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SIMATIC PCS 7

Introduction

SIMATIC PCS 7 offer

Central
Engineering

Automatic
Generation

Integration
Intelligent
Instruments
Fieldbus
Decentral
Architecture

Open System
&
Integration
Capability

Redundancy
on all levels

Integrated
Safety
System

Integrated
&
Redundant
BATCH

Asset
Management

Migration
Strategies for
Siemens and
3rd-party
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)
thus offering highly integrated and stable automation solutions
LIBRARIES
COMPONENTS
STANDARDS

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

Financial impact

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


Design &
Engineering

Modernization
& Upgrade

Operation

Installation &
Commissioning

Maintenance

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
Conti sectors

SIMATIC
BATCH

Clear reduction in costs:


hardware, logistics, training

Batch Sectors

SIMATIC PCS 7

Increase in productivity:
flexibility over the entire life cycle
of the plant

SIMATIC PCS 7
Large Bandwidth of Scalability (1:1000)
Pilot
plant

Production
plant

Interconnected plants at a
production location

...to the distributed system in client/


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

as powerful as you need it to be!

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 Software
SIMATIC

Industrial
Workstation

SIMATIC Controller
SIMATIC NET
PROFIBUS DP

Totally Integrated Automation

Components

SIMATIC PCS 7

SIMATIC PCS 7
Engineering Station

SIMATIC PCS 7
Engineering System
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

SIMATIC PCS 7 Engineering System


Overview of the Tools
OS Engineering

Automation
Engineering

User OS

SIMATIC BATCH

faceplates

Import/Export
Import/Export CFC/SFC
CFC/SFC
Assistant
Assistant

Libraries
Libraries

PCS 7 Engineering
HW
HW
Config
Config

Plant
Plant
Hierarchy
Hierarchy

Graphics
Graphics
Designer
Designer

Faceplate
Faceplate
Designer
Designer

SIMATIC
SIMATIC
S7
SIMATIC
SIMATIC
SIMATIC
S7
SIMATIC
BATCH
BATCH Route
Route Control
ControlF-Systems
F-Systems PDM
PDM
HEAT
HEAT

MIX
MIX

SIMATIC Manager
uniform database
Technological function blocks with
faceplates and CFC templates for
standard applications
(e.g. motor, valve, controller)

Engineering for network/


communication/hardware

Engineering SIMATIC PDM


for field device
for
configuration
failsafe
systems

SIMATIC PCS 7 Engineering System


Views

Component view
For configuration of the control system
hardware
(I/O modules, CPU, bus systems etc.)
Plant view
Hierarchical plant architecture according to
process engineering aspects
(e.g. plant / process area / unit according to
process model)
Process object view
A centralized development environment for
all aspects of a process engineering
measuring point
Integrated plant view

SIMATIC PCS 7 Engineering System


Component View
Hardware configuration
of an AS station with I/O

Configuration of a
module without
hardware jumpers

One view of all


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

All components and applications of a plant in a single location


Hierarchical navigation to configuration of the hardware
Selection of components from hardware catalog and placement using
Drag and Drop

SIMATIC PCS 7 Engineering System


Plant View: Hierarchical Representation of the Plant

Plants

Process
Area
Piece of
equipment Control device
(Process Object)

Integrated in process
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

SIMATIC PCS 7 Engineering System


Comprehensive Processing via Process-Object View

Processing of all aspects such as general information, parameters, signals, messages / alarms,
General
image objects or archives directly in tabular format

Efficient editing of all objects:

Block copy / paste (for attributes)

Cooperation with Excel / Access


(Copy / Paste)

Find / replace attributes

Browser for convenient


signal connection

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

OS
Crossreference

Name, comment,
AS assignment

Block symbols,
I/O fields,
status
indicators

Archives
Cycles, units

CFC
& SFC
Parameter/
Connections
Limits,
settings,
cross-measuring
point
connections

Process
Objects
Hardware
Assignment
I/O channels,
signal names

Messages
Message texts
priorities

SIMATIC PCS 7 Engineering System


Process Object View: EXPLORER-/EXCEL Look & Feel

Integrated plant view in EXPLORER form, allows configuration of


a measuring point (Tag) using EXCEL Look & Feel

SIMATIC PCS 7 Engineering System


Process Object View: Comprehensive Filter Functions

2-level filter
function

Selective filtering of relevant parameters allows you to optimize


your configuration activities

SIMATIC PCS 7 Engineering System


Process Object View: User Friendly

Block parameters can be


changed without opening CFC

Project library for storing process tag types and


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

Collaboration with MS EXCEL


using Copy & Paste

Added Efficiency from ability to leverage project data from MS


EXCEL (taglist, alarmlist etc.)

SIMATIC PCS 7 Engineering System


CFC: Graphical Configuration of Continuous Automation
Functions
Graphical Engineering-Tool CFC (Continuous Function Chart)

Place blocks
by Drag and
Drop

Automatic
connection to
other charts and
hardware signals

Block libraries with


search function

Simple engineering of all measuring points using preconfigured blocks

SIMATIC PCS 7 Engineering System


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

Graphical engineering tool SFC (Sequential Function Chart)

Standardized elements (step, transition, jump...)

Automatic generation of the operator visualization system

Handling of exceptional states, operating modes...

Link to CFC diagrams by means of simple actions

Type / instance concept for centralized modifications

On-line Modifications

SIMATIC PCS 7 Engineering System


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

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


Idle - Starting - Run - Completing - Error(Completed) - Completed - Holding - Held Resuming - Error - Held(Error) - Resuming(Error) - Aborting - Aborted - Stopping -Stopped

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


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

Heating

Cooling

Shutdown

Condition for
control strategy

Heating
Cooling

...

....

Coordinated automatically by PCS 7

Shutdown

SIMATIC PCS 7 Engineering System


SFC: Type Instance Concept Highlights

Chart I/Os can be configured for SFC charts

Inputs and outputs for controlling and monitoring status of the SFCs are available, additional inputs and
outputs can be configured for SFC types

Write statements in steps to outputs

Read transition conditions from inputs

Configure Interface to SFCs just like standard chart I/Os (e.g. setpoint with limits)

The SFC chart can be placed in the CFC chart like a block,
the SFC control block is not needed

New object: SFC type in the CFC

In the SIMATIC Manager or SFC: Chart > New > SFC Type...

Chart I/Os as described above

Real type-instance concept

Each placement in the CFC chart creates an instance: re-usability

Changing the type changes all instances: central editing

Test mode and SFC visualization also for instances

General display driver block and block symbol for SFC instances are supplied

Easy integration of SIMATIC BATCH

No interface blocks required

SFC Coordination is handled automatically

Equipment modules are created as SFC types which

contain the sequential control, operating state logic, control strategies

are connected directly to the process tags

Better specifications and improved performance compared to PCS 7 V5.2

SIMATIC PCS 7 Engineering System


SFC: Type Instance Concept Block Interface
SFC

Configure chart I/Os


(inputs/outputs/in/outs)

CFC

SFC operating states can be triggered


by interconnections (inputs)
SFC status can be determined from
interconnections (outputs)

SIMATIC PCS 7 Engineering System


SFC: Type Instance Concept Central Editing
Definition of the SFC type

SFC instances in the CFC

Online visualization of
SFC Status

SIMATIC BATCH
OS faceplate

SIMATIC PCS 7 Engineering System


All OS Functions Automatically Generated

Complete plant overview


for the operator

Overview (n levels),
graphic level, key level

Display hierarchy

Hierarchical display organization

Messaging and archiving system

Alarm Summaries, symbols,


faceplates
User-friendly operator navigation
Jump from group display directly to
relevant graphic
Loop-in alarm
(jump from alarm directly to graphic)
Acknowledgements from alarms directly
in the graphic

tional
i
d
d
a
o
N
ring !!!
e
e
n
i
g
n
e

SIMATIC PCS 7 Engineering System


Downloading and Testing Changes Online
ES

OS

Simple online change


(also for non-redundant
systems)

Selective download of
redundant servers allows online
testing of changes before
complete system update

New measuring point


(Loop)

ES

OS server

A
B

Download server A, clients 1 and 2


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

*) see Engineering System

Alternative automatic
download with "MAKE" *)

SIMATIC PCS 7 Engineering System


All OS Functions Automatically Generated

Automatic generation of symbols, faceplates, alarm and process


value archives

onal
i
t
i
d
d
a
No
ring !!!
e
e
n
i
g
n
e

Anlage

Teilanlage

Technische
Einrichtung

Technische
Funktion

SIMATIC PCS 7 Engineering System


Libraries

Blocks in the PCS 7 library


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

for ES
and AS

for OS

SIMATIC PCS 7 Engineering System


Function Blocks Configuration of OS Symbols

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

1 block type
(e.g. motor)

n symbols in the OS

1 faceplate to the
block type
(e.g. motor)

SIMATIC PCS 7 Engineering System


Make

Overview of all configuration changes in the project

Execution per START command

HW Config (PCS 7 V6.0 SP3)

CFC

SFC

OS

SIMATIC BATCH

"Smart compiling and downloading


of all changes in the correct order!

First make all changes, then compile and download all changes in one step throughout entire
project!

Better turnaround times since there is no wait between


the various engineering changes

SIMATIC PCS 7 Engineering System


Using a Project Library

Project administrator:
Creates project library
Selects from standard block types / measuring
point types or defines custom, project-specific
elements
Defines attributes of the blocks
Visible / hidden
Default values
Default alarm texts
Hides all other libraries in the GUI

Project engineer:
Works from one project library
Easy to search for blocks and template
charts
Configuration Management by ensuring
that only project standard elements are
used in the application
Makes version control of new block and
template charts easy

SIMATIC PCS 7 Engineering System


Faceplate Designer for Creating Custom Faceplates
Library
basic elements

Creation and modification


of custom faceplates
Assistant creates the basic frame
Library with basic elements
Easy-to-use (Drag and Drop)
Easy-to-learn (Graphics Designer)

Assistant
Faceplate frame

Faceplate

SIMATIC PCS 7
Automation System

SIMATIC PCS 7
Automation System
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

SIMATIC PCS 7 Automation System


Controllers built by SIMATIC, Worldwide Market Leader

Robust components from SIMATIC, the worldwide market leader


Fanless operation up to 60C
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

Typical controller capacity


(sample project)

SIMATIC PCS 7 Automation System


High-Available CPUs

Using of high-available CPUs to

avoid high restart costs following a fault

prevent expensive downtimes

facilitate operation without monitoring or


maintenance personnel

3 different CPU types

With 2 integrated PROFIBUS DP-Master interfaces

With 2 slots for Sync-Module

Can be used with F-runtime lic ense and F-compatible CPU in failsafe
S7-400F/FH systems

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

SIMATIC PCS 7 Automation System


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

Periphery
1 PROFIBUS DP onboard*
Redundancy
2 sync modules

414-4H/F

Periphery
2 PROFIBUS DP onboard*
Redundancy
2 sync modules

* Onboard PROFIBUS DP is
restricted. No subsystem
like PA or HART is possible.
External DP-CPs supports
data record routing.

417-4H/F

Periphery
2 PROFIBUS DP onboard*
Redundancy
2 sync modules

SIMATIC PCS 7 Automation System


Memory, Performance, Quantity Framework
(Standard CPUs 3)
CPU 412-3H

CPU 414-4H

CPU 417-4H

Working memory

512/256 kB

2x 1,4 MB

2x 15 MB

CPU/processing
times

min. 0,075 s

min. 0,045 s

0,018 s

FB / FC

3000

3000

8000

DB
Flags/Clock
memories
Timers/counters

6000

6000

16000

8 kByte

8 kByte

16 kByte

2.048

2.048

2.048

8 k/8 k

8 k /8 k

16 k / 16 k

65.536 / 65.536

65.536 / 65.536

131.072 / 131.072

4.096 / 4.096

4.096 / 4.096

8.192 / 8.192

Address areas I/O


(Byte)
Digital channels I/O
Analog channels
I/O
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)
Communication
interfaces

14; inkl. CP 443-5 Extended und IM 467


X1: MPI

X1: MPI
X2: DP

X1: MPI
X2: DP

SIMATIC PCS 7 Automation System


Scalable Availability
Standard System
single power supply
single system bus
single controller

double power supply


single system bus
single controller

double power supply


double system bus
single controller

H System
double power supply
double system bus
double controller

quad power supply


double system bus
double controller

quad power supply


quad system bus
double controller

SIMATIC PCS 7 Automation System


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

Entry level with CPU 412H


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

Fiber optic connection for


synchronization

Expandable
Shared rack
Separated rack for
distances up to 10 km
(to maximize availability
and minimize commoncause failure)

SIMATIC PCS 7 Automation System


High-Available Controller: Automatic Event Synchronization
Possible Synchronization procedures:
synchronization

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

CPU B

Synchronization

CPU A

synchronization

CPU B

synchronization

CPU A

Command

CPU B

Event

CPU A

Time

CPU B

Cycle

CPU A

SIMATIC PCS 7 Automation System


High-Available Controllers: Connecting Switched Periphery
Redundant IM 153-2

Redundant PROFIBUS DP

AS 41x HF

ET200M H/F
(Standard & F-Modules)
ET200iSP

L+
L+

ET 200M
with active backplane bus
Special bus module (BM)
IM

Y-Link
SIMOCODE

PROFIBUS PA

IM

Active
backplane bus

SIMATIC PCS 7 Automation System


Overview AS
Availability
Redundancy

Depend on PC

Scalability
balanced data

Big memory, low periphery


less communication

Expandability
Modular

Not expandable

Performance
Highest performance

High performance

SIMATIC PCS 7 Automation System


Overview AS
Availability
S7 400 H-CPU Redundancy
S7 400 Std-CPU modular assembly,
red. Power supply
BOX 416 PCI PC independent,
400 based controller

Expandability
S7 400 CPU more than 1200 DP-slaves,
additional interfaces
(modular assembly)
BOX RTX up to 250 DP-slaves
(with second CP5613)
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
S7 400 CPU balanced memory, periphery
and communication

Performance
BOX and AS RTX very fast controller,
depends on PC

BOX 416 PCI like S7 400 CPU firmware V4

S7 400 Std-CPU speed graduate controller


from low to high performance

BOX and AS RTX big memory, low periphery


and less communication

S7 400 H-CPU a little bit slower


than Std-CPU
BOX 416 PCI like S7 400 CPU firmware V4

SIMATIC PCS 7
Operator System

SIMATIC PCS 7
Operator System
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

SIMATIC PCS 7 Operator System


Overview
User
Management
Alarm System

Web access
Process
Visualization
Excel

Archive
System

Programming
Interfaces

Standard
Interfaces

Report System
Data Management

SIMATIC PCS 7 Operator System


Hardware & Software Components

Configurations
Clients
Single-user
system

32

Server
1

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
System software also available without hardware
(for simulation purposes)
Packages for Operator Systems
- Variety of quantities available
- Upgrades via PowerPacks

12

Optional
redundant server

Package

System capacity
Number of servers / server pairs

12

Number of clients (screens)

32

Number of POs per multiuser system 12 * 8.500


Number of AS per server/ pair of
server

64

# PO
250
1.000
2.000
3.000
5.000
8.500

Single user
X
X
X
X
X
-

Client/Server
X
X
X
X
X
X

SIMATIC PCS 7 Operator System


Redundancy
Client
A

Client
A

Server
A

Client
A

Client
B

Client
B

Server
B

Client
B

Initial state:
Distribution of the clients
between redundant servers
(preferred server for each Client)
Automatic client switchover in
the event of server failure
(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)

High availability of the operator control level

Automatic client switching after


server recovery
(back to initial state/preferred
server)

SIMATIC PCS 7 Operator System


Graphical User Interface (GUI)
Alarm line

Overview
section

Navigation
window
Faceplate

Picture
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

SIMATIC PCS 7 Operator System


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

Alarm
Loop

system

in alarm

Acknowledge

alarm

Print

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


Switching

between the

Navigation

buttons

button sets
Previous

Alarm

Store

Screen

Trend

Plant

Picture

screen

/ retrieve picture

Reports

list

composition

configuration

selection via
process tag

Picture

Picture

Acknowledge

list

between the

button sets

Password

system

Switching

information
horn

Language

setting

Batch

Control Center

Route

Control Center

SFC

Visualization

User

Administration

Exit

runtime

SIMATIC PCS 7 Operator System


GUI: Standard Faceplates

Digital value

Motor - Reversing
right/left direction

One-button
operation

Counter for
switching operations

Analog Indicator

Dosing / Totalizing

Operating time counter

Interlock

Motor
slow/fast

Motor

Motorized Valve
two feedback signals

Valve
One Feedback

Analog output
with limit

One-out-of-three
digital value operation

Digital output

PID controller

Step controller

Ratio controller:
V = U1 * U2 + BIAS

SIMATIC PCS 7 Operator System


GUI: Examples for Standard Block symbols

PID controller

Valve

Dosing / Totalizing

Valve

Analog Indicator

Motor

Motor

One-button
operation

Step controller

Picture selection

SIMATIC PCS 7 Operator System


GUI: Block Symbols - Faceplates
Plant picture with
block symbol
Maintenance view

Limits

Faceplate

Parameter view

Batch view

Alarms

Trend window

Faceplate
extended view

SIMATIC PCS 7 Operator System


GUI: Multi-Screen

Multi-Screen Technology
One control device (mouse/keyboard) for
multiple monitors (1...4)
Provides ease-of-use functions
(e.g. store screen composition/layout)
No additional configuration required
Configuration of monitor layout
Project Editor
Max. 4 Monitor (each max. 1600 x 1200)

Comprehensive overview of the process (information at your fingertips)


Simple operation using multiscreen technology

SIMATIC PCS 7 Operator System


OS Configuration using Project Editor
Project Editor

Simple, menu-operated configuration of GUI


Screen resolution
OS client monitor configuration
(1, 2, 4 monitors)
Arrangement / separation of overview
(max. 64 areas)
Faceplate settings
(size and position)

Adaptation of the overview areas


e.g. 6 areas

e.g. 20 areas

Simple and convenient to optimize operators standard view

SIMATIC PCS 7 Operator System


Alarm Management
Preconfigured alarm lists
- New list (all unacknowledged alarms)
- Old list (all active, acknowledged alarms)
- Went out list (all unacknowledged, cleared)
- Operator input list (all operator messages)
- Control system list (all control system alarms)
- Log list (all alarms in chronological order)
Alarm classes
- A Alarm (high / low)
- W Warning (high / low)
- S Control system
- O Operator input prompt

Alarm system functions


- Loop-in alarm
(jump from alarm directly to process
screen)
- Acknowledgement
(single, via page, via faceplate, for entire picture)
- Chatter suppression (in AS)
(alarms reannunciated only after
acknowledgement)

Alarm priorities
- Priority 0 (lowest) ... Priority 16 (highest)
Quote: "A warning from the main reactor is
more important than an alarm from an auxiliary tank"

- Highest priority alarms in alarm line (overview)


Alarm selections
Criteria: e.g. date, time, area, class, priority

Comprehensive system support for alarm analysis

SIMATIC PCS 7 Operator System


Alarm Management: Screen Hierarchy & Group Displays

Operator prompting through screen hierarchy and group displays:


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

A
A

Alarm Navigation plus overview of Plant alarm status

SIMATIC PCS 7 Operator System


SFC Visualization
SFC Engineering

SFC Runtime

Single Steps
with operator
input

Automatic generation of
displays from the ES

Automatic generation of displays


from the ES
Navigation window for each chart
Overview window with step /
transition box
Several SFCs in multichart
diagram

Detailed view
with operator
input

Dynamically configured
step and transition
boxes
Group displays for
operator input
Loop-in alarm from
operation prompt
SFC

tional
i
d
d
a
o
N
ring !!!
e
e
n
i
g
n
e
Various operator authorization /
privilege levels
Modification & downloading
during runtime operation:
- transitions
- steps
without having to stop SFC

SIMATIC PCS 7 Operator System


Trend Displays

Engineering
Minimum, maximum and unit of measurement is
automatically transferred from engineering to
runtime during download.
These three parameters are used for the scale of
a trend.
Features
Flexible trend display format maximizes usability
Fast online viewing of process data

Basic functionality of the trend displays:


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

SIMATIC PCS 7 Operator System


Additional Features

Language setting
at runtime

Smartcard reader
for simple and
secure user
identification

Signal module
(alarm horn for
visual and
audible signals)

Video overlay
in process
screens

Centralized time
synchronization
with DCF 77 or
GPS receiver

Customizable user
right settings
(functions, plant
sections, etc.)

SIMATIC PCS 7
Fieldbus Components

SIMATIC PCS 7
Fieldbus Components
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

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

PROFIBUS supports:

HART communication

Fail-safe technology (PROFIsafe)

Drive integration (PROFIdrive)

Device profiles

And much more

Now more than 20 Million installed


nodes !!!

SIMATIC PCS7 / PROFIBUS


SIEMENS PROFIBUS Devices
Process Instrumentation and Analytics
Pressure

Temperature

Analytics

Flow

Controller
Positioning

High end

Mid range

Level

Distributed I/O

Panels
Intrinsically
safe

Motion Control
Drives

Modular
Bitmodular

Failsafe

MCC

SIMATIC PCS7 / PROFIBUS


Technical Overview
S7-400

15 km

OLM
Fiber optic

PROFIBUS DP

RS485

Max. 124 DP slaves per PROFIBUS


DP master system

Electrical networks can be extended


with repeaters (segments)

RS485

(Diagnose)
Repeater Max. 1,200 m

Coupler RS485iS
Max. 1,200 m
DP/PA Link

OLMs (Optical Link Module) for long


distances, also provide greater EMC
stability

RS485iS coupler for PROFIBUS DP


in hazardous areas

Copper with RS485 and fiber optic


use the same communication
protocol

PROFIBUS PA provides power on


the bus for smart field devices

DP/PA Link takes only one address


on the upstream DP bus

5
RS485iS
1,900 m

PROFIBUS PA

.... 31

max. 31 DP slaves per segment

SIMATIC PCS7 / PROFIBUS


Physical Properties
Physical-Layer Application

max. segment length


@ transmission rate

PROFIBUS
DP

RS 485

Remote I/O
Intelligent drives
Intelligent field devices

RS 485iS

Remote I/O Ex

Fiber Optic

PROFIBUS
PA

MBP
(Manchester
Coded Bus
Powered)

Fast Transmission
Wide distance
EMC stability
Field devices
Power supply via bus
Ex Applications

1200 m @ <93,75 kBit/s


1000 m @ 187,5 kBit/s
400 m @ 500 kBit/s
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
400m @ 500 kBit/s
200m @ 1.5 MBit/s
Up to 15,000m @ 12 MBit/s
between two OLMs

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


1,000m @ 31.25 kBit/s (Ex)

SIMATIC PCS7 / PROFIBUS


Central Access to all Connected Devices
Faceplate

Application (CFC)

M
OS

Process picture

ES

SIMATIC PDM

PROFIBUS DP

PROFIBUS PA

z. B. Simocode pro

SIMATIC PCS 7
Remote IO

SIMATIC PCS 7
Remote IO
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

S7 400
Controller
with S7 400 I/O

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


with fiber optics, single or redundant

Several DP chains allowed for each controller: up to 10 via


external CPs and up to 4 via internal DP interfaces

Comprehensive range of I/O modules


- Standard signal modules (low price for each channel)
- Control system modules (diagnostics, output substitute
value for each channel)
- Intrinsically safe (Ex) modules for connecting
actuators/sensors in zone 0/1
- Function modules (e.g. closed loop controller, motor
starter, weighing module, counter module)
- HART modules (for integrating HART field devices)
- Safety modules (for failsafe applications)
- S7 400 I/O modules for CPU main rack

Hot Swappable modules, I/O configuration changeable during


runtime operation

AS interface for easy integration of actuators / sensors

EIB instabus for integration of building automation

ET 200M
ET 200M
(Failsafe)

OLM

PROFIBUS-DP

SIMATIC PCS 7 Remote IO


Overview

Fiber Optic

ET 200iSP

OLM

ET 200S

PROFIBUS-DP

DP/AS-I
DP/EIB

Serial

(e.g. Modbus)

SIMATIC PCS 7 Remote IO


Flexible Solutions for Signals from Hazardous Areas

PROFIBUS DP

ET 200M

DP/PA Link
PROFIBUS PA
Zone 0

RS485iS Coupler

ET
200iSP
ET 200S

Zone 1
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

SIMATIC PCS 7 Remote IO


ET 200M

Protection level IP20, operating range 0...60C (-20...60C)


Redundant connection (for H CPUs)
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
No slot restrictions
20 or 40 pin front connector in screw, spring-loaded
or fast connect type (1.5mm2/0.75mm2)
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.

Power supply

I/O module

Interface module
for Profibus DP
IM153-2

Expandable
backplane
Aluminium rail

SIMATIC PCS 7 Remote IO


ET 200M: Range of Modules

Digital inputs
8, 16, 32 channels
DC 24 V, DC 48-125 V
AC 120/230V, NAMUR

Digital outputs
8, 16, 32 channels
DC 24V, DC 48-125 V, AC 120/230 V, AC/DC 24-48V
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

SIMATIC PCS 7 Remote IO


ET 200M: New 8-Channel HART Modules

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


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

SIMATIC PCS 7 Remote IO


ET 200M: Support for Redundant IO Modules

I/O redundancy for selected modules


from the ET 200M series

Configuration via browser

PROFIBUS DP

AS 412 H
AS 414 H
AS 417 H

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

SIMATIC PCS 7 Remote IO


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

*) F-Module in Standard Mode

SIMATIC PCS 7
Field Devices & Drives

SIMATIC PCS 7
Field Devices & Drives
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

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

SIMATIC PCS 7 / Field Devices & Drives


Process Sensors
Level
Capacitance Ultrasonic

Flow
Radar

Temperature

Ultrasonic

Coriolis

Rack

Head
2-wire

PA

Clamp On
MID
Field

Pressure

Positioners
Electro
pneumatic

Panel
Instruments

Weighing

Process Controllers SIWAREX


Components

Weigh
Feeders

Pneumatic

Process Recorder

Belt
Scales

HART

SIMATIC PCS 7 / Field Devices & Drives


Motor Control
Motor Control Management

PCS 7 SIMOCODE pro Library (V7.0)


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

Frequency Inverters

SIMOCODE
PRO

Drive ES PCS 7 DRVPCS7 Library (V6.1)


In HW-Config.: Insert MICROMASTER 4
lite below Frequency converter in the
Standard Library

MICROMASTER

SIMATIC PCS 7
Process Safety

SIMATIC PCS 7
Process Safety
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

SIMATIC PCS 7 Process Safety


Objective of Safety Engineering

To avoid accidents and damage when a fault


occurs and to ensure maximum safety for

People

Process

Environment/
nature

SIMATIC PCS 7 Process Safety


Cause of Faults in Automation Systems

Operation &
maintenance

15%
Installation &
commissioning

6%
15%

Planning &
implementation

* Health and Safety Executive

21%

Changes after
commissioning

44%
Specification

SIMATIC PCS 7 Process Safety


International Safety Standards

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

IEC61511
There are sector-specific standards based on IEC 61508, such as IEC 61511
for the process industry or IEC 61513 for the nuclear industry
These sector standards are important for planners and operators of
corresponding plants.

SIMATIC PCS 7 Process Safety


Safety Concept for a Plant

Disaster
protection

Disaster protection

Collection
basin

Passive protection

Overpressure
valve, rupture
disc

Safety system
(automatic)

Active protection

Plant
personnel
intervenes

Basic
automation

Safety Instrumented
System (SIS)

Safety
shutdown

Process alarm
Process
value

Normal activity

Process control
system

SIMATIC PCS 7 Process Safety


SIMATIC Safety Integrated
Process Safety

Distributed Safety

Controller
CPU 412H
CPU 414H
CPU 417H

Controller
for PROFIBUS
ET 200S F-CPU
CPU 315F/317F-2DP
CPU 416F-2

Engineering
CFC
Safety Matrix

for PROFINET
CPU 315/317F-2PN/DP
CPU 416F/CP443-1ADV

Engineering
FBD, LAD
PROFINET with
PROFIsafe-Profile

PROFIBUS with PROFIsafe-Profile

Actors
Sensors

ET 200M ET 200ecoET 200S

ET 200pro

ET 200S

ET 200pro

SIMATIC PCS 7
Communication

SIMATIC PCS 7
Communication
WEB Client

SIMATIC IT

Office LAN (Ethernet)


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

Engineering / Maintenance
Station

ROUTE Control
BATCH Server

OS Server

CAS

Industrial Ethernet
AS 41x HF

SIMOCODE

ET200M HF
ET200S

ET200iSP
PROFIBUS PA

FOUNDATION Fieldbus H1

PROFIBUS DP

PROFIBUS DP

AS 41x

ET200M HF
(Standard & F-Modules)
ET200M HF
ET200iSP

PROFIBUS PA

SIMATIC PCS 7
Communication

Advantages

Redundant
Gigabit rings for highavailability & highperformance
communication in the
SIMATIC PCS7 process
control system

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!

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!