PCS7 V701 Technology

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Welcome
For internal use only / © 2007 SIEMENS AG

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Process Control System
SIMATIC PCS 7
Version 7

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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
Summary
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SIMATIC PCS7
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
Summary
s
SIMATIC PCS7
Introduction
Engineering System
Chapter Title
Automation System
PC Based Automation
Operator System
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
s
SIMATIC PCS7
Introduction
Automation System
Engineering System
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
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
PC Based Automation
Engineering System
Automation System
Operator System PCS 7 BOX
Asset Management
Fieldbus PCS 7 AS RTX
Remote IO SIMATIC Rack PC
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Operator System
Engineering System
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
Summary
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SIMATIC PCS7
Introduction
Asset Management
Engineering System
Automation System
Operator System Asset Visualization
Asset Management
Fieldbus Monitoring Levels
Remote IO Views
Devices
Asset Report
Process Safety
Communication Monitoring Process Components
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Fieldbus
Engineering System
Automation System
PC Based Automation PROFIBUS
Operator System PROFIBUS PA
Asset Management
Fieldbus FOUNDATION Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Remote IO
Engineering System
Automation System
Operator System ET200M
Asset Management
Fieldbus ET200s
Remote IO ET200iSP
Devices
ET200pro
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Devices
Engineering System
Automation System
Operator System Process instrumentation
Asset Management
Fieldbus Analytics devices
Remote IO Motor Control
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Process Safety
Engineering System
Automation System
Operator System F-Components
Asset Management
Fieldbus Flexible Modular Redundancy (FMR)
Remote IO F-Engineering
Devices
Safety Matrix
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Communication
Engineering System
Automation System
Operator System IE Switches (SCALANCE, ESM, OSM)
Asset Management
Fieldbus Ethernet Communication Processors
Remote IO Industrial Wireless LAN
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
SIMATIC BATCH
Engineering System
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
FDA Compliance
MIS / MES
Interplay with SIMATIC Routcontrol
Migration
Add-On Reporting
Licensing Interfaces
System Functions
Summary
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SIMATIC PCS7
Introduction
Engineering System
Automation System
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
MIS / MES Visualization & Logging
Migration Quantity Structures & Licenses
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
MIS / MES
Engineering System
Automation System
Operator System SIMATIC IT Integration
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Migration
Engineering System
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
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Add-On
Engineering System
Automation System
Operator System Examples
Asset Management
Fieldbus PCS 7 Lab
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
Licensing
Engineering System
Automation System
Operator System Engineering Licenses
Asset Management
Fieldbus Examples
Remote IO Frequently Asked Questions
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS7
Introduction
System Functions
Engineering System
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
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
s
SIMATIC PCS7
Introduction
Summary
Engineering System
Automation System
PC Based Automation
Operator System
Asset Management
Fieldbus
Remote IO
Devices
Process Safety
Communication
SIMATIC BATCH
MIS / MES
Migration
Add-On
Licensing
System Functions
Summary
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SIMATIC PCS 7
SIMATIC PCS 7
Introduction

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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

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
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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!

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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 !

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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

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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
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SIMATIC PCS 7
SIMATIC PCS 7
Engineering Station

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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

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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
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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

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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
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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”
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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
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Process Object View: EXPLORER-/EXCEL Look & Feel
Integrated plant view in EXPLORER – form, allows configuration

of a measuring point (Tag) using EXCEL – Look & Feel
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Process Object View: Comprehensive Filter Functions
1 2-level filter
2
function
Selective filtering of relevant parameters allows you to optimize

your configuration activities
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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.)
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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

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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

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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
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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

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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)

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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

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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

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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

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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

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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

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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

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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)
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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

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“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
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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

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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

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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“)
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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

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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
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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

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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)

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Export CAx Data in XML Format (1)
1. Selection of Export Filters CAx

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Export CAx Data in XML Format (2)
2. Start of Export Procedure

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Import CAx Data in XML Format (1)
1. Open the target Project in VXM

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Import CAx Data in XML Format (2)
2. Start Object Import Procedure

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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
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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
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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

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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
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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

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All ES Licences installed on the data server
(access via network)
n x PCS 7 ES floating
1 x PCS 7 AS RT float.

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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

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PID – Tuner
Free and integrated component of ES software

Optimization of different controller types

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PID – Tuner
Comparison of measurement and process model

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PID – Tuner
„Modellfit“: Value for the quality of the simulated model

Calculated process parameter
Save and read of control parameter

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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

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List of changes since last download

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

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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

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Audit Trail – Downloading to AS

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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)

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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
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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
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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

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SIMATIC PDM
Simple Device Integration
EDD from CD, DVD or Internet and without PC reboot
textual descriptions (EDD)

operation system-independent
pure import

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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

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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
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SIMATIC PDM
Parameter View (Single device)
Online - Dialog
Update diagnostic status
Upload / download of
parameters Only readable
Read- and writeable
Grouping of device
parameters

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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

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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

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SIMATIC PDM
Document Manager
Document Manager – assign all relevant documents to the device

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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)
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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

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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

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SIMATIC PCS 7
SIMATIC PCS 7

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SIMATIC PCS 7 Library

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)

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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
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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

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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
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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
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SIMATIC PCS 7
SIMATIC PCS 7
Automation System

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SIMATIC PCS 7
Automation System
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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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
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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

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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

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Interfaces (PN-CPUs)
414-3PN
Periphery
1 PROFIBUS DP onboard
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
Industrial Ethernet
2 ports (switch)
Support for data record routing
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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
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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
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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)

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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 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)

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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 CP (LAN) 14; inkl. CP 443-5 Extended und IM 467
Communication interfaces X1: MPI X1: MPI X1: MPI

X2: DP X2: DP

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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

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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

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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

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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
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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

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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)

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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
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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
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High-Available Controller: Central Controller Configurations
Compact with rack UR2-H

(splitted backplane bus)
Distributed with
two standard racks
10 km

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High-Available Controllers: Connecting Switched Periphery
Redundant IM 153-2
AS 41x HF
ET200M H/F
Redundant PROFIBUS DP

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

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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

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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
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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

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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

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SIMATIC PCS 7
SIMATIC PCS 7
PC Based Automation

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SIMATIC PCS 7
PC Based Automation
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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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)

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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

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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
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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

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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
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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

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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

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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

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SIMATIC WinAC RTX: Showing the Diagnostic Buffer

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PCS 7 Box RTX vs. 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

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PCS 7 Box RTX vs. 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

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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
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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
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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

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SIMATIC PCS 7 AS RTX

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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
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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

s

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

s

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)

s

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)
s

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
s

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
s

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
s

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

s

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

s

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

s

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
s

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
s

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
s

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
s

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
s

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

s

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

s

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

s

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

s

Ambient conditions
Electromagnetic compatibility (EMC):

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)
high-frequency power supply 10 V, 80% AM (1kHz), 10 kHz to 80 MHz (IEC 61000-4-6)
on lines
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%
s

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

s

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

s

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

s

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)

s

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

s

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

s

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)
(2 Screen Multi VGA)
(4 Screen Multi VGA)

s

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

s

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

s

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

ss
SIMATIC PCS 7
SIMATIC PCS 7
Operator System

s
SIMATIC PCS 7
Operator System
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

s
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

s

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

s

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
s

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)
s

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
s

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

s

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
s

GUI: Examples for Standard Block symbols
One-button Picture selection

PID controller Valve Motor
operation
Dosing / Totalizing Valve Motor Step controller
Analog Indicator

s

GUI: Block Symbols - Faceplates
Plant picture with

block symbol
Maintenance view Alarms
Limits Trend window
Faceplate Faceplate –
Parameter view Batch view
extended view
s

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
s

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

s

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

s

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

s

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

s

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.

s

Engineering
Assign function blocks to alarm groups

s

Engineering
… than define „hiding rules“

s

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
s

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
s

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)

s

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

s
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
s

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

s

Storage Plus Viewer

s

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)

s

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)
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

s

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

s

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

s

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

s

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
s

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

s

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

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
s

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

s

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
s

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
s

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

ss
SIMATIC PCS 7
SIMATIC PCS 7
Asset Management

s
SIMATIC PCS 7
Asset Management
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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

s

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
s

Separation of Process and Maintenance Information
Operator Diagnostics
control OS MS
& Maintenance
& Monitoring Request
Process event Diagnostic event
OS: Operator Station MS: Maintenance Station

s

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

s

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

s

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
s

Monitoring Levels
PC Level
Ethernet Level
User Area
AS Level

s

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

s

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
s

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

s

Description of Information
Green Wrench:
Order Parts
Order Replacements
Yellow Wrench
Schedule Craft Labor
Schedule Contact Service
Expedite Parts

s
Beschreibung der Informationen

Description of Information
Before Red Wrench
Schedule repair before serious problem

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

s

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

s

Uniform View: Log Display
contains all
diagnostics and error messages
operator logs
maintenance requests
Request Status
Diagnostic Status

s

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

s

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

s

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

s

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

s

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

s

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

s

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

s

Asset Report
All important information concentrated

The same structure for all Assets
Asset – Status
Identity
Maintenance -
Status
Detailed diagnostic
Current massages

s

Asset Report as XML
All important information concentrated

The same structure for all Assets
Document Info
Maintenance -
Status
Current massages
Identity

s

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.

s

User Diagnostic - Hierarchy
Overview
Integrated „Plant Asset Management“
Plant Overview and Detailed View
Faceplate
“ASSETMON”
Detailed view

s

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”
s

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

s

“ASSETMON" configuration in CFC and PDM
Call PDM from

Faceplate
Engineering of
values, texts und
messages
Link to PDM
via PLT-ID
s

“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

ss
SIMATIC PCS 7
SIMATIC PCS 7
Fieldbus Components

s
SIMATIC PCS 7
Fieldbus Components
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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

s

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

s

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
s

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

s

Central Access to all Connected Devices
Faceplate
Application (CFC)
M
OS ES
Process picture
SIMATIC PDM
PROFIBUS DP
PROFIBUS PA
z. B. Simocode pro

s

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

s

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
s

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)
s

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

s

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

s

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
s

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

s

PROFIBUS PA: Safe Device Installation using Active Field Distributor (AFD)
Active Field Distributor (AFD)
Automatic partial segment isolation

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

s

PROFIBUS PA: Changing Hardware in Run
Add new devices

Expand line
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

s

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

s

PROFIBUS PA: Diagnostics with PDM
Standard Device specific

diagnostics detailed diagnostics

s

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
s

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
s

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

s

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 . . .

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

s

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
s

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

s

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

s

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

s

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
s

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

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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

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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

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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

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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

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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
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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”

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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
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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.
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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)
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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

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FF-H1 Segment Diagnostics via Web-Interface of the 3420 (1)
Detailed diagnostics possible via the FIM3420 web interface

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FF-H1 Segment Diagnostics via Web-Interface of the 3420 (2)
Diagnostics status of the FF field devices available via the FIM3420 web interface

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SIMATIC PCS 7
SIMATIC PCS 7
Remote IO

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SIMATIC PCS 7
Remote IO
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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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

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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

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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.

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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
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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

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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
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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

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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.
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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
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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)

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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

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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

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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

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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)

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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%)

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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

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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

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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
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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

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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

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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

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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
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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

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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
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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
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)
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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

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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

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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

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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

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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

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SIMATIC PCS 7
SIMATIC PCS 7
Field Devices & Drives

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SIMATIC PCS 7
Field Devices & Drives
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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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

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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

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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

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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
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SIMATIC PCS 7
SIMATIC PCS 7
Process Safety

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SIMATIC PCS 7
Process Safety
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

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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

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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

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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.
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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
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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.
s

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
s

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

s

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

s

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

s

Process Safety with Safety Integrated

s

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

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

s

The “Right” Level of Integration
ENG HMI ENG
INTERFACED
DCS Gateway SIS
ENG HMI
INTEGRATED
DCS SIS
ENG HMI
COMMON
DCS SIS

s

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

s

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

s

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

s

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

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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

s

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

s

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

s

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

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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

s

Flexible Modular Redundancy (FMR)
DO
DO
DI
AI
AI
Simplex Dual
1oo1 LS
DO
DO
DI
AI
AI
Triple
AI
1oo2 Valves 2oo3 PT

s

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

s

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

s

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

s

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

s

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

s

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

s

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.

s

Configuration
Function Blocks with Corresponding Block Icons in the OS
With corresponding Faceplate
Changes are logged in

the OS operations list

s

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

s

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

s

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

s

The Realization Phase with Safety Matrix

s

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

s

The Operation Phase with Safety Matrix

s

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

s

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

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 Matrix supports the phases of the Safety Lifecyle
ss
SIMATIC PCS 7
SIMATIC PCS 7
Communication

s
SIMATIC PCS 7
Communication
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

s
SIMATIC PCS 7
Communication
Advantages
Redundant
Gigabit rings for high-
availability & high-
performance
communication in the
SIMATIC PCS7 process
control system

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

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

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

s
SIMATIC PCS 7
Managed Switches SCALANCE X-200 IRT
SCALANCE X200-4 IRT, X201-3P IRT and

X202-2 IRT

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

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
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

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
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

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
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!
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!

ss
SIMATIC PCS 7
SIMATIC PCS 7
SIMATIC BATCH

s
SIMATIC PCS 7
SIMATIC BATCH
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

s
SIMATIC BATCH
Basic Functionality
Create Recipes
Engineer Process
Model
Plan Batches
Start / Monitor /
Control Batches
Document
Report
Batches

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
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

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

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

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

s
SIMATIC BATCH
SFC Interface
SFC Type SFC Instances
OS Faceplate
Visualization
SIMATIC BATCH

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

s
SIMATIC BATCH
Recipe Operations (ROP) Library
Library for Recipe Operations (ROP)

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)

s
SIMATIC BATCH
Instance (Unit / Phase) Independancy (2)
Plant Neutral Class Recipe

Class
Silo
Class
Reactor
Control Recipe
Class concept enables unit-independent recipes

s
SIMATIC BATCH
Equipment Properties
Evaluation of equipment properties for identification of unit candidates

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

s
SIMATIC BATCH
Online Operation
Start Hold Stop

Pause after Step Resume Abort

s
SIMATIC BATCH
Batch Planning (1)
Planning tool in the BATCH Control Center
Maximum quantity per unit
Required quantity
Automatic allocation to
different batches

s
SIMATIC BATCH
Batch Planning (2)
Batch Disposal and Chaining

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

s
SIMATIC BATCH
Integrated SIMATIC Route Control
Simplification of material transfers by SIMATIC Route Control

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

s
SIMATIC BATCH
Report System: Standard
XML based Report System with integrated Browser

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

s
SIMATIC BATCH
Advanced Report
SQL based Report System by use of Crystal Reports

s
SIMATIC BATCH
MES Connectivity
Interface to SIMATIC IT
Open Interface for customer specific extensions (API)

ss
SIMATIC PCS 7
SIMATIC PCS 7

s
SIMATIC PCS 7
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

s

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

s

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

s

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

s

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.)

s

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

s

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

s

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

s

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

s

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

s

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)

s

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
s

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...)

s

Use these transfer phases in SIMATIC BATCH Recipes to transfer materials

between units
Easier implementation of complex material transfer sequences

s

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“

s

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

s

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.

s

Instead of material transfer by pressure, the material can be transported also

by pump draw.

s

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)

s

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

s

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
s

Valve Manifold Example for Modes (2)
Source tanks Destination tanks
T1 T2 T3 T4 T5 T6 T7
Product flow

s

RC Center

s

RC Log

s

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

s

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

ss
SIMATIC PCS 7
SIMATIC PCS 7
MIS / MES Integration

s
SIMATIC PCS 7
MIS / MES Integration
WEB Client
SIMATIC IT
Client Station
WEB Server
ROUTE Control
OS Server CAS
BATCH Server
Industrial Ethernet
AS 41x AS 41x HF
ET200M HF
PROFIBUS DP
ET200M HF
PROFIBUS DP
ET200M HF
ET200S
ET200iSP
SIMOCODE ET200iSP
PROFIBUS PA
PROFIBUS PA

s
SIMATIC PCS 7 - MIS / MES Integration

Levels of Automation
Vertical integration

s

SIMATIC IT Integration
Production order / Continuous process

batch data data (trends)
Engineering data Alarms & Events

(tags, objects)
Field area

s


s

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.

s

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)

s

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

s

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

s

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

s

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)

ss
SIMATIC PCS 7
SIMATIC PCS 7
Migration to PCS 7

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

s

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

s

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

s

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

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.

s

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.

s

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

ss
SIMATIC PCS 7
SIMATIC PCS 7
Add-On

s
SIMATIC PCS 7 AddOn

AddOn Types (1)
any applications
interconnections
system connection
special process
migration
branches
libraries
specific periphery
participate refine
s
SIMATIC PCS 7 AddOn

AddOn Types (2)
additional hardware for OS
additional analyses
construction parts
simulation
assistance increase
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

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
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
ss
SIMATIC PCS 7
SIMATIC PCS 7
Licensing

s
SIMATIC PCS 7 Licensing

Modular and Scalable
small large
basic options
...
s

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
s

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

s

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

s

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
s

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 !

s

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
s

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

s

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 – 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
4 x PCS 7 – Runtime License AS V7.0 (PO 100)

s

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)

s

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

s

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

s

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

s

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

s

Example: AS/OS Update from PCS 7 V6.x to 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

s

Example: OS Update from PCS 7 V6.x to PCS 7 V7.0

WinCC RT 8k Tags WinCC RT PO 250

WinCC RT PO 8500
WinCC RT 256k Tags

s

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 €

s

AIDA Project: Important Differences
New Hardware with improved performance
ES unlimited without runtime
No extra charge for Simatic Logon
AS PO License

s

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 €
s

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
s

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).

s

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

s

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.

s

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

s

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

ss
SIMATIC PCS 7
SIMATIC PCS 7
System Functions

s

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
s

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

s

SIMATIC Logon: Applications
ES:
OS:
Download in AS
Access
(with Audit Trail)
protection
BATCH: BATCH:
Electronic signatures Access
protection

s

Access Control
Windows Security Settings
SIMATIC Logon Settings

s

Audit Trail: SIMATIC Logon Eventlog Viewer

s

Access Control and Audit Trail: ES Download to AS

s

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
s

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
s

Versioning: Object Level and Project Level
CFC chart Recipes
ES Project

s

Versioning: Version Cross Manager
Tracking engineering
changes: comparison of
two project versions
offline

s

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

s

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
s

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

s

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)
s

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
s

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

s

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
s

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

s

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.

s

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

s

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
s

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

s

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

ss
SIMATIC PCS 7
SIMATIC PCS 7
Summary

s
Summary
PCS 7 System Architecture

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

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.

ss
SIMATIC PCS 7
Thank you !

PCS7 V701 Technology

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For internal use only / © 2007 SIEMENS AG

Process Control System

For internal use only / © 2007 SIEMENS AG

SIMATIC Route Control Version Cross Manager

Fieldbus Recipe System

For internal use only / © 2007 SIEMENS AG

Siemens is The automation partner for solutions

Save time with TIA (Totally Integrated Automation)

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

Installation & Maintenance

For internal use only / © 2007 SIEMENS AG

One control system for all sectors

For all primary and secondary plants

Pilot Production Interconnected plants at a

Scalable ...to the distributed system in client/

… as powerful as you need it to be!

SIMATIC PCS 7 BOX

The compact, low-cost process control system for small

… 1st step in a Totally Scalable Solution !

Totally Integrated Automation

For internal use only / © 2007 SIEMENS AG

Office LAN (Ethernet)

For internal use only / © 2007 SIEMENS AG

SIMATIC PCS 7 Engineering System

Technological function blocks with

Engineering SIMATIC PDM

SIMATIC PCS 7 Engineering System

Process object view

For internal use only / © 2007 SIEMENS AG

SIMATIC PCS 7 Engineering System

One view of all

All components and applications of a plant in a single location

SIMATIC PCS 7 Engineering System

SIMATIC PCS 7 Engineering System

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

SIMATIC PCS 7 Engineering System

Integrated plant view in EXPLORER – form, allows configuration

SIMATIC PCS 7 Engineering System

Selective filtering of relevant parameters allows you to optimize

SIMATIC PCS 7 Engineering System

Block parameters can be

Project library for storing process tag types and

Collaboration with MS EXCEL

Added Efficiency from ability to leverage project data from MS

SIMATIC PCS 7 Engineering System

Graphical Engineering-Tool CFC (Continuous Function Chart)

Block libraries with

Simple engineering of all measuring points using preconfigured blocks

SIMATIC PCS 7 Engineering System

Graphical engineering tool SFC (Sequential Function Chart)

For internal use only / © 2007 SIEMENS AG

SIMATIC PCS 7 Engineering System

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

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

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

Heating Condition for

SIMATIC PCS 7 Engineering System

Chart I/Os can be configured for SFC charts

New object: SFC type in the CFC

Easy integration of SIMATIC BATCH

For internal use only / © 2007 SIEMENS AG

SIMATIC PCS 7 Engineering System

SFC operating states can be triggered