe
Cell Procedure

Recipe Unit
Unit Procedure

Equipment Recipe
Module Operation

Control Recipe
Module Phase

For internal use only / © 2007 SIEMENS AG

page 379 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
S88.01 Model: „Flat“ Recipes

“Flat” Recipes according ISA S88.01

Process Recipe
Cell Procedure

Unit

Equipment Recipe
Module Phase

Control
Module

For internal use only / © 2007 SIEMENS AG

page 380 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Seamless Integration in PCS 7 Engineering System

Full Integration in the PCS 7 Engineering System

no project specific interfaces optimized data exchange ES/RT via internal interfaces
all engineering data is created in the ES and transferred to the Batch-Server for
convenient recipe creation no double entry of project data

For internal use only / © 2007 SIEMENS AG

page 381 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
SFC Interface

SFC Type SFC Instances

OS Faceplate

Visualization

SIMATIC BATCH

For internal use only / © 2007 SIEMENS AG

page 382 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Recipe Editor

The Recipe Editor provides tools for easy and intuitive recipe creation

ROP Lib. ROP RPH Operator Dialog Transition

Parallel Branch Alternative Branch Sync. Bar Loop

For internal use only / © 2007 SIEMENS AG

page 383 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Recipe Operations (ROP) Library

Library for Recipe Operations (ROP)

For internal use only / © 2007 SIEMENS AG

page 384 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Instance (Unit / Phase) Independancy (1)

Allocation Strategies
Operator Selection
Prefered Unit
Longest out of use
Process Parameters

Class based Recipes

for plants with groups of similar units
for many the most important motive in S88
e.g. “separation between recipe and equipment”
with different allocation strategies (late binding)

Benefits
efficient recipe creation and maintenance
Compliant with S88 expectations
Optimized plant / equipment usage (esp. F&B)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC BATCH
Instance (Unit / Phase) Independancy (2)

Plant Neutral Class Recipe

Class
Silo

Class
Reactor

Control Recipe

Class concept enables unit-independent recipes

For internal use only / © 2007 SIEMENS AG
page 386 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Equipment Properties

Evaluation of equipment properties for identification of unit candidates

For internal use only / © 2007 SIEMENS AG

page 387 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Separation Formula / Procedure

Formula 1 Formula 2
Quantity 1000 Kg 500 Kg
Temperature 90 C 80 C
Time 10 min 15 min
Salt Yes Yes
Pepper No No
Sugar 100 g 150 g

Separation of Formula and Procedure

Control Recipe #1 Control Recipe #2
Formula Categories
Product info is linked to Formula

For internal use only / © 2007 SIEMENS AG

page 388 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Online Operation

Start Hold Stop

Pause after Step Resume Abort

For internal use only / © 2007 SIEMENS AG

page 389 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Batch Planning (1)

Planning tool in the BATCH Control Center

Maximum quantity per unit

Required quantity

Automatic allocation to
different batches

For internal use only / © 2007 SIEMENS AG

page 390 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Batch Planning (2)

Batch Disposal and Chaining

For internal use only / © 2007 SIEMENS AG

page 391 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Fulfills 21 CFR Part 11

Audit Trail (offline and online)

System supported Versioning

Access protection with SIMATIC Logon

Electronic signature with possible comment or
forced comment

For internal use only / © 2007 SIEMENS AG

page 392 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Integrated SIMATIC Route Control

Simplification of material transfers by SIMATIC Route Control

For internal use only / © 2007 SIEMENS AG

page 393 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Integrated SIMATIC Route Control

PCS 7 Engineering:
Engineering of Locations and Unit assignment
Engineering of „Routes“ within SIMATIC Route Control
Recipe Editor: Assign Transfer parameters with Locations

For internal use only / © 2007 SIEMENS AG

page 394 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Report System: Standard

XML based Report System with integrated Browser

For internal use only / © 2007 SIEMENS AG

page 395 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Report System: Advanced Report

Batch Control Center

Based on MS SQL Server + Crystal Reports embedded Report Viewer
Includes one set of report templates
Creation of own templates with „Crystal Reports Report

Designer“ (not included) possible

Export of complete reports to PDF files <template.rpt>
XML-based report system still available

SB - DB
Report
pdf

OS - DB

Report-Database

For internal use only / © 2007 SIEMENS AG

page 396 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
Advanced Report

SQL based Report System by use of Crystal Reports

For internal use only / © 2007 SIEMENS AG

page 397 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC BATCH
MES Connectivity

Interface to SIMATIC IT
Open Interface for customer specific extensions (API)

For internal use only / © 2007 SIEMENS AG

page 398 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
SIMATIC Route Control

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
SIMATIC Route Control
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

page 400 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC Route Control

What is SIMATIC Route Control ?

RC is an option package of SIMATIC PCS 7, available since PCS 7 V6, RC is

a system for manual and automatic transfer of materials
RC configuration is based on the route network (partial routes) and process
elements which are assigned to that partial routes. Process elements are
motors, drives, pumps, valves, sensors, etc.
RC engineering is parametrization instead of programming:
CFC instead of SCL, AWL
Hierarchical configurations
Drag & drop
Full integration with SIMATIC BATCH possible but no must.
Material transfers run in different steps (up to 32), which can be executed also
in parallel, e. g.
Base position (close all valves)
Open transfer route (open transfer valves)
Material transfer (open source valve)
In parallel: Start ventilation

For internal use only / © 2007 SIEMENS AG

page 401 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC Route Control

Typical Applications

Transfers of any kind

Liquid and solid material transfers
Food and beverage (Oil, grain, beer), fine grained powder, resins, coals, blood
plasma
Use cases
Silo/tank storages, e. g. in harbors
Fermenting and storage areas in breweries
Powder mix units (grained powder)
Lime transfers (bunker stations)
Conveyor belts

For internal use only / © 2007 SIEMENS AG

page 402 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC Route Control

Features / Use Cases (1)

As soon as about 5 material transfers are running in parallel, Route Control

could be used, particularly the engineering provides the most benefit.
RC is predestinated for applications that are modified from time to time
(reconstruction and extention of plant).
RC is able, even for complex route net works to ensure secure material
transfers.
Source and destination locations can be switched on the fly without any
interruption of the transfer.
RC can be used for BATCH and non BATCH applications. In BATCH
applications, it is fully integraded by:
BATCH recipe phase parameters = RC locations
BATCH recipe phase = SFC controlling the RC transfer steps
RC messages are part of the BATCH report
RC supports also complex and user defined process elements

For internal use only / © 2007 SIEMENS AG

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SIMATIC Route Control

Features / Use Cases (2)

Offline route search validation of configured route net work before applying
to runtime secure process
Standardization of material transfers via modes base position, open source,
transfer, etc. identical SFCs e. g. for BATCH recipes reduces
engineering effort
Bulk engineering via export and import of CSV files (MS EXCEL).
3 levels of operating routes:
RC block symbol (WinCC pictures)
RC Faceplate (source, destination, material, mode indicators)
RC Center (full detailed information: elements / commands / feedback, batch
name, states, maintenance mode, etc.)
RC messages dedicated OS alarm archive
RC log (Transfer start/stop/hold, partial routes, mode changes, etc.)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Workflow

PCS 7 Project
Plant Hierarchy (ISA-88.01) and locations (source, destination, via)
NetPro / HW Configuration (AS-AS, AS-RC server communication - with wizard support)
CFC: Route interface blocks
CFC: Route element interface blocks and process element blocks
SFC sequences (equipment phase or user program)
Transfer into RC engineering (wizard supported)
RC Engineering
Mode table, partial routes and assignment of elements to partial routes, mode and
command and feedback of assigned element
Material sequence configuration
Offline route tests
Download to RC server
RC Server / RC Center / AS
Automatic and manual controlled material transfers

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Benefits (1)

RC is integrated in PCS 7 engineering: CFC, HW configuration / NetPro,

process object view, plant hierarchy (locations)
Reuse of same information leads to reduced engineering times
RC provides wizards: automatic configuration of AS-AS and AS-RC server
communication, transfer to RC engineering, bulk engineering and upgrade
wizards
Reduced engineering times, shorter turn-around times on modifications,
offline search secured production
RC is is „parametrization“ instead of „programming“, similar views in
engineering and runtime
Improved readability even for „non programmers“. Intuitive and simplified
engineering by drag & drop
RC is integrated with SIMATIC BATCH: plant hierarchy, locations = equipment
properties, batch reports contain RC transfer messages
Information at a single point

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Benefits (2)

RC alarms are contained in WinCC alarm archive and retrieval (alarm

controls) and RC alarms are part of SIMATIC BATCH reports
Single point of access: operator via alarm control, batch operator via batch
report, external systems via OpenPCS 7
RC is integrated in WinCC: RC provides a block symbol and faceplate for
monitoring and control in WinCC pictures – details via RC Center. RC
supports web pictures (block symbol, faceplate). Links between RC, SB and
SFC are integrated
Direct navigation from WinCC pictures (block symbol) to transfer details
(faceplate) to route details (RC Center)
RC supports redundant RC servers, redundant networks, H-machines
High availability of the production and DCS
RC supports full client / server configuration
Even largest projects can be realized
RC log provides detailed information
FDA tracing of material transfer incl. partial routes

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Benefits (3)

User defined elements - Non standard or complex elements with several

commands can be realized. Such elements are handled by RC like standard
elements, e. g. turn-head distributor, swing panels, etc.
Also special use cases can be realized
Up to 300 transfers in parallel
Also complex networks can be handled, material is transferred securly and
without mixing it.
Transfers can run automatically but also manually
For simple transfers or any time the user can control the material tranfer
manually from a technological point of view instead of the elements directly
Material check: Current material is stored in a partial route (linking element),
allowed material sequences can be configured that are checked during route
request
Only configured material sequences will be allowed – no polution with other
materials

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Benefits (4)

External setpoint values possible via parameter elements: setpoint can be set
at runtime, e. g. pump speed, weights, flows, etc.
Parameters can be provided by recipes or user program
Maintenance mode: AS can be set to maintenance mode, new routes
prevented, system will wait for pending active ones to be terminated
Secured production process – no loss of product
Monitoring and fault times provide some „tolerance“. When an element is
turned on, the physical elements normally needs some time to get ist desired
position ( monitoring time). The element can leave its position for some time
(< fault time)
RC is following the physical behaviour of the process elements.
RC can be licensed in different steps: <30, <100, <300 transfers and if
redundancy is used. RC Center supports floating licenses
RC is scalable in aspect of the number of running transfers and size of the
configuration

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Material Transfers

1 2
T1 T2 T1 T2

T3 Parallel Transfers and

switch over of source
T3 T4
Blending of materials
and/or destination
„on-the-fly“

3 1
And many 4
T1 CIP use cases
more …

T2 T1
2

Cascaded transfers T3
via two routes Cleaning processes (CIP)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Block Library

Material Transfer Block RC_IF_ROUTE

Central interface block for one material transfer, receives: source, destination, via
locations, modes, material, monitoring and fault times from the user block (e. g. SFC)
and provides feedback about route state.
Interface Blocks RC_IF_...
Designed for PCS 7 library, but can be used as well with other libraries because of their
common interface.
Connect the process elements with Route Control. Interface blocks for all standard
elements are available: MOTOR, VALVE, VAL_MOT, MOT_REV, MOT_SPED, LE,
SENSOR, CONDUCT, VOLUME, TIMER
For user defined objects: USER_CE, USER_SE, USER_PE
For remote objects (external project): REMOTE_CE, REMOTE_SE, REMOTE_PE
For integration with BATCH or other user programs: SFC - RC_IF_ROUTE_SFC,
RC_IF_ROUTE_SFC_BATCH
System Blocks (configuration and diagnose)
RC_IF_CFG, RC_IF_XC_DIAG, RC_IF_XC_LIFE, RC_IF_REMOTE_SEND, _RECV
Examples
Many CFC examples are provided with the library, just drag and drop into your project
For internal use only / © 2007 SIEMENS AG
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SIMATIC Route Control

SIMATIC Batch Integration (1)

Configured Route Control Locations in SIMATIC Manager

Construct Recipe Phases (SFC Types)

that Supervise Route Control‘s Material
Transfer Capabilities

Route Control together with SIMATIC Batch helps to pick the most efficient route during
a Batch allocation (Breweries, Diary, Pharma...)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

SIMATIC Batch Integration (2)

Use these transfer phases in SIMATIC BATCH Recipes to transfer materials

between units

Easier implementation of complex material transfer sequences

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

SIMATIC Batch Integration (3)

The recipe phase provides source, destination locations, material and batch
name.
The interface SFC controls the transfer steps (Search route, provide
source/destination, base position, start transfer, open source valve, start
pump, …)
The RC block (AS kernel) executes all necessary actions, controls the
elements and receives their feedback.
Batch (control) recipe SFC Route block Elemente
Elements
Source,
Destination

Mode = „base
position“

Mode =
„Open Route“

Source, Dest, Start, Mode =

Stop, Hold,… „Open Source“ M
Runs, held
Error … Mode =
„Start Pump“

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

User Defined Process Elements (1)

Examples of already realized user objects:

Pressure transfers
Turn head distributor
Swinging panels
User defined logic is hidden by a user block (FB), which is interconnected with
the RC interface blocks. The RC wizard identifies also user element blocks by
certain UDA (user defined attributes)
User defined logic User block CFC: Interconnection with RC
Interface blocks

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

User Defined Process Elements (2)

At a pressure transfer unit all valves are closed, a certain quantity of material
put in, and next the pressure is increased (air). After opening the outlet valve,
the material is transferred via pipes to the destination.

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

User Defined Process Elements (3)

Instead of material transfer by pressure, the material can be transported also

by pump draw.

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 s

SIMATIC Route Control

User Defined Process Elements (4)

At a turn head distributor the material gets into via an aperture and depending
on the position of the head it is put out.
From the RC engineering perspective a turn head distributor can be handled
as user element with several commands and feedback values
(position/feedback 1..n)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

User Defined Process Elements (5)

On a swinging panel, two outlets are interconnected by a flexible tube of pipe

section. 1 2 3 4

In this example, outlet 2 and 8

are interconnected
The swinging panel is realized
by an user object with several
parameter elements (PE =
set point position) and sensor
elements (SE = actual position)
and therefore by using
standard elements!

5 6 7 8
Schlauchkuppelstation.vsd

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Valve Manifold Example for Modes (1)

Source tanks Destination tanks

T1 T2 T3 T4 T5 T6 T7

12 9

5 8

10 P 11 4
1 6 7

2 3

Mode 1 (“Check valves”): Valve (1..4) = Closed?

Mode 2 (“Open transfer valves”) V5..V9 = “Pos1”, V10,11 = “Pos2”
Mode 3 (“Open source valve”) V12 = Open
Mode 4 (“Start Pump”) P = On Pos1: No Pos2:
interconnection connected
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC Route Control

Valve Manifold Example for Modes (2)

Source tanks Destination tanks

T1 T2 T3 T4 T5 T6 T7

Product flow

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

RC Center

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

RC Log

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Quantity Structures

Parameter Scope Quantity

Number of AS PCS 7 project 32

Number of partial routes PCS 7 project 64,000

Number of parallel transfers PCS 7 project 300

Number of modes / steps Route 32

Number of control elements (CE) AS 1,024

Number of sensor elements (SE) AS 1,024

Number of linking elements (LE) AS 1,024

Number of parameter elements (PE) AS 1,024

Number of user defined elements PCS 7 project Only limited by PCS 7 project

Number of elements per transfer AS 450

Distribution of routes over … AS PCS 7 project 32, typical ≤ 6

Route request PCS 7 project ≤ 30 s, typical 5-10 s

Number of commands Element Not limited

Number of RC servers PCS 7 project 1 or 2 (redundant)

Number of RC clients (RC Center) PCS 7 project 32

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC Route Control

Licenses

RC Engineering
RC Engineering
RC Engineering 30 days

RC Client
RC Client package

RC Server
Base package (up to 30 transfers)
Power package (30 100 transfers)
Power package (100 300 transfers)

RC Upgrade Package
V6.1 V7.0 / V7.0 SP1

For internal use only / © 2007 SIEMENS AG

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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
MIS / MES Integration

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7
MIS / MES Integration
WEB Client
SIMATIC IT

Office LAN (Ethernet)

Client Station
WEB Server
(OPEN PCS 7) Engineering / Maintenance
OS LAN (Ethernet) Station

ROUTE Control
OS Server CAS
BATCH Server

Industrial Ethernet

AS 41x AS 41x HF

ET200M HF
PROFIBUS DP

ET200M HF
(Standard & F-Modules)

PROFIBUS DP
ET200M HF
ET200S

ET200iSP
SIMOCODE ET200iSP

PROFIBUS PA
PROFIBUS PA
FOUNDATION Fieldbus H1

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

Levels of Automation

Vertical integration

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration

Production order / Continuous process

batch data data (trends)

Engineering data Alarms & Events

(tags, objects)

Field area

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration

TIA (Total Integrated Automation) of SIMATIC PCS 7 and SIMATIC IT unifies

automation technology on one platform on a vertical integration
Integration of DCS, MES and ERP levels (from the field up to enterprise level).
SIMATIC IT communication with ERP support B2MML, XML and a certified
SAP connector.
It covers ISA-88.00.01 and ISA-95.00.01
It is used in continous, batch, hybrid and discrete manufacturing
The modularity of SIMATIC PCS 7 and SIMATIC IT leads to increased
productivity, optimization and flexibility
Addressed customers
SIMATIC IT for customers that have already PCS 7 and need a MES system.
Customers can migrate or upgrade to S7 and PCS 7 when SIMATIT IT is already in
place
Provides a full integrated solution to customers that are asking for a new solution.

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration - Functionality

SIMATIC PCS 7
Short and long term archive
Monitoring and control (OS Client / Server)
Realtime and archive data
BATCH and Route Control
SIMATIC IT
Production Modeler
Historian (Trend/Event viewer, KPI, Production analysis, shift reports, EBR) – Data:
Process values, alarms & events, batch data, manual input (laboratory), legacy
data.
Reporting
Historical Data Display
MS EXCEL Addin
Plant Performance Analyzer
Transparent access to data by means of OpenPCS 7 and internal interfaces
(no license required if directly binded)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration – Batch Recording (1)

Storage of batch data SIMATIC IT SIMATIC PCS 7

Batch header data Site -

(Start/End times, product name…) Area -
Process cell
RUP / ROP / RPH data + parameters Process cell
(PCS 7 project)
Operator Dialogs/Comments/Audit Trail Unit Unit
Equipment
-
Storage of batch-related messages Module

Direct interface with WinCC - Process Objects

Messages are linked to corresponding Batch elements

Storage of batch-related measures

Measures configured in Recipes are retrieved from WinCC archive
Data is stored in PPA and linked with corresponding Batch elements
On-event data retrieval (according to recipe)

Batch reporting based on SIMATIC IT Report Manager

Batch data is stored in PPA, in order to allow easy reporting
Historian universe supports all Batch-related data

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration – Batch Recording (2)

For each recipe procedural element, the following information is archived:

Element Name and id
Start/end time of the procedural element
End time of the procedural element
Type of procedural element (RUP, ROP, RPH)
Unit name
Each procedural element can have parameters:
Process Parameters (PP)
Input/Output Material Parameters (PI/PO)
For each Process Parameter, the following information is collected:
Parameter name
Data type and units of measurement of the parameter
Parameter value (actual/set point)
High/Low value
For each PI/PO parameter, additional information is collected:
Material name and code
Actual/Planned amount

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration – Batch Recording (3)

Historian Client can be used to analyze Batch data

Analyze Batches and Recipe Element parameters
Compare data over multiple Batches
Trend analysis within Batch context
Standard Batch reports are available

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - MIS / MES Integration

SIMATIC IT Integration – Integration Pack 2007

The Integration Pack 2007 will provide different enhancements:

New OpenPCS 7 layer; a brand new communication layer integrating
SIMATIC IT with PCS 7, no need to install WinCC multi client on SIMATIC IT
machines anymore.
Improved PCS 7 Tag browser
Performance enhancements; improved communication for faster data exchange
and reduce network load.
Direct access to S7 (in non-PCS 7 scenarios); drivers included to directly access
an S7, useful when the floor level is too simple and PCS 7 normally is not used
there.
New SCI interface (replaces CIB); the batch API is now exposed to Production
Modeller directly by SCI though a dedicated GSI interface.
The Integration Pack 2007, which also includes a manual, is
based on SIMATIC PCS 7 V7.0 SP1 and SIMATIC IT V6.3 SP1
and available at the export centre of SIMATIC IT or via web:
(http://support.automation.siemens.com/WW/view/de/22253700)

For internal use only / © 2007 SIEMENS AG

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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Migration to PCS 7

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7 - Migration

Step by Step Options SIMATIC IT
Legacy-System SIMATIC PCS 7

HMI HMI Cl. Cl.

HMI Conversion of
replacement legacy HMI
by PCS 7/OS engineering
Eng.
Eng.
Server Server

Gateway for
data
Controller interchange
Conversion of S7 400
S, H, HF
controller Gateway
engineering
PROFIBUS PA
DP / IO
Attachment of legacy
I/O cards to

PROFIBUS DP
PCS 7/AS Motor

I/O
Qualified
migration services
during each step Field Termination
of the migration Adapter ET200M
project
Marshalling

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - Migration

Migration Elements

Mig.Elements Example of migration element Description

- Connection of PCS 7 OS-

OS-connection to server to system bus
system bus
+ - OS migration tool (e.g. DBA)
- Faceplate Library

- Tool / Services for conversion of process views

Tool for OS-data migration (only makes sense, if process views with
higher resolution are available)

- Tool for conversion of AS-

Engineering data to PCS 7
Tool for AS-data migration

- Gateway between system bus

Gateway between bus of of the legacy system and PCS 7
the legacy system and
PCS 7
+ (mainly for AS-AS-
communication)
- Engineering tool for gateway

- reuse of I/Os
Reuse of legacy system I/Os (Connection of legacy I/Os to PCS 7/
or field termination assembly
(FTA) + … AS – mainly for Siemens systems)
- Field Termination Assemblies
(FTAs) for field wiring

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - Migration

Migration of Siemens Control Systems
SIMATIC BATCH SIMATIC IT
SIMATIC IT

SIMATIC IT Services

PCS 7 OS clients PCS 7 ES PCS 7 OS clients

PCS 7/OS Server PCS 7/TM OS PCS 7/APACS+OS PCS 7/505 OS PCS 7/OPMC OS
Prograf 4-mation
AS APT SIMATIC IT

CS275 MBus H1 TF IE
41x 417H AS 235 TI505 S5

PROFIBUS
PROFIBUS

SIMATIC PCS 7 TELEPERM M APACS+ PCS Open PMC

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 - Migration

Migration of 3rd Party Control Systems
SIMATIC BATCH SIMATIC IT
SIMATIC IT

SIMATIC IT Services

PCS 7 OS clients PCS 7 ES PCS 7 OS clients

PCS 7/OS Server PCS 7/90 OS PCS 7/F2K OS PCS 7/PVX OS PCS 7/OPEN OS

41x 417H
PROFIBUS

3rd-party DCS with

SIMATIC PCS 7 Bailey ABB Freelance Emerson PROVOX OPC connectivity

For internal use only / © 2007 SIEMENS AG

page 441 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 / Migration Technology

Technology- and Development-Platform

Adapt
Data Base Automation
Generate
SIMATIC PCS 7 DBA is an effective
Common User Interface Convert Engineering System migration product for
Plug-in Interface
OS-migrations (while
Batch keeping the controller
DBA
stepwise HMI level). It’s designed
adaptable Graphics
DCS DCS DCS DCS Database
DCS
flexible Control SW
as a universal
A B C D E
I/O migration platform for
various legacy
systems.
Legacy DCS DBA is available for
• Function Blocks Innovative DCS APACS, TI505, Open
• Address Information SIMATIC PCS 7 PMC, Infi90,
• Control Software
• Graphics Freelance and
Provox.

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 / Migration Technology

DBA (Data Base Automation) for OS Migration

What does DBA (Data Base

Automation)?
Usable for OS-migration of various
systems (APACS, TI505, Open PMC,
Infi90, Freelance and Provox)
DBA reads linear AS-engineering
data and filters by means of a list all
OS-relevant blocks
DBA shows all found blocks in a list
and allows the assignment to a
technological hierarchy
DBA generates OS-variables…
… and creates the screens according
the hierarchy
DBA adds dynamic icons from a
template, that match with the found
blocks in the OS-screens. This also
includes faceplates and messages.

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 / Migration Technology

Integration in PCS 7 Engineering System

Technological Hierarchy
(S88 compliant)

Controller objects
assigned to Technological
Hierarchy

Flat list of controller

objects (PID, Motor, etc.)
List of legacy Controller’s

For internal use only / © 2007 SIEMENS AG

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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Add-On

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7 AddOn

AddOn Types (1)

any applications
interconnections

system connection
special process

migration
branches

libraries
specific periphery

participate refine
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 AddOn

AddOn Types (2)

additional hardware for OS

additional analyses

construction parts
simulation

assistance increase
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 AddOn

Examples (1)

Video monitoring
Motor starter
Simocode

Frequency converter Fingerprint

Master drives mouse

Big screen Ex operating units Cabinet engineering

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 AddOn

Examples (2)

CEMAT cement industry package

Block library fuel
Industry-specific libraries
technology

Bus analysis tool BANY Process simulation with SIMIT

4-quadrant display
Adaptive controller ADCO
For internal use only / © 2007 SIEMENS AG
page 449 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 AddOn

PCS 7 Lab

SIMATIC PCS7 BOX- complete system with I/O station:

8 x analog input modules (AI) 0(4)..20 mA
8 x analog input modules (AI) + / - 10 V
4 x PT 100 measurements
8 x analog outputs 0(4)..20 mA
16 x digital inputs
16 x digital outputs
2 x serial interfaces (RS 232)

SIMATIC PCS 7 LAB features:

Fast set-up/configuration changes and commissioning
Reliable control and monitoring of reactions
Easy control system configuration
Efficient data evaluation
High level of reliability thanks to the automated system
For internal use only / © 2007 SIEMENS AG
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 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Licensing

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7 Licensing

Modular and Scalable

small large

basic options

...
For internal use only / © 2007 SIEMENS AG
page 452 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Licensing

Volume License Concept

1 PO:
operable and observable block, that is capable to send alarming events
app. 50 OS variables

unlimited
Engineering
System

Managed by ES
at download PO instead of
variables

Neu Neu

Automation Operator
System System
For internal use only / © 2007 SIEMENS AG
page 453 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Licensing

Process Objects

Operation- and fault messages

Display on process view Trend value (Archiv)

Object properties:
Tag-Name
Unit
Short description
Operator window Comment
(Faceplate) CFC Message text
Trend archive
1 PO

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Smooth Scalability

Easy to handle: PO’s for OS and AS (Process oriented)

AS PO’s are controlled by the Engineering System
Smartest adaptation to plant requirements (finer stepping)
Price reduction for small, medium and large plants

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Basic Idea
Engineering V6.x : Automation Program V6.x:
Operating V6.x :
• dynamic complex license • Controller with big reserve
• shared license
• high entry price (OS Runtime) • high entry price
• difficult to calculate (variables)
• huge PO Steps

New model: New model: New model:

• lower price • counts Process Objects • Pay for controller load
• OS Runtime limited (2h) • 100 PO steps

€
Runtime

Neu

mnaged ES
variables

Paper License

Neu RT Lib
variables
OS Runtime

POs
Neu
AS AS
ES ES HW HW
OS OS

Engineering System Operator System Automation System

V6.x

V6.x

V6.x
V7

V7

V7
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Licensing

Rules

Hardware prices are not affected

All Runtime components (incl. AS) are now based on licenses depending
on application size
Process objects (PO) are counted in ES, OS and AS
Per PO app. 50 variables are allowed
SB counts units (phases are not relevant anymore)
Unlimited Engineering licenses are offered at a fixed price
PID Tuner is free of charge
SIMATIC Logon is free of charge

AS Runtime Licenses have to be present only during productive operation !

For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Licensing

Reduced Amount of Engineering Packs

New
Solution for
ES Single-PC
AS/OS
unlimited ES/OS
250 PO
ES/OS
1000 PO
2000 PO
Simplify
ES (AS)
unlimited Engineering Licenses
New

ES (OS) PCS 7 V7.0

unlimited

ES
PCS 7 V6 ES/OS
250 PO/8k Var.
6 Packages ES/OS
1000 PO/32k Var.
ES/OS
2000 PO/64k Var.
3 PowerPacks ES/OS
3000 PO/100k Var.
ES/OS
5000 PO/159k Var.
8500 PO/256k Var.

ES (AS) ES (OS)
ES/OS
250 PO ES/OS
8k Var.
ES/OS
1000 PO ES/OS
32k Var.
ES/OS2000 PO ES/OS64k Var.
ES/OS3000 PO ES/OS100k Var.
ES/OS5000 PO
unlimited
ES/OS
150k Var.
256k Var.
18 Packages
15 PowerPacks
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Licensing

Engineering Bundles

AS RT PO 250
AS/OS
PO 250 WinCC RC 250
AS RT PO 1000
AS/OS
PO 1000 WinCC RC 1000

AS RT PO 2000
AS/OS
PO 2000 WinCC RC 2000
AS RT PO 600
ES
Unlimited WinCC ES PO
unlimited

ES (AS) Does not contain any AS RT PO Licenses !

Unlimited

WinCC ES PO unlimited
ES (OS)
Unlimited

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

3 Special AS/OS Bundles for V7.0

PCS 7 Runtime Basic Package AS 414-3 - 6ES7650-3XG07-0YX0

Contains: 1 x AS 414-3 UR2 without PS and Memory Card
1 x PCS 7 – OS Software Single Station V7.0 (PO 1.000)
1 x PCS 7 – Runtime License AS V7.0 (PO 1.000)

PCS 7 Runtime Basic Package AS 416-2 - 6ES7650-3XH07-0YX0

Contains: 1 x AS 416-2 UR2 without PS and Memory Card
1 x PCS 7 – OS Software Single Station V7.0 (PO 1.000)
1 x PCS 7 – Runtime License AS V7.0 (PO 1.000)

PCS 7 Runtime Basic Package AS 417H-1H - 6ES7650-3XJ07-0YX0

Contains: 1 x AS 417H-1H UR2 without PS and Memory Card
1 x PCS 7 – OS Software Single Station V7.0 (PO 1.000)
4 x PCS 7 – Runtime License AS V7.0 (PO 100)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: Initial Purchase (1)

Runtime-
600 PO License for 600
PO‘s (AS)

Engineering
unlimited

ES-SW for AS and OS (ES-Unlimited) is shipped together with 600 AS RT POs

(Additional Runtime Licenses for AS RT PO can be added)

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: Initial Purchase (2)

Runtime-
600 PO License for 900
PO‘s (AS)
900 PO

100 PO 100 PO 100 PO

Each AS-Bundle contains a Runtime-License for 100 AS RT PO, that can be

transferred to ES

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: Initial Purchase (3)

AS Load
-100
+150
+100
+100
50 PO
PO

(600) 100 addional

PO‘s
have to be
purchased

(100) (100) (100)

150 PO
200 300
400 PO
PO 250 PO
400

On AS-Load time the count of PO`s used by the project is determined and debited
against the available POs on the ES
If more PO`s are required, it`s possible to purchase additional AS RT PO licenses

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: Initial Purchase (4)

1.000 PO
1000 PO‘s
for operator
systems

200 PO + 400 PO + 400 PO

For OS runtime 1000 PO`s are required

In additon the count of variables is determined:
per PO app. 50 variables are allowed

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: AS Engineering Update from PCS 7 V6.x to PCS 7 V7.0

PCS 7 V6.x PCS 7 V7.0

CFC PO 250 AS RT PO 250
CFC PO 1000 AS RT PO 1000
CFC PO 2000 AS RT PO 2000
CFC PO 3000 AS RT PO 3000
CFC PO 5000 AS RT PO 5000
CFC PO 8500 AS RT PO 8500

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: AS/OS Update from PCS 7 V6.x to PCS 7 V7.0

PCS 7 V6.x PCS 7 V7.0

WinCC RC 8k Tags WinCC RC PO 250
WinCC RC 32k Tags WinCC RC PO 1000
WinCC RC 64k Tags WinCC RC PO 2000 oder

WinCC RC 100k Tags WinCC ES PO unlimited

WinCC RC 150k Tags WinCC ES PO unlimited

WinCC ES PO unlimited
WinCC RC 256k Tags

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Example: OS Update from PCS 7 V6.x to PCS 7 V7.0

PCS 7 V6.x PCS 7 V7.0

WinCC RT 8k Tags WinCC RT PO 250
WinCC RT 32k Tags WinCC RT PO 1000
WinCC RT 64k Tags WinCC RT PO 2000

WinCC RT 100k Tags WinCC RT PO 3000

WinCC RT 150k Tags WinCC RT PO 5000

WinCC RT PO 8500
WinCC RT 256k Tags

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

Price Comparison Result: AIDA Project

PCS 7 PCS 7
V6.1 SP1 V7.0 SP1

ES ES
OS OS
& AS & AS
498.372 € 469.294 €

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

AIDA Project: Important Differences

New Hardware with improved performance

ES unlimited without runtime

No extra charge for Simatic Logon

AS PO License

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

AIDA Project: Different Calculation Models

PCS 7
V7.0 SP1

SW-Update only
PCS 7
V6.1 SP1
496.376 € -2.596 €

498.372 € Smaller Standard-Controller

484.464 € -14.508 €

Less Standard-Controller
469.294 € -29.078 €
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Licensing

Example: Comparison PCS 7 Box (250 PO’s)

V 6.1 V7

New

1 x PCS7 BOX 416 AS/OS/ES (PO 250/ RC 8K ) 1 x PCS7 BOX 416 AS/OS/ES (AS/OS: PO 250)
6ES76502MA160YX0 6ES76502MA070YX0

same price
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 Licensing

FAQ (1)

How does the License check work ?

Licenses are checked on the ES Station and automatically debited or booked by
ALM (Automation License Manager) during download.
AS RT PO Licenses are not stored on the CPU
AS RT PO status is stored within the Project.

What happens if a CPU or memory card failure occurs ?

The AS RT PO Licenses are not debited again.
CPU and memory card ID are persisted together with the Project.
Therefore an exchange of one of this two components can be managed
( from AS firmware version V4.5 on).

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

FAQ (2)

What happens if a license is defect or missing ?

The AS can be loaded, but an appropriate message box appears
The AS will keep running

How many AS RT PO Licenses are counted in case of a H-System ?

As an H-System is handled as one System, the AS RT PO`s are counted only once

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

FAQ (3)

AS RT PO licenses are of which type?

AS RT PO licenses are floating licenses.
They can be stored on a central license server
In case of multi project or multi user applications the ALM debits the required
amount of PO`s at AS download time.

What happens, if the ES is reinstalled or has to be exchanged ?

The AS RT PO are not bound to a PC
As usual the licenses have to be backed up before.

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 Licensing

FAQ (4)

Does PCS 7 V7.0 + SP1 require new licenses ?

Yes, but the Update from PCS 7 V7.0 is free of charge - FAQ 26581309

Neu

The License Library V6.x won‘t be available anymore. What license

should be ordered instead ?
The Runtime License Library is replaced by AS RT PO 100

Neu

For internal use only / © 2007 SIEMENS AG

page 475 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 Licensing

Conclusion

The new license concept:

provides a finer scalability
does not increase the costs for our customers
is easier to handle and much more transparent

For internal use only / © 2007 SIEMENS AG

page 476 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
System Functions

For internal use only / © 2007 SIEMENS AG

 s

SIMATIC PCS 7 System Functions

Authentication and Audit Trail
Windows Services
User administration
Creation of groups (e.g. Administrator, Operator)
Creation of users and group assignments
Safety mechanisms, e.g.
Password properties (e.g. length, expiration, etc.)
Monitoring of logon attempts
Audit Trail
For system access (e.g. entering new users)

SIMATIC Logon
Administration
Assignment of Windows user groups to the applications
Logon service, e.g.
Auto logoff
Password and change dialog
Logon device (e.g. keyboard, smartcard reader)
Interface to 3rd-party and custom project applications

OS BATCH ES Others
Access protection Route Control
Access protection Access protection
Audit Trail License Manager
Audit Trail Batch control and
System message …
Recipe management Audit Trail
with archiving Electronic signature Download in CPU
Production information ES online mode
Entry in the batch log
For internal use only / © 2007 SIEMENS AG
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 s

SIMATIC PCS 7 System Functions

SIMATIC Logon

General Functions
Language settings
Environment (domain/workgroup)
Centralized one-time configuration of workgroups
without domain computer
Logon device (keyboard, smartcard reader, etc.
Automatic logoff

Interface to Windows
Assignment of Windows user groups to the specific
applications

Logon Dialog, Signature Dialog

User name
Password
Domain or local computer

Auto Logoff
Message prompt
Logoff, then new logon by any user

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 System Functions

SIMATIC Logon: Applications

ES:
OS:
Download in AS
Access
(with Audit Trail)
protection

BATCH: BATCH:
Electronic signatures Access
protection

For internal use only / © 2007 SIEMENS AG

page 480 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Access Control

Windows Security Settings

SIMATIC Logon Settings

For internal use only / © 2007 SIEMENS AG

page 481 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Audit Trail: SIMATIC Logon Eventlog Viewer

For internal use only / © 2007 SIEMENS AG

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 s

SIMATIC PCS 7 System Functions

Access Control and Audit Trail: ES Download to AS

For internal use only / © 2007 SIEMENS AG

page 483 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Audit Trail: OS Alarmlogging

Message
Action performed or Type:
Old value / New value „Operator
With comment option Input“

Comment field to
Input reason of change

Date/time- Operator
Stamp Origin Name
Process
area
For internal use only / © 2007 SIEMENS AG
page 484 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Electronic Signature

Configuration in SIMATIC BATCH

Electronic signature for operator actions in runtime:

Parameter change over I/O-Field
Button operation
etc.
Implementation by project
methods (API) using the
Option SIMATIC Logon
For internal use only / © 2007 SIEMENS AG
page 485 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Versioning: Object Level and Project Level

CFC chart Recipes

ES Project

For internal use only / © 2007 SIEMENS AG

page 486 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Versioning: Version Cross Manager

Tracking engineering
changes: comparison of
two project versions
offline

For internal use only / © 2007 SIEMENS AG

page 487 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Time Synchronization and Time Stamping

Possibilities of time synchronization

External time master "SICLOCK" on the plant bus
OS server is time master with
PC system time
Master Time signal via serial port (GPS / DCF 77 antenna)
Master Time signal via bus from external PC SICLOCK

Time stamping
Process alarms
Analog block, e.g. "Analog value high"
Motor block, e.g. "Motor fault"
Time stamping cyclic in the AS *)
Precision: AS scan rate, e.g. 500 msec.
Error messages of the I/O
ET200M
E.g. "wire break"
Time stamping acyclic in the AS
Precision : approx. 50 msec.
ET200iSP
Digital signals on the input/output station
Digital signals via IM153-2 / IM151-2
Precision : 1 msec.
Time master/slave

For internal use only / © 2007 SIEMENS AG

page 488 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

Comprehensive Protection by the PCS 7 Security Concept

Defense in Depth
security
Division into Windows
architecture
segments and security patch
security cells management

Network Support access

subnets, IP and remote
addresses and service
name resolution (VPN, IPsec)

Active directory
Virus scan and
and Windows
firewalls
work groups

User and access Time

rights synchronization

Process Control System PCS 7

documented in
PCS 7 Security Concept
For internal use only / © 2007 SIEMENS AG
page 489 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Defense in Depth Security Architecture

A Defense in Depth architecture requires:

Segmentation and room security
Zones that are capable of operating autonomously for a period of time
Strict control of specified access points between the layers

Results in layers of security between the outside world and the control
system

For internal use only / © 2007 SIEMENS AG

page 490 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Planning and Defining Security Cells (Zones)

Guidelines:
A security cell is capable of operating
autonomously for a period of time

All members of the security cell are

trustable

Access to security cells only via well

defined access points

Access to security cells is checked

and logged (network traffic and
persons)

All members of the security cell are

directly connected (not through leased
lines)

Members with high network load are

integrated directly in the security cell
(to prevent bottlenecks)
For internal use only / © 2007 SIEMENS AG
page 491 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Recommendations for Network Management

Assignment of IP Addresses

Select IP addresses from the inter-nationally reserved private

address listings, e.g. 192.168.x.x

Use of DHCP* allows central address management

DHCP provides dynamic address assignment (ensuring

uniqueness)

DHCP server must be available within

the security cell

Connection to External Networks

Connection to public networks by NAT (Network Address

Translation)

NAT “hides” internal addresses and port numbers from the

public network (addresses not forwarded to the internet)

Name Resolution

Name resolution by DNS or WINS

Use of symbolic names

Name resolution service must be

available within the security cell.

*Dynamic Host Configuration Protocol For internal use only / © 2007 SIEMENS AG
page 492 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Network Size and Requirements dictate when to
use Windows Workgroups versus Windows Domains

Domains recommended when:

The plant contains 10 or more computers.
The plant undergoes changes on a routine
basis (new users, changing computers, new
security policies, changing passwords).
Central (redundant) user administration
required.

What does this ensure?

The production plant can be configured
independently from the requirements of the
IT department.
A separate security policy can be used for
the control system.

Process Control System PCS 7

documented in PCS 7 Security Concept

For internal use only / © 2007 SIEMENS AG

page 493 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Strict User / Access Management is a Key Part of
an Effective Security Strategy
Philosophy for Access Management

Principle of minimal rights: Grant

users and computers the minimum set of
access rights that are required to perform their
function.

PCS 7 uses SIMATIC Logon

No administrator right are required *

Central management of users, passwords, and

permissions.

Clear assignment of roles and rights

Connects to Windows user management.

Therefore user logins/pwd are common
between applications and need be entered only
once.

Periodic check of role assignments and rights is

required.
*exceptions possible e.g. during setup or similar
For internal use only / © 2007 SIEMENS AG
page 494 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Patch Management of Windows Operating System
is critical as this Area is often targeted by “Hackers”

PCS 7 Support for MS Security Patches

It is permissible to load new MS Security

Patches as soon as they are released:
Windows operating system
Internet Explorer
SQL Server

New Security Patches are tested immediately

for compatibility with the latest versions of
PCS 7

Test results are published via internet within

2 weeks

Use of Windows Server Update Services is

recommended as part of patch management
strategy

documented in Process Control System PCS 7

PCS 7 Security Concept
For internal use only / © 2007 SIEMENS AG
page 495 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Virus Scanners should be used to help secure a
PCS 7 System

Virus scanners
Should be placed at the access points (eg. Engineering Station)
to filter incoming and outgoing traffic.

The following virus scanners are approved:

Trend Micro Office Scan
Symantec Norton Antivirus
McAfee virusscan

May not have a negative impact on the system performance.

Released for real time scan (filtering of incoming traffic is

sufficient).

Direct scan (manual and periodic scan of the file system) only
during maintenance (not online).

Updates of new anti virus software not permitted while online.

For internal use only / © 2007 SIEMENS AG

page 496 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Firewalls can be used to separate Security Zones
from each other
Firewalls examine and filter data traffic according to
certain rules

They secure the access points to the security cells

Inside the security cells no firewall are required

(unless required e.g. by a security policy)

Types of firewalls: packet filter,

stateful inspection, application proxy

Can check the traffic by means of a virus scan

module (optional)

Allow or refuse network traffic by performing a

computer and user authentication

Microsoft ISA Server* can accept and decrypt IPsec

data traffic by proxy

Scalance S Security Modules hardened for industrial

environments

For internal use only / © 2007 SIEMENS AG

page 497 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Scalance S Security Modules

Scalance S Security Modules provide many different security functions:

Firewall, NAT, DHCP Server, Data encryption -
all within a rugged, industrial, form factor!
Infrastructure (Hardware) Client Products(Software)

SCALANCE SCALANCE SCALANCE SOFTNET

S 602 S 612 S 613 Security Client
VPN Software

Firewall Filtering of IP-, MAC addresses and ports

Encryption, authentication and

VPN integrity of data
For internal use only / © 2007 SIEMENS AG
page 498 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Use of an ISA Server 2004 Firewall (as
documented in the PCS 7 Security Manual)

Firewall client
Web proxy client Winsock proxy client (layer 5)
supports HTTP, FTP and Supports complex protocols
Gopher TCP/UDP
User authentication User authentication

Secure NAT client

All TCP/IP hosts. VPN client
Configuration by IP routing T2TP\IPSec or PPTP
table remote user dial-in
site-to-site linking
Additional Benefits

Allows blocking / unblocking of communication ports based on IPSec credentials (used for secure
communication)
Ensures data traffic is unique, authenticated, auditable, controllable, and uninhibited for important
connections

For internal use only / © 2007 SIEMENS AG

page 499 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

SIMATIC PCS 7 System Functions

PCS 7 Security Concept: Service Access and Remote Maintenance

Prerequisites
Up-to-date security patches must be installed

An up-to-date and properly configured virus

scanner must be installed

In case of external access the local firewall

has to be active

Access rights have to be limited to the minimum

necessary

Recommended procedures
Authentication and encryption using IP-Security (IPSec)

Authentication and encryption using Secure Sockets Layer (SSL und https)

If accessed from outside, VPN (Virtual Private Network) and quarantine control

documented in Process Control System PCS 7

PCS 7 Security Concept
For internal use only / © 2007 SIEMENS AG
page 500 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

SIMATIC PCS 7
Summary

For internal use only / © 2007 SIEMENS AG

 s

Summary
PCS 7 System Architecture

For internal use only / © 2007 SIEMENS AG

page 502 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

Summary
SIMATIC PCS 7 TOP 10 Unique Features

1 SIMATIC Platform World Market Leader – high quality standard, worldwide logistics and support, ongoing innovation
2 One Stop Shop All components developed and manufactured by Siemens
3 TIA Concept Covering all automation tasks – from raw material to packing, from field to ERP level
4 Scalabilty From 100 to 100.000 I/O’s – from PCS 7 Lab to large client-server plants with 100’s of controllers
New 9 High-performance Operation&Engineering
10
Single point of entry (Process Object View)
Integrated Batch / Integration of customer specific libraries
Route Control System SMART Alarm Management
New
21 CFR Part 11 / ISA-88 compliant Security (Logon, Firewall etc.)
Automatic Material Transport APC integrated
8 Integrated Asset management
Automatic generation of diagnostic screens
Easy fault analysis and repair tracking
Performance Monitoring of Plant Assets New
7 High Availability - 5 Integrated Fail Safe Technology
Flexible Modular Same hardware S7-400
Redundancy (FMR) Safety Matrix
OS / Batch 6 True decentralized architecture
New
Central Archive Server with Profibus
Ind. Ethernet World No.1 fieldbus
Controller Integration of Remote I/O’s, motors, drives,
Profibus DP New analyzers, intelligent field devices etc.
Profibus PA HART
For internal useNew
only / © 2007 SIEMENS AG
I/O
page modules (8-channel
503 Index AI/AO redundant)
Dec-07 Productmanagement PCS 7 FF interface A&D AS PA PM
 s

Summary
SIMATIC PCS 7 V7 – with New Features to Production Excellence

New features support the

entire production lifecycle

Advanced Process PROFIBUS PA Alarm Management Predictive Step by step

Control Redundancy with Asset Management Migration
Smart Alarm Hiding of mechanical
plant parts Investment
for cost optimized for high availability protection and
engineering and easy for secure for e.g. pumps, modernization
extension process control heat exchangers during production

Design and Installation and Modernization and

Engineering Operation Maintenance
Commisioning Upgrade

For internal use only / © 2007 SIEMENS AG

page 504 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 s

Summary
General Statements to SIMATIC PCS 7

PCS 7 is THE standard DCS for Siemens – today and in the future based
on SIMATIC. The development of PCS 7 will be continued consequently,
based on a clear Roadmap / Strategy.

Technical innovation is foreseen and under continuous evaluation.

Innovation or improvements will not change the functional product

philosophy. Therefore, any PCS 7 version will be compatible and/or can
be upgraded to it’s successor version.

Each PCS 7 version is fully supported at least 5 years (HW at least 10

years)

Our lead and strategic customers are seen as valuable partners to

discuss existing or upcoming functionality to improve PCS 7.

For internal use only / © 2007 SIEMENS AG

page 505 Index Dec-07 Productmanagement PCS 7 A&D AS PA PM
 ss
SIMATIC PCS 7
Takes you beyond the limits !

Thank you !

For internal use only / © 2007 SIEMENS AG