Prevention of

overload using
"CPU_RT"
Siemens
SIMATIC PCS 7 V9.0 SP1 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/55692652 Support
 Legal information

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 Table of contents

Table of contents
Legal information ......................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 Principle of operation............................................................................ 5
1.3 Components used ................................................................................ 8
2 Cycle Performance Analysis ............................................................................ 9
2.1 Presentation of cycle performance data ............................................... 9
2.2 Scenario 1: High controller cycle load (maintenance required) ......... 11
2.3 Scenario 2: OB Request error (maintenance request) ....................... 12
2.4 Scenario 3: Exceeding the maximum cycle time (maintenance
alarm) ................................................................................................. 13
3 Overload behavior ........................................................................................... 14
3.1 Parameterization of the overload behavior ........................................ 15
3.2 Signal behavior in case of overload ................................................... 17
3.3 Reset of emergency operation in case of controller overload ............ 17
4 Summary .......................................................................................................... 19
5 Appendix .......................................................................................................... 20
5.1 Service and support ........................................................................... 20
© Siemens AG 2019 All rights reserved

5.2 Links and literature ............................................................................. 21

5.3 Change documentation ...................................................................... 21

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 1 Introduction

1 Introduction
1.1 Overview
The controller of an automation system has two primary tasks. On the one hand,
the process is automated by the controller, on the other hand, the controller must
evaluate and forward all operations and displays.
All tasks are processed sequentially (one after the other) in the controller. The
cycle time represents the time that the operating system needs to execute a
program, that is, one OB 1 cycle, including all program sections and system
activities interrupting this cycle. In order to ensure an appropriate processing time,
the SIMATIC series controllers have a maximum basic cycle (OB1) monitoring time
of 6 seconds. This results in a time limitation of the applications in addition to the
memory. If the so-called cycle control point is not reached within 6 seconds, OB 80
(time error) is called and a system message is sent. If the cycle control point is
reached after a further 6 seconds, the controller stops without the "CPU_RT" block.
For process automation, SIMATIC PCS 7 offers the possibility of reacting to
temporary and permanent cycle overloads by controlled, automatic load shedding.
This functionality is realized by the function block "CPU_RT" and is available from
version 7.0 of PCS 7.
By means of the function block "CPU_RT", the necessary relief measures in case
of cycle overload of a PCS 7 controller are carried out automatically. The
"CPU_RT" block combines the following functions:
© Siemens AG 2019 All rights reserved

• Maintaining operability through new overload behavior by means of multi-stage

reduction of the cyclic load
• Prevention of overload through cycle performance analysis and visualization of
performance data in the Maintenance Station

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 1 Introduction

1.2 Principle of operation

If you compile CFCs with the option "create module driver", a plan named
"@CPU_RT" will be created. It will include the "CPU_RT" function block, which will
be integrated in all relevant execution levels (OB100, OB1, all OB 3x, and OB 8x)
by the module driver wizard.

Note The CFC plan "@CPU_RT" is a system plan. These must not be deleted.
© Siemens AG 2019 All rights reserved

Note The "CPU_RT" block is placed in the system plans by the PCS 7 module driver
wizard. As of PCS 7 V7.0 in conjunction with PCS 7 Library, Basis Library or
Advanced Process Library as of V7.0, all controllers have the new overload
behavior.
When migrating an older project without using new functions, the "CPU_RT" will
not be installed automatically.

Note Further information about the function of the block "CPU_RT" can be found in the
manual PCS 7 Basis Library (V9.0) SP1 under the following link
https://support.industry.siemens.com/cs/ww/en/view/109754974.

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 1 Introduction

Applications
The following application cases were considered with the block "CPU_RT":
• Applications with little time reserve have the highest risk of overload. Systems
with high time load can go into overload quickly through a defective
component. A typical case for this is a defective measuring line that produces a
flutter alarm. The "CPU_RT" block enables you to determine the overall
runtime (with interruptions by higher-priority process levels) through OBs
during commissioning and in normal operation, apart from the net runtime of
the organization block (OB). Early load relief of time-critical OBs represents a
good protection against controller overload.
• A further application case is the modification and extension of the user
program when the cycle load is already high. A change or extension of the user
program causes an overload of the controller after loading into the automation
system (AS). The "CPU_RT" block specifically reduces the cycle overload of
the controller. Process levels or OBs representing a very high load are
temporarily reduced (load shedding - emergency operation) until the temporary
load has diminished. This ensures the permanent operability of the system
even in case of overload. It is possible to undo changes during operation or to
restructure the user program accordingly, in order to return to normal
operation. An example of this is load reduction by moving program parts to
slower OBs.
• Adding communication connections lead to a controller overload under certain
circumstances. In this case, the module also enables the change to be
© Siemens AG 2019 All rights reserved

reversed in "emergency" mode.

If an overload occurs during operation for no obvious reason, you can localize the
cause by a detailed performance analysis of the "CPU_RT" block. In particular, the
net times (pure OB running time without interruptions) must contain an indication of
where additional time losses occurred (see section 2.1 "Presentation of cycle
performance data"). This can even be done retroactively in normal operation, due
to the new overload behavior.

Requirement
A prerequisite for the automation solution is that SIMATIC PCS 7 is available in
version V7.0 or higher.
The function for determining the cycle performance data of the "CPU_RT" function
block requires a controller firmware revision level that supports the "SFC 78"
system function.
Controller Firmware versions
For Single Controller 5.0 or higher
For H-Controller 4.5 or higher

In addition to the "SFC 78" system function, the "Maintenance Station Standard"
option package is also required to fully utilize the new controller overload behavior
and cycle performance analysis.

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 1 Introduction

Range of functions
Depending on which controller firmware of the controller is available and whether
you use the "Maintenance Station Standard" option package, a different range of
functions is available. The following three configurations are possible:
• Configuration 1
CPU with firmware that supports the system function "SFC 78" and existing
option package "Maintenance Station Standard".
• Configuration 2
CPU with firmware that does not support the system function "SFC 78" and
existing option package "Maintenance Station Standard".
• Configuration 3
Without existing option package "Maintenance Station Standard". In this case it
is irrelevant whether the CPU supports the system function "SFC 78" or not.

Function Configuration 1 Configuration 2 Configuration 3

Cycle Performance Analysis Yes No No

Display of cycle performance data on Yes No No

OS
Display cycle performance data in Yes No No
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CFC
notifications Yes Yes* Yes*

Parameterization via faceplate Yes Yes No

(via CFC)
New controller overload behavior
Yes Yes Yes

* No operator message "Net time consumption of all OBs exceeds Max Limit"
because performance data is not calculated.

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 1 Introduction

1.3 Components used

The following hardware and software components were used to create this
application example:
Component
SIMATIC PCS 7 ES/OS
IPC547G W7
SIMATIC PCS 7 V9.0 SP1
APL library V9.0 SP1
Maintenance Station Standard
PCS 7 CPU410-5H
Note
For the PCS 7 V9.0 SP1 example project
Part of SIMATIC PCS 7 ES/OS IPC547G W7
Part of SIMATIC PCS 7 V9.0 SP1
Not a part of SIMATIC PCS°7 V9.0 SP1, additional
licenses required
Controller for the Process Automation

Note If the hardware is different, observe the minimum requirements for installing the
software components. The minimum requirements can be found in the PCS 7
Readme under the following link:
https://support.industry.siemens.com/cs/ww/en/view/109750097.

This application example consists of the following components:

© Siemens AG 2019 All rights reserved

Component Note
55692652_CPU_RT_DOC_PCS7V90SP1_de.pdf This document

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 2 Cycle Performance Analysis

2 Cycle Performance Analysis

The "CPU_RT" block determines the runtime of the individual OBs and their
participation in the cycle time (cycle performance analysis). This performance data
and load information can help you even in the project engineering phase for
structuring the user program, allowing you to selectively plan reserves for
extensions, utilize the capacity of the individual process level homogeneously, and
prevent later controller overload.

Note The cycle performance analysis is only available for controllers with SFC 78.

2.1 Presentation of cycle performance data

Requirement
The prerequisite for visualizing the cycle performance data is:
• The user program has been loaded into the automation system (AS) or S7-
PLCSIM and the OS (WinCC Runtime) has been compiled and loaded.
• The Maintenance Station has been successfully parameterized and loaded.
Instructions for this can be found in the PCS 7 Maintenance Station manual
under the following link
© Siemens AG 2019 All rights reserved

https://support.industry.siemens.com/cs/ww/en/view/109759590.
• The option package "Maintenance Station Standard" is available.
• The CPU supports the system function "SFC 78".

Configuration
Via the asset block icon of the controller you can select the faceplate that
represents the total load of the controller.
1. Start OS runtime.
2. Open the faceplate of the respective CPU.
3. Click on the "Performance" (5) tab.

1 3 4

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 2 Cycle Performance Analysis

Meaning
1. Parameterized limit value for the maximum utilization of the CPU
2. Bar chart for the current and average utilization of the CPU in %.
3. Bar chart for the gross and net running time of the OB in %.
4. Due to the CPU load the maximum cycle time of the OB was exceeded.
5. Register of the Performance View

The net runtime is the runtime needed to process the blocks placed in the OB3x if it
is not interrupted by higher-priority OBs.
The overall runtime is the runtime that was actually needed for processing the code
placed in OB3x, including the runtimes of higher-priority OBs.
The vertical bar shows the overall load of the controller in % and the sum of all net
runtimes (cycle times) of all OBs.

A detailed analysis can be found in the register "OB3X". There the determined
cycle times are displayed in the individual process task (OBs).
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Note The overall utilization of a single controller after commissioning should not
exceed 75%, so 25 percent reserve is left for future program extensions or
additional communication jobs (message burst).

Example
The net runtime of the OB38 is 5ms. With a sampling time of OB 38 from 10ms, the
overall utilization rate is 50 percent. In this case the overall and net runtime are
identical for OB38, if it is not interrupted by higher-priority OBs
The net runtime of the OB35 is 45ms. With a sampling time of 100ms, the overall
utilization rate is 45 percent. The overall runtime is clearly higher than the net
runtime, the reason being that OB35 is interrupted by higher-priority OB38.
There is a risk of overload with an overall load of 95 percent. The overall runtime of
OB35 indicates that this OB is close to an OB request error. In case of additional
acyclic events or high communication load a controller, overload might occur in this

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 2 Cycle Performance Analysis

described example. Due to the overall load and the overall runtime of OB35 the
program must be restructured.
Program extensions in OB35 or in faster OBs can lead to overload. In general, the
faster the sampling time of the used OB, the more the risk of an overload of the
cycle time increases. The consequence here would be that you move existing or
newly added program parts into slow OBs.

Conclusion
Typically the program logic and processing for slower process signals (e.g.
temperatures) is placed in the OB3x with 1 to 2 seconds call interval and more
dynamic process values (e.g. pressure) are processed in faster OBs. This
preventive measure is the decisive measure to avoid a cycle overload of the
controller.

2.2 Scenario 1: High controller cycle load (maintenance

required)
If the overall load (sum of the mean values of all net runtimes in % of OB3x, OB8x
+ OB1) exceeds the overall load alarm limit, the message "Net time consumption of
all OBs exceeds max. limit" is displayed and the maintenance status is set to
"Maintenance demand".
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Due to this preventive maintenance message, you should take measures to relieve
the cycle in the user program in order to avoid overloading the controller cycle.
Examples of this are adapting, splitting or transferring the user program.

If the "SFC 78" is not supported, the controllers do not report exceeding the net
time consumption.

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 2 Cycle Performance Analysis

2.3 Scenario 2: OB Request error (maintenance request)

If the overall load of the controller reaches the limit of 100 %, OB request errors are
triggered. In this case, cyclic OBs are no longer processed appropriately and called
within the specified time frame, because they are interrupted, for example, by
acyclic OBs (diagnostic alarms). This makes the program processing time (overall
time) longer than the call interval of the OB (e.g. OB35: 100ms).
If the parameterizable number of request errors is exceeded, the message "OB 3x
request error" is output and the maintenance status is set to "Maintenance
request".
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When there is no longer an overload situation, the maintenance status will be reset
and the process control message will be marked as "going out".

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 2 Cycle Performance Analysis

2.4 Scenario 3: Exceeding the maximum cycle time

(maintenance alarm)
If the set cycle monitoring time (HW Config > CPU properties) is exceeded (default:
6000ms), the message "Cycle time exceeded: 6000ms, OB1" and the maintenance
status of the CPU is set to "Bad or maintenance alarm".

NOTE The CPU 410-5H has a fixed cycle time monitoring of 6 seconds.
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The possible causes for exceeding the cycle monitoring time are:
• High communication load
• Accumulation of alarm events
• Accumulation of acyclic error events (flutter alarms)
• Incorrect dimensioning of wake-up alarms when adding new program parts

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 3 Overload behavior

3 Overload behavior
In case of a cycle overload the controller can prevent it from becoming inoperable
through controlled load shedding.
The load shedding takes place by means of the block "CPU_RT" and is achieved
by reduction of cyclic run levels. Load shedding represents an emergency mode,
the cause of which needs to be eliminated as soon as possible.
Emergency operation starts when the cycle monitoring time has been exceeded
twice. In this case, the cycle control point was not reached for at least 12 seconds
due to a temporary or permanent overload.
The control system message "Emergency operation, cyclic OBs are reduced" is
output with the standard priority "16". This means that this message is displayed in
the list of messages with the highest priority.

Note If the option package "Maintenance Station Standard" is available, a

Maintenance Alarm is additionally generated at the diagnostic image block of the
affected CPU.
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In emergency operation, the blocks are skipped or suspended depending on the

reduction factor. This ensures that you can continue to edit all blocks.
You can parameterize two escalation levels:
• Stage 1:
The cycle monitoring time has expired twice (approx. 12s). The OB 3x released
for reduction are reduced once.
• Stage 2:
If time errors continue to occur, all OB 3x are incrementally reduced.

Note Emergency operation is not to be understood as a permanent bridging of the

cycle overload state of the controller. Emergency operation serves to intercept
temporary overloads. Emergency operation should be reacted to as quickly as
possible, e.g. by restructuring the program, undoing it or moving imported
changes. For this reason, emergency operation is also reported as a
maintenance alarm in the diagnostics area.

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 3 Overload behavior

3.1 Parameterization of the overload behavior

Requirement
Prerequisite for the parameterization of the overload behavior are:
• The user program has been loaded into the automation system (AS) or S7-
PLCSIM and the OS (WinCC Runtime) has been compiled and loaded.
• The Maintenance Station has been successfully parameterized and loaded.
Instructions for this can be found in the PCS 7 Maintenance Station manual
under the following link
https://support.industry.siemens.com/cs/ww/en/view/109759590.
• The option package "Maintenance Station Standard" is available.

Configuration
To parameterize the overload behavior, proceed as follows:
1. Start OS runtime.
2. Open the diagnostic faceplate of the CPU.
3. Parameterize the desired overload behavior.

In the following figure OB 33 and OB 35 are excluded in the first escalation stage
and are not squared there.
© Siemens AG 2019 All rights reserved

Note If you do not have the option package "Maintenance Station Standard", you must
parameterize the overload behavior directly at the block "CPU_RT" in the CFC
plan "@CPU_RT". The block inputs "OB3x_ATTN" are available for this purpose.

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 3 Overload behavior

The maximum number of reduction ratios can be set in the faceplate at the
parameter "Max. number of underruns STOP request" or at input "MAX_RTRG".

• MAX_RTRG=0
If MAX_RTRG = 0, the function "Stop avoidance on overload" is switched off,
the CPU immediately switches to the operating mode "Stop" if the overload
behavior occurs (as with SIMATIC PCS 7 versions smaller than V7.0).
© Siemens AG 2019 All rights reserved

• MAX_RTRG=1
Only the first stage of the new overload behavior is initiated.
If the load shedding through stage 1 is not sufficient, the controller switches to
STOP at "MAX_RTRG" = 1 after exceeding the cycle monitoring time (>18s)
three times and stage 2 is not initiated.
• MAX_RTRG = 2
After the cycle monitoring time (18s) has been exceeded three times, stage 2
is initiated. All OBs are squatted once. If this load shedding is also insufficient,
the controller switches to the STOP state after the cycle monitoring time (>24)
has been exceeded four times.
• MAX_RTRG = x
If you assign a value greater than "2" to the input, the cycle monitoring time can
be exceeded x times. The reduction factor is increased each time the value is
exceeded.

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 3 Overload behavior

3.2 Signal behavior in case of overload

Total load Alarm limit (only for CPUs with SFC 78):
If the total load (sum of the average values of all OB net runtimes) exceeds the
upper limit set at the parameter Total load alarm limit or MAX_VAL (CPU_RT), the
message "Net time consumption of all OBs exceeds Max Limit" is output.

Note See section 2.2 "Scenario 1: High controller cycle load (maintenance required)".

Max. Number of OB request errors

If the number of OB request errors parameterizable at the parameter "Message
from request error" or N_REQ_ERR (CPU_RT) is exceeded, the message "OB 3x
request error" is output.

Note See section 2.3 "Scenario 2: OB Request error (maintenance request)".

3.3 Reset of emergency operation in case of controller

© Siemens AG 2019 All rights reserved

overload
CPU with SFC 78
The emergency operation is automatically and slowly reduced if the overall load of
the CPU is less than the maximum overall load of the controller configured at the
parameter "Cancel reduction ratio for" or MAX_VAL (CPU_RT).

For this, the percentage overall load is calculated with a reduction factor minimized
by one. If the overall load calculated in this way for the parameterized number
(UndoCycle) of cycles of the slowest OB does not exceed the parameterized limit
value, the reduction factor is decremented by one. This happens until the used
cyclic OBs have reached reduction factor 1.

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 3 Overload behavior

The reduction is then set to 0 for the OBs excluded by the user (OB3x_ATTN =
FALSE). Finally, the reduction ratios for all other cyclic OBs are set to 0.

CPU without SFC 78

If no SFC 78 is available, the time at which the withdrawal of stop-avoidance
measures can be initiated cannot be calculated. The reduction ratios are reset
when the slowest OB processes a number of cycles again (UndoCycle).
© Siemens AG 2019 All rights reserved

Note In this case, the UndoCycle value should not be too small to avoid too frequent
oscillation between stop avoidance measures and normal operation.

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 4 Summary

4 Summary
If you use the PCS 7 Library V7.0 or higher, the Basic Library or the Advanced
Process Library, the "CPU_RT" block is always installed by the module driver
wizard. The installation is independent of the use of the Maintenance Station and
the firmware of the controller.
After upgrading the driver modules from old projects to PCS 7 V7.0, there is a
changed behavior of the controller in case of stop avoiding by cycle overload.
In emergency operation of the controller the cyclic OBs are reduced. This behavior
has an effect on integral calculations, fast shutdown functions, or fast controls. In
case of overload the controller STOP or the controller emergency operation
(permanent operability) can be used.
Therefore, you can set the desired behavior in case of cycle overload via the
diagnosis faceplate of the CPU. If the option package "Maintenance Station
Standard" is not available, the settings can also be made at the CPU_RT" block.

Note The block "CPU_RT" can be deactivated by setting the parameter "MAX_RTRG"
to "0". In this case the CPU immediately switches to the operating mode "Stop" if
the overload behavior occurs (as with SIMATIC PCS 7 versions smaller than
V7.0).

Since an overload of the controller usually occurs due to incorrect project planning
© Siemens AG 2019 All rights reserved

or the frequent occurrence of acyclic events (flutter/diagnostic alarms OB8x), the

permanent operability of the system and the possibility of troubleshooting and fault
rectification while the system is running are preferred. Therefore, the new overload
behavior of the controller is preset from version PCS 7 V7.0.

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 5 Appendix

5 Appendix
5.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. Please send queries
to Technical Support via Web form:
www.siemens.com/industry/supportrequest
© Siemens AG 2019 All rights reserved

SITRAIN – Training for Industry

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
www.siemens.com/sitrain

Service offer
Our range of services includes the following:
• Plant data services
• Spare parts services
• Repair services
• On-site and maintenance services
• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows
Phone:

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 5 Appendix

5.2 Links and literature

No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/55692652
\3\ SIMATIC Process Control System PCS 7 Maintenance Station
https://support.industry.siemens.com/cs/ww/en/view/109759590
\4\ SIMATIC Process Control System PCS 7 Basis Library (V9.0 SP1)
https://support.industry.siemens.com/cs/ww/en/view/109754974

5.3 Change documentation

Version Date Modifications
V1.0 01/2007 First edition on the DVD PCS 7 V7.0
V2.0 11/2009 Layout adaptation for publishing in the Service & Support
Portal under "Applications & Tools" (see link "Links and
literature")
© Siemens AG 2019 All rights reserved

V3.0 11/2011 Revised; new screenshots; Layout adapted

V4.0 05/2019 Updated to PCS 7 V9.0 SP1 with new layout and
screenshots

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