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Automation and Drives

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

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Introduction of Speaker

SIMATIC PCS 7

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Demonstration Center for Process Automation
Engineering System
System Functions
Batch / Route Control Dr. Friedhelm Geiger
MIS/MES Integration A&D AS PA PM
Add-ons Tel.: ++49-721-595-2319
Migration friedhelm.geiger@siemens.com
Summary
Karlsruhe facilities
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SIMATIC PCS 7 -
Highlights of the Control System
SIMATIC PCS 7 Based on the robust hardware / software components from
Technology SIMATIC, the global market leader
Introduction Integrated automation as well as production
and process engineering
Profibus
Horizontal and vertical integration with TIA, Totally Integrated
I/O
Automation
Controller
Flexibility due to scalable performance and modular design
F-Engineering
Consistent engineering throughout the system for all components with a
Communication
shared database; high-performance bulk engineering
Operator System
Windows-based, hierarchically structured GUI
Engineering System
High availability of the control system due to redundancy on all levels
System Functions
Batch / Route Control Homogeneous integrated safety (certified up to AK6 / SIL 3 by the German
Technical Inspectorate)
MIS/MES Integration
Decentralization to include PROFIBUS DP/PA components
Add-ons
Homogeneous integrated batch package (Simatic BATCH) ISA S88 compliant
Migration
Numerous possibilities for custom solutions (function blocks, faceplates,
Summary
Visual Basic programs, interfaces etc.)
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SIMATIC PCS 7
A Control System for All Sectors and Industries
SIMATIC PCS 7
Technology

Introduction
Profibus Custom add-on's
I/O A control system for all sectors for each industry
SIMATIC PCS 7 is the automation solution SIMATIC
Controller BATCH
for all sectors
F-Engineering Continuous e.g. Polymer, Continuous Sectors Batch Sectors
Communication Batch e.g. Pharma, F&B
SIMATIC PCS 7
Operator System
For primary and secondary processes
Engineering System SIMATIC PCS 7 can handle not only the tasks for process and production control; it also
controls the total automation of all secondary, upstream and downstream processes
System Functions
Example: An industrial facility for plastic production
Batch / Route Control
Industrial power plant Chemical plant Process water
MIS/MES Integration
SIMATIC PCS 7
Add-ons
Migration Cost reduction from common hardware, logistics, training
Summary Increased productivity over entire lifecycle of the plant
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SIMATIC PCS 7
Scalability.from 100 to 100,000 I/O
SIMATIC PCS 7 Plants with multiple production facilities
Technology Production Plants
Labs / Pilot Plants
Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions Scalable
from the PCS 7 Introduction Package (~150 PO) ... ... to a distributed system with client/server
Batch / Route Control
architecture (~ 60.000 PO)
MIS/MES Integration
An integrated control system platform
Add-ons
Optimal adaptation to the plant size
Migration
Variety of expansion possibilities
Summary

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SIMATIC PCS 7 BOX


The integrated entry solution for small applications
SIMATIC PCS 7
Technology
6ES7650-2HA06-
Introduction ES OS
0YX0 ES / OS / AS
Profibus
I/O
Controller Ind. Ethernet

F-Engineering AS: S7-400


Box PC
Communication
Profibus Profibus
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration Advantages of SIMATIC PCS 7 BOX Includes
Complete DCS (AS, OS, ES) SIMATIC Box PC 620
Add-ons
Very compact WinAC Slot CPU 416
Migration Can be extended and integrated PCS 7 Engineering 250 POs
Summary Aggressive pricing PCS 7 OS Runtime Single Station 8000 Var.

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SIMATIC PCS 7 BOX


The integrated entry solution for small applications
SIMATIC PCS 7
Technology

Introduction
Profibus PCS 7 BOX
I/O SIMATIC ET200M
Controller
F-Engineering
Communication
Operator System
Engineering System Sitrans P SIMATIC PCS 7 OS/ES
System Functions DSIII
Batch / Route Control PROFIBUS DP

MIS/MES Integration
PROFIBUS PA

Add-ons
Migration
Summary

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

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

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

Summary Bundles (AS, OS, ES)

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Process Interfacing with PROFIBUS


SIMATIC PCS 7
Technology

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

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Process Interfacing with PROFIBUS


Overview
SIMATIC PCS 7
Technology
DP with over 1,000
Introduction
different devices
Profibus
I/O DP with over 9,000,000
Die Welt von PROFIBUS is the No. 1 field bus

Controller installed nodes system in the world
F-Engineering PROFIBUS PROFIBUS DP and PROFIBUS PA
form a coherent unit
Communication Integrated

Operator System HART technology Worldwide organization "PROFIBUS


International" with 1,100 members
Engineering System
Integrated
System Functions
Batch / Route Control
failsafe technology
MIS/MES Integration
PA with over 150
Add-ons
different devices
Migration
PA with over 210,000
Summary
installed nodes
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Physical Properties Ba

SIMATIC PCS 7
Technology Max. length per
Physical Application
Introduction Layer segment/Baud Rate

Profibus Remote I/O 1,000 m at 187.5 kps


PROFIBUS RS 485 Intelligent drives 400 m at 500 kps
I/O
DP Intelligent field devices 200 m at 1.5 mps
Controller 100 m at 12 mps
F-Engineering
RS 485-IS
Remote I/O Ex -"-
Communication DP/PA Link Ex

Operator System Fiber Optic Fast transmission


Wide distance > 10 km at 12 mps
Engineering System
EMC stability
System Functions
PROFIBUS Process devices
Batch / Route Control IEC61158-2 Power supply via bus
PA Ex applications
MIS/MES Integration
Standardized PA profile 1,900 m at 31.25 kps
Add-ons
Migration
Summary

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Process Interfacing with PROFIBUS


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

Migration 1 2 3 4 .... 31
Summary 1 2 ....
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Process Interfacing with PROFIBUS PA


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

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

Controller
F-Engineering
Communication DP/PA Link consists of:
Interface module IM157 to connect to PROFIBUS DP and conversion of the bus
Operator System
transmission rates e.g. 12 Mbps to 31.25 kbps
Engineering System can be used redundantly to connected to redundant CPUs (H-System)
System Functions requires only one PROFIBUS DP address
max. 244 bytes of I/O data
Batch / Route Control max. theoretical limit of 64 subordinate PA devices (Example: 5 bytes per device: 244/5 = 48
MIS/MES Integration devices)
DP/PA coupler for electrical isolation of PROFIBUS DP/PA segments and power supply
Add-ons for the PA segments
Migration max. 5 coupler per link
max. 31 devices per DP/PA coupler
Summary
2 models (non-Ex, Ex (ZONE 0,1,2))
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Specifications and Design Ba

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

I/O Number of devices


Controller Typical power consumption of PA field devices:

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

System Functions
Cable Characteristics
Batch / Route Control 9V must be available at the PA device
Fast and easy assembly
MIS/MES Integration PROFIBUS PA cable: approx. 44 km with split-connect

Add-ons DP/PA coupler performance


Non-Ex coupler: (19 - 9)V/(400mA*44 km) = approx. 560 m (max. 1,900m)
Migration
Ex coupler: (13.5 - 9)V/(110mA*44 km) = approx. 920 m (max. 1,000m)
Summary

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Cycle Times Ba

SIMATIC PCS 7 Master Class 1 Master Class 2


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

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

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Process Interfacing with PROFIBUS PA able


The Barrier Concept vail 03
A /20
SIMATIC PCS 7 DP/PA coupler 12
PROFIBUS DP non-Ex (400 mA)
Technology Allows use of the non-Ex DP/PA couplers
(400mA) in Ex applications
Introduction Barriers for isolating non-Ex and Ex
Profibus PROFIBUS PA Backbone zones
with increased safety (EEx e) Outputs are protected from short circuits
I/O 24 VDC .... Simple to add new field devices
115 VAC
Controller 230 VAC 40mA per output (Eex i)
....
F-Engineering 60mA per output (Eex e)
Communication Version with external power supply,
therefore no load on the PA buses
Operator System Barriers can be cascaded
Engineering System
spur line

PROFIBUS PA Uses sub-distribution boxes


System Functions instrinsically safe (EEx i) Operating temperature -40...55C

Batch / Route Control


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

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Input / Output
I/O Modules
SIMATIC PCS 7
Technology

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

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

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

ET 200S - Ex modules (for connecting actuators / sensors in zone 0 / 1)


Operator System - Function modules (e.g. controller, motor starter, weighing module)
Engineering System - HART modules (for integrating HART field devices)
OLM

- F modules (for failsafe applications)


System Functions DP/AS-I
- Central modules of S7 400
Batch / Route Control
PROFIBUS-DP

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

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Flexible Solutions for Signals from


Hazardous Areas
SIMATIC PCS 7
Technology

Introduction
ET 200M
Profibus
I/O

PROFIBUS DP
Controller
PROFIBUS PA
F-Engineering
DP/PA Link
Communication Zone 0

Operator System
ET 200iS
Engineering System Zone 1
ET 200S
System Functions Zone 2

Batch / Route Control


MIS/MES Integration ET200M, ET200S, DP/PA link / coupler can be located in zone 2 (Class I Div 2)
Add-ons ET200M modules for connection to signals from zone 1
Migration ET200iS for operation directly in zone 1 (Class I Div 2), for connection to
signals from zone 0 (Class I Div 1)
Summary
PROFIBUS PA for signals from zone 1 and zone 0
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I/O Module ET 200M


Overview
SIMATIC PCS 7 Protection level IP20, operating range 0...60C (-20...60C)
Technology
Redundant connection (for H CPUs) Power supply Interface module
Introduction I/O Module Redundancy (1 Sensor -> 2 Modules) for Profibus DP
IM153-2
Profibus Electrical isolation from the backplane bus
I/O Modularly expandable with plug-in backplane
bus on aluminium rail
Controller
Max. 8 modules per station
F-Engineering I/O module
No slot restrictions Expandable
Communication backplane
20 or 40 pin front-panel connector with screw and
Operator System Aluminium rail
spring construction (1.5mm2/0.75mm2)
Engineering System Economical DI/DO modules without diagnostics (MLFB -0AA0)
System Functions Diagnostic-capable modules with comprehensive monitoring (MLFB x-0AB0)
Batch / Route Control Missing sensor power / load voltage
Short-circuit, wire break
MIS/MES Integration
Substitute value applied due to automation system failure
Add-ons Incorrect parameters in module
Migration Watchdog triggered
EPROM error
Summary
RAM error etc.
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I/O Module ET 200M cku
Range of Modules Ba

SIMATIC PCS 7 Digital inputs Digital outputs


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

I/O Analog inputs Electronic / relay outputs


2, 4, 8 channels
Controller
Multifunctional modules for U, I, TC, RTD, resistance
F-Engineering
Specific modules for
Communication Voltage: e.g.: 0-10V, +/-10V; Current: +/-20mA, 0/4..20mA (2, 4 wire)
Operator System Thermoelement types B, C, E, J, K, L, N, R, S, T, U (internal linearization)
Pt 100/200/500/1000, Ni100/120,200/500/1000, Cu10 (2, 3, 4 wire, internal linearization)
Engineering System
Resistance: 150, 300, 600 Ohm
System Functions
Variable resolution/accuracy (up to 16 bit, 0.1%)
Batch / Route Control HART
MIS/MES Integration Analog outputs
Add-ons 2, 4, 8 channels
Migration Voltage: 0-10V, +/-10V; Current: +/-20mA, 0/4..20mA (2 or 4 wire)
Variable resolution/accuracy (up to 16 bit, 0,1%)
Summary
HART
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I/O Module ET200M


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

Controller
F-Engineering
PROFIBUS DP

Communication I/O Module


Operator System Sensor

Engineering System
I/O module
System Functions redundant

Batch / Route Control


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

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I/O Module ET200M


Redundant I/Os module range
PCS 7 V6.0 SP3
SIMATIC PCS 7
DI
Technology
16xDC 24 V 6ES7 321-1BH02-0AA0
32xDC 24 V 6ES7 321-1BL00-0AA0
Introduction
8xAC 230 V 6ES7 321-1FF01-0AA0
Additional High End Solution:
Profibus DI with Diagnostics
16xDC 24 V 6ES7 321-7BH01-0AB0 Add FEM (Ordering via A&D SE, Khe)
I/O 16xNamur 6ES7 321-7TH00-0AB0 PROFIBUS DP Slave
4xNamur Ex 6ES7 321-7RD00-0AB0
Controller Redundancy via Optical Link
24xDC 24 V 6ES7 326-1BK00-0AB0 *)
8xNamur Ex 6ES7 326-1RF00-0AB0 *)
F-Engineering
DO
Communication 32xDC 24 V/0.5 A 6ES7 322-1BL00-0AA0
8xDC 24 V/2 A 6ES7 322-1BF01-0AA0
Operator System 8xAC 230 V/2 A 6ES7 322-1FF01-0AA0
DO with Diagnostics
Engineering System
8xDC 24 V/0,5 A 6ES7 322-8BF00-0AB0
System Functions 16x24 V/10 mA (Ex) 6ES7 322-5SD00-0AB0
10x24 VDC/2A 6ES7 326-2BF00-0AB0 *)
Batch / Route Control AI with Diagnostics
8x12Bit 6ES7 331-7KF02-0AB0
MIS/MES Integration 8x16Bit 6ES7 331-7NF00-0AB0
4x15Bit (Ex) 6ES7 331-7RD00-0AB0
Add-ons
6x13Bit 6ES7 336-1HE00-0AB0 *)
Migration AO with Diagnostics
4x12 Bit 6ES7 332-5HD01-0AB0
Summary 8x12 Bit 6ES7 332-5HF00-0AB0
4x15 Bit (Ex) 6ES7332-5RD00-0AB0 *) F-Baugruppe
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Redundant I/Os cku
Digital Input Ba

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

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


Time Discrepancy in msec.
Controller Reaction after discrepancy: AND,
OR, last value
F-Engineering
Communication
Module External Missing Short
Operator System Discrepancy Internal Power Supply Sensor Wire Break Circuit
MLFB analysis Diagnostics *) Missing Supply (Resistor 1) (Resistor 2)
Engineering System Standard Modules
16xDC 24 V 6ES7 321-1BH02-0AA0 x
System Functions 32xDC 24 V 6ES7 321-1BL00-0AA0 x
8xAC 230 V 6ES7 321-1FF01-0AA0 x
Batch / Route Control Modules with Diagnostics
16xDC 24 V 6ES7 321-7BH01-0AB0 x x x x x
MIS/MES Integration
16xNamur 6ES7 321-7TH00-0AB0 x x x x x x
Add-ons 4xNamur Ex ***) 6ES7 321-7RD00-0AB0 x x x x x
24xDC 24 V 6ES7 326-1BK00-0AB0 **) x x x
Migration 8xNamur Ex ***) 6ES7 326-1RF00-0AB0 **) x x x x x

*) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module
Summary **) no discrepancy analysis, always or after discrepancy
recommended

**) Calculation of critical parameters for Ex applications necessary dependant on sensor


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Redundant I/Os cku
Digital Output Ba

SIMATIC PCS 7
Technology
Assignment of redundant modules
Introduction
( ) ( )
Profibus
I/O
Controller
F-Engineering
Communication Wiring without Module Behaviour on
external Internal Wire No Load Short CPU Stopp
Operator System MLFB diodes Diagnsotics *) Break Voltage Circuit selectable
Modules without Diagnostics
Engineering System 32xDC 24 V/0.5 A 6ES7 322-1BL00-0AA0

System Functions 8xDC 24 V/2 A 6ES7 322-1BF01-0AA0


8xAC 230 V/2 A 6ES7 322-1FF01-0AA0 x
Batch / Route Control Modules with Diagnostics
8xDC 24 V/0,5 A 6ES7 322-8BF00-0AB0 x x x x x x
MIS/MES Integration 16x24 V/10 mA (Ex) **) 6ES7 322-5SD00-0AB0 x x x x x
10x24 VDC/2A 6ES7 326-2BF00-0AB0 x x x x x x
Add-ons
Migration
Summary *) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module recommended
**) Calculation of critical parameters for Ex applications necessary dependant on actuator

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Redundant I/Os cku
Analog Input Ba

SIMATIC PCS 7
Technology
Assignment of redundant modules
Introduction
R
Profibus I
+ -
I/O
Discrepancy Analysis in HW-config.
Controller Tolerance window (% endvalue)
Time Discrepancy in msec.
F-Engineering
Reaction after discrepancy: lower,
higher value
Communication
I
+ -
Operator System
Engineering System
Module Indirect current Current
Discrepancy Internal measurement measurement with
System Functions MLFB analysis Diagnsotics *) with Resistor external source Wire Break

Batch / Route Control Modules with Diagnostics


8x12Bit 6ES7 331-7KF02-0AB0 x x x
MIS/MES Integration 8x16Bit 6ES7 331-7NF00-0AB0 x x x x x
4x15Bit (Ex) **) 6ES7 331-7RD00-0AB0 x x x x
Add-ons 6x13Bit 6ES7 336-1HE00-0AB0 ***) x x x

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

SIMATIC PCS 7
Technology

Introduction
Assignment of redundant modules
Profibus
I/O
Controller I

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

Add-ons
Migration
recommended
Summary
*) see module specification, e.g. Watchdog, E-PROM, RAM Failure, Wrong Parameter in Module
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Automation and Drives

p
I/O Module ET 200M cku
Controller Modules FM355 Ba

SIMATIC PCS 7 Features


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

Profibus Back-up function control even after AS failure


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

System Functions Pressure control


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

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Automation and Drives

I/O Module ET 200M ck up


Serial Communication with CP341 Ba

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

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

Operator System 3964 (R)

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

MIS/MES Integration
Add-ons
Migration
Summary

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Automation and Drives

I/O Module ET 200M ck up


Counter Module FM350 Ba

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

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

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Automation and Drives

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

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

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Automation and Drives

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

Introduction PROFIBUS DP devices address the


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

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

MIS/MES Integration
Integrated control system diagnostics

Add-ons
Migration
Complete integration of intelligent field devices in PCS 7 enables
Summary simple operation and efficient engineering
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Automation and Drives

p
Intelligent Field Devices cku
Neutral, multi-vendor integration in PCS 7 Ba

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

Intelligent Process Devices from SIEMENS


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

Technology SITRANS F US SITRANS FM

SITRANS T3K ULTRAMAT23

Introduction
Profibus Weighing system - SIWAREX

I/O Pressure
ULTRAMAT SIPAN32
Level
Controller SITRANS P DSIII SITRANS LR 400 SITRANS LC

Motor starter - SIMOCODE


F-Engineering
OXYMAT 61 CALOMAT 6
Communication
Operator System Positioner

Engineering System Frequency converter master drives


SIPART PS2 SITRANS LR 300 SITRANS LS
200/300
System Functions
Batch / Route Control
Process Devices
MIS/MES Integration PROFIBUS PA
Add-ons
ET200M ET200iS ET200S

Migration Process devices


Distributed I/O
Summary
Motor controls
PROFIBUS DP PROFIBUS DP
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Automation and Drives

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

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

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Automation and Drives

ed
Controllers - vanc re
a
Ad rdw 4
built by SIMATIC, worldwide market leader Ha /200
07
SIMATIC PCS 7
Technology Robust components from SIMATIC, the worldwide
market leader
Introduction Fanless operation up to 60C
Profibus Hot Swap modules during runtime operation
I/O Comprehensive configuration
Controller Convenient, graphical high-level languages (CFC, SFC)
F-Engineering Standard programming languages (e.g. SCL, Ladder Logic)

Communication Scalable performance and function


Standard AS414, AS416, AS417
Operator System
Failsafe (F) and fault-tolerant (H) AS414H/F, 417H/F
Engineering System
Changes can be made during runtime operation
System Functions
User program
Batch / Route Control
I/O configuration
MIS/MES Integration Typical controller capacity AS 414-3 / AS 417-4 /
AS 416-2 AS 416-3
Add-ons AS 414H AS 417H
(sample project)
Digital-In DI 150 300 850 1500
Migration Digital-Out DO 315 630
50 150
Summary Analog-In AI 50 100 275 500
Analog-Out AO 20 50 130 200
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Automation and Drives

Contoller Slot CPU WinAC Slot 416


PLC as a PC Card (in combination with PCS 7 Box)
SIMATIC PCS 7
Technology Memory Card

Introduction (RAM/Flash)
PROFIBUS DP
Profibus Interface
2 x 1.6 MB Memory
I/O
All S7-400 commands
Controller
2 PROFIBUS DP Interface
F-Engineering seperate 24 V DC feed in
Communication LED Only limitation: no CIR
Stop/Run
Operator System Connection to

Engineering System Back-up battery


PROFIBUS DP
System Functions Interface
To external
Batch / Route Control Power Supply 24V DC

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

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Automation and Drives

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

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

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

Summary

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Automation and Drives

Fault-tolerant Controller AS 414H / AS 417H


SIMATIC PCS 7
Technology

Introduction
Entry level with CPU 414H

Profibus 768 kB RAM

I/O High-end with CPU 417H


Controller up to 20 MB RAM

F-Engineering
Fiber optic connection for synchronization
Communication
Operator System
Expandable

Engineering System Shared rack

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

Summary
Scalable even for fault-tolerant controllers
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Automation and Drives

High-Availability Controller cku


p
Synchronization Ba

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

Introduction
Profibus

redundant CPU B
redundant CPU A
redundant CPU B
redundant CPU A
I/O

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

Controller
F-Engineering
SIEMENS
Communication
patent
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration Guarantees bumpless switchover
Add-ons Fast switchover time (typically 30ms)
No loss of information
Migration
No loss of alarms
Summary Resumes processing of program where it left off
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Automation and Drives

High-Availability Controller cku


p
Event Synchronization Ba

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

CPU B
Redundant CPU A
Communication Synchronized events:

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

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Automation and Drives

Failsafe Automation
SIMATIC PCS 7
Technology

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

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Automation and Drives

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

F-Engineering Failsafe (F) systems

Failsafe and fault-tolerant (FH) systems


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

Method of Operation - Failsafe System S7-400F


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

Controller Failsafe F-I/O

PROFIBUS-DP
ET200M
F-Engineering program
Communication I/O
ET200M
Operator System
Engineering System F-I/O
ET200S
System Functions Uses standard S7-400 hardware
Batch / Route Control (S7-414/417H) with F software up to SIL3, AK6
MIS/MES Integration Standard and failsafe program in one controller
Communication with failsafe I/O modules using Profisafe
Add-ons
A detected error in the F program does NOT result in AS stop
Migration
Standard program section continues to run
Summary Shutdown logic stops the affected F program section (F-STOP)
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Automation and Drives

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

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

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Automation and Drives

Safety in F - Engineering
Access protection, signature, comparison function
SIMATIC PCS 7 Unique signature of the
Technology F program for validation of
safety program
Introduction
Profibus
Comparison function
I/O for two versions of a
program
Controller
F-Engineering
Communication
Operator System
Access protection for
Engineering System CFC program
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration List of all F blocks with
Summary signature and default values
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Automation and Drives

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

Introduction
Profibus
Causes represent a
I/O process upset
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control Beispiel:
Ex: PT_35A exceeding a high limit
forcing the BV_24 to close Intersections associate
MIS/MES Integration
a Cause with an Effect
Add-ons
Easy description of logic in a matrix format
Migration
Automatic Code Generation without additional user interaction
Summary
Engineering and Online Visualization on Operator Station
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Automation and Drives

F - Engineering
Safety Matrix - Advantages
SIMATIC PCS 7 Powerful Programming Language
Technology
Easy (user friendly) visualization of logic
Introduction Consistent view for design, documentation, test & monitoring
Profibus Reduces Development Effort
I/O Automatic insertion of channel drivers
Controller Built-in first out alarming
Automatic visualization support for PCS 7 OS
F-Engineering
Built-in user interface to safety logic (Bypass, Reset, Override,etc)
Communication
Eliminates Translation Errors
Operator System Logic automatically generated from safety design
Engineering System Automatic insertion of Safety Matrix CFC logic
System Functions Simplifies Documentation
Batch / Route Control Creates matrix reports

MIS/MES Integration
Built-in version tracking
Manages & Verifies Configuration Changes (IEC 61511)
Add-ons
Automatic generation of change documentation
Migration
Summary

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Automation and Drives

S7-400F/FH Configuration Alternatives


SIMATIC PCS 7
Technology Single-channel Single-channel Redundant
Introduction
one-sided I/O switched I/O switched I/O

Profibus S7-400F S7-400FH S7-400FH


I/O
Controller ET200M ET200M ET200M
PROFIBUS DP

PROFIBUS DP

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

Communication
ET200M redundant
Operator System
F-I/O
Engineering System
System Functions SIL 2, AK4 Redundant S7-400FH Redundant S7-400FH
SIL 3, AK5 or 6 Redundant PROFIBUS-DP Redundant PROFIBUS-DP
Batch / Route Control Redundant IM 153-2 Redundant IM 153-2
SIL 2, AK4 Redundant failsafe I/O
MIS/MES Integration
SIL3, AK5 or 6 Discrepancy analysis
Add-ons SIL 2, AK4
SIL3, AK5 or 6
Migration
Summary

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Automation and Drives

F Engineering: I/O ET200S


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

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

Operator System F Power module PM-E F


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

MIS/MES Integration F Motor starter


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

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Automation and Drives

F-Engineering: Certificate of the Technical


Inspectorate
SIMATIC PCS 7
Technology

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

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Automation and Drives

Network Components
SIMATIC PCS 7
Technology

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

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Automation and Drives

Network Components
Fast Ethernet - Network Configuration
SIMATIC PCS 7
Technology

Introduction Redundant Optical Ring

Profibus
Redundancy Manager
I/O
(RM) (= OSM)
Controller
F-Engineering 100 Mbps
10 Mbps
Communication
Operator System
Engineering System :::

System Functions Optical Switch Module


with 6 connectors (OSM)
Batch / Route Control
MIS/MES Integration
Add-ons Configuration rules
+ Good diagnostics approx. 50 OSM / ring
Migration
+ Fast redundancy: max. 3000 m between two OSM
Summary approx. ring circumference: 150 km
switching of communication paths within 0.3 sec
("long distance" version up to 900 km)
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Automation and Drives

Network components cku


p
Fast Ethernet - Load Optimization and Full Duplex Ba

SIMATIC PCS 7
Technology

Introduction

s
Profibus

s
10

Mbp
bp
0M

s
0M

bp
I/O

100
bp

M
10

0
s

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

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


Stand by Stand by

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

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

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Automation and Drives

Operator System
SIMATIC PCS 7
Technology

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

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Automation and Drives

Operator System
Overview
SIMATIC PCS 7
Technology

Introduction Alarm System Programming


Interfaces
Profibus
I/O
Process
Visualization
Controller
F-Engineering Excel

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

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Automation and Drives

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

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Automation and Drives

Operator System
GUI
SIMATIC PCS 7
Alarm line Overview
Technology
section
Introduction
Navigation
Profibus window
I/O
Picture
Controller Faceplate area
F-Engineering
Communication
Operator System
Engineering System
System Functions Button area
Batch / Route Control Standard user interface (overview and Picture area, buttons, trends, alarms, faceplates)
MIS/MES Integration is provided by the system - no engineering required !
Multi-window design with fixed areas - prevents overlap of the overview and button areas
Add-ons
Easy to operate due to hierarchical structure and simple navigation
Migration
Well-designed GUI for reliable operation
Summary
of the process even in critical situations
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Automation and Drives

p
Operator System cku
GUI Block Symbols - Faceplates Ba

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

Migration
Summary Parameter view
Faceplate
Batch view extended view
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Automation and Drives

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

Communication A A


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

MIS/MES Integration
Add-ons
A A
A

Migration
Summary
Alarm Navigation plus overview of Plant alarm status
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Automation and Drives

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

Introduction
A

Profibus Loop-in alarm


I/O Alarm with highest priority A

in alarm line (overview)


Controller
F-Engineering A

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

System Functions
Batch / Route Control
A

MIS/MES Integration Loop-in alarm

Add-ons A

Migration
Summary
Alarm Management by quickly navigating to the source of the fault
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Automation and Drives

Operator System
Client / Server Architecture & Archive Server
SIMATIC PCS 7 OS client (multi-client)
Technology Process visualization
Access to every OS server
Introduction
Combines process values,
Profibus alarms, etc. from all servers
Central into a single view
I/O archive server OS Client max. 32
OS server
(process value archive)
Controller Communication with AS
F-Engineering 12 servers (red.), 32 OS clients
OS server max. 12
(redundant) Archiving of process values,
Communication Terminal bus
alarms
Operator System Archive synchronization

Engineering System .... (for redundant servers)


Archive configurations
System bus
System Functions Integrated in every OS server
As central archive server (only
Batch / Route Control
MIS/MES Integration
.... process values)

Add-ons
Flexible adaptation of the HMI to the plant architecture
Migration Simultaneous operation of several plant areas with a single OS client
Summary Optimized communication due to separation of the terminal and plant bus
and true client/server architecture
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Trend Displays Ba

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

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Performance Ba

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

Add-ons
Migration
Summary

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Automation and Drives

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

Introduction
Profibus
I/O
Controller
F-Engineering
Alarm Messages
Communication
Curves
Operator System
Engineering System
System Functions
Batch / Route Control
Archived variables in table format
MIS/MES Integration
Add-ons Batch protocols
Migration StoragePlus with integrated viewer
Viewing of archived data with standard Internet Explorer
Summary
easy client - server structures (office) possible
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Automation and Drives

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

Copyright Siemens AG 2003 *) see Engineering System


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Automation and Drives

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

Operator System 004


2
uly
System Hardware J
SIMATIC PCS 7
Technology New preconfigured, turn-key packages
Introduction
Profibus
I/O Basic SIMATIC Rack PC IL40S
Controller OS server

F-Engineering OS client
Combination OS / ES station
Communication
Operator System
Engineering System
Hardware Features
System Functions
CPU: Pentium 4, 2,8 GHz, 800 MHz FSB
Batch / Route Control RAM: 512/1024 MB RAM (OS client/OS server, ES)
MIS/MES Integration Hard Disk: 80 Gbyte / 2 x 120 Gbyte RAID controller (OS client/OS server, ES)
CD / DVD R/RW
Add-ons
Ind. Ethernet (3COM or CP1613)
Migration
Summary

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Engineering System
SIMATIC PCS 7
Technology

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

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Automation and Drives

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

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

Batch / Route Control


MIS/MES Integration
Add-ons
Engineering for
Migration failsafe Programming
Engineering for network/ SIMATIC PDM
systems of custom user
communication/hardware for field device
Summary function blocks
Automation configuration
engineering
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Automation and Drives

Engineering System
Views
SIMATIC PCS 7
Technology
Component view
For configuration of the control system hardware
Introduction (I/O modules, CPU, bus systems etc.)
Profibus
I/O
Controller
F-Engineering
Plant view
Hierarchical plant architecture according to
Communication
process engineering aspects
Operator System (e.g. plant / process area / unit according to
Engineering System
process model)

System Functions
Batch / Route Control
Process object view
MIS/MES Integration A centralized development environment for all
Add-ons aspects of a process engineering measuring
Migration point
Integrated plant view
Summary

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Automation and Drives

Engineering System
Component View
SIMATIC PCS 7
Technology Hardware configuration
of an AS station with I/O
Introduction
Profibus
I/O Configuration of a
module without
Controller
hardware jumpers
F-Engineering
Communication
Operator System
Engineering System One view of all
hardware components
System Functions (AS, OS, ES, etc.)
and applications
Batch / Route Control
(OS, Batch, etc.)
MIS/MES Integration
Add-ons All components and applications of a plant in a single location
Migration Hierarchical navigation to configuration of the hardware
Summary Selection of components from hardware catalog and placement
using Drag and Drop
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Automation and Drives

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

Introduction
Profibus
I/O
Controller
F-Engineering
Communication Plants

Operator System
Engineering System
Process
System Functions Area
Batch / Route Control Piece of
equipment Control device Integrated in process
MIS/MES Integration object view
(Process Object)
Add-ons
Migration Good overview provides easy to understand representation of
functional plant architecture in the engineering system
Summary
Powerful navigation helps to search quickly and dive in
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Automation and Drives

Engineering System
Process Object View...the "Integrated Development Environment
SIMATIC PCS 7 General
Technology Name, comments, AS assignment etc.
CFC & SFC
Introduction OS cross- parameters /
reference interconnections
Profibus
Block symbols, Alarm Limits,
I/O
I/O fields, settings,
Controller status display Engr range,
F-Engineering high-level
interconnections
Communication
Operator System
Engineering System Process
System Functions Object
Archives Alarms
Batch / Route Control
Cycles, Message text,
MIS/MES Integration units Alarm priorities
Add-ons
Migration
Summary Hardware configuration
I/O channels, signal names
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Automation and Drives

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

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

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Process Object View: Comprehensive Filter Functions Ba

SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
1 2
Operator System 2-level filter
function
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary Selective filtering of relevant parameters allows you to
optimize your configuration activities
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Ba
Process Object View: User Friendly
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering Block parameters can be
changed without opening CFC
Communication
Operator System
Project library for storing process tag types
Engineering System
and example solutions
System Functions Import and export of process tags and
variations of the example solutions
Batch / Route Control
MIS/MES Integration
Add-ons Collaboration with MS
EXCEL using Copy & Paste
Migration
Summary Added Efficiency from ability to leverage project data from
MS EXCEL (taglist, alarmlist etc.)
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Automation and Drives

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

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

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

Communication Automatic AS-OS synchronization

Operator System
Copy pictures and charts from Reactor_1 together
Engineering System
System Functions Easy editing of the copies
Rename objects (Chart names)
Batch / Route Control Configure hardware connections of new plant section

MIS/MES Integration
Compile OS: All references to Reactor_2
Add-ons in the OS are automatically renamed
Pictures (including dynamic links)
ated

Migration Scripts are u p d
tions

Archive tags
S c o n n ec
g in ee ring !!!
Summary O n ual en
ut m a
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Automation and Drives

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

Introduction Place blocks


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

Batch / Route Control


MIS/MES Integration
Block libraries with
Add-ons search function
Migration
Summary Easy engineering of the measuring point logic using
graphical connections of preconfigured blocks
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Automation and Drives

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

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

Add-ons
Migration
Summary

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Function Blocks Configuration of OS Symbols Ba

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

SIMATIC PCS 7
The order of the blocks and the sequence groups/charts are automatically
Technology
optimized during compiling based on the data flow through the program (optional)
Introduction Ensures that interconnected logic is executed in the correct order
A separate sequence group is automatically created for each new CFC chart
Profibus (with the same name)
I/O All blocks of a chart are automatically inserted into the sequence group

Controller
F-Engineering CFCs SFCs
Communication
Operator System
Engineering System Block sequence
System Functions
Batch / Route Control Optimized
MIS/MES Integration
by PCS 7
Add-ons
Migration
Summary

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Automation and Drives

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

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary Powerful and easy-to-use tools for configuring all aspects of
sequential control via drag and drop and fill in the blank
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Editing of sequential controls conforming to IEC 1131 (3) Ba

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

....
Batch / Route Control
MIS/MES Integration
Add-ons
Shutdown
Migration ....
1 2 8
Summary Coordinated automatically by PCS 7
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Automation and Drives

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

SIMATIC PCS 7 SFC Configure chart I/Os


Technology (inputs/outputs/in/outs)
Introduction
Profibus CFC

I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
SFC operating states can be triggered by
Add-ons interconnections (inputs)
Migration
SFC status can be determined from
Summary
interconnections (outputs)
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SFC: Type Instance Concept Central Editing Ba

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

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

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Automation and Drives

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

Engineering System
Efficient Bulk-Engineering
SIMATIC PCS 7 CAD / CAE
Standardized contol technological libraries with
Technology Typical preassembled, tested blocks and charts (typicals)
Typical
Libraries Import plant data (e.g. process tag list or I/O list) from
Libraries
Introduction Measurement, the higher-level CAD/CAE world
controller, motor, valve, etc.
Profibus
Import / Export Assistant
I/O
Automatic generation of
Controller controller configuration based on
TH
F-Engineering the imported process tag list and
the typicals
Communication - Creation of the plant hierarchy
OS Picture Hierarchy
Process - Editing of saved process tag
Operator System
Object OS Pictures charts
Engineering System charts Automatic derivation of the OS
System Functions picture hierarchy, automatic
interconnection of blocks and
Batch / Route Control placement in pictures
MIS/MES Integration Operator
Controller System
Add-ons
Commissioning of individual Process Objects with the
Migration convenient graphical tools CFC, SFC
Summary Export of optimized parameters back to CAD/CAE world
during commissioning (documentation of As-built)
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Automation and Drives

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

Migration
Summary

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Automation and Drives

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

Batch / Route Control


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

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Automation and Drives

Engineering System
Version Cross-Checker (VXC) 1
SIMATIC PCS 7
Technology
PCS 7
Introduction VXC
Profibus
+ -
I/O
CFC charts CFC charts
Controller
SFC charts SFC charts
F-Engineering Block types Block types
Signals Signals
Communication
Run sequence Run sequence
Operator System Program a Program b
Engineering System
Tool for comparing and displaying differences between two versions of
System Functions
an AS program
Batch / Route Control Highlights what is new, missing or different between the two versions
MIS/MES Integration Results are shown in tree / tabular format
Fast determination of differences with hierarchical "branching" and color high-
Add-ons
lighting of the difference
Migration A tool that is useful for the smallest applications and for large plants
Print and/or save the results in CSV format
Summary

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Automation and Drives
21 CFR
Engineering System V6.0 SP1 Part 11
complia
Audit Trail Downloading to AS nt
SIMATIC PCS 7
Technology

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

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Automation and Drives

System Functions
SIMATIC PCS 7
Technology

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

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Automation and Drives

p
Access Protection with SIMATIC Logon cku
Windows 2000 Functions Ba

SIMATIC PCS 7 User administration, security functions


Technology Central user administration with domains / workgroups on the MS Windows level
Create, delete, lock, unlock users
Introduction
Assignment of users to user groups
Profibus Double token logon (user ID + password)
I/O Unique logon names within the domain/workgroup
Define the logon name format (e.g. min. 6 characters, etc.)
Controller
Double input of password
F-Engineering Define the re-usablility of the password
Define the password format (min. length, special characters etc.)
Communication
Password expiration
Operator System User can be forced to change his password on first logon attempt
Engineering System User can be locked out after n failed logon attempts
MS Windows access rights only for authorized persons
System Functions
Various access levels
Batch / Route Control Access settings for each PC
MIS/MES Integration Audit Trail procedures
Event Viewer for audit log entries:
Add-ons All administrative actions
Migration All user access actions
(logon, logout, password change by user etc.)
Summary
Logging of all (failed) logon / logout attempts
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Automation and Drives

Time Synchronization and Time Stamping


SIMATIC PCS 7 Possibilities of time synchronization
Technology
External time master "SICLOCK" on the plant bus
Introduction OS server is time master with

Profibus
PC system time
Master Time signal via serial port (GPS / DCF 77 antenna)
I/O Master Time signal via bus from external PC
Controller
Time stamping
F-Engineering SICLOCK
Process alarms
Communication Analog block, e.g. "Analog value high"
Operator System Motor block, e.g. "Motor fault"
Time stamping cyclic in the AS
Engineering System Precision: AS scan rate, e.g. 500 msec.
System Functions Error messages of the I/O *)

Batch / Route Control E.g. "wire break"


Time stamping acyclic in the AS ET200M *)
MIS/MES Integration Precision : approx. 50 msec.
Add-ons Digital signals on the input/output station
ET200iS
Migration
Digital signals via IM153-2 / IM151-2
Precision : 5 msec.
Summary
Time master/slave
*) ET200M: 16 x DI: 6ES7321-7B/TH0*-0AB0 ET200iS: 4 x DI: 6ES7 131-5RD00-0AB0
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Automation and Drives

SIMATIC BATCH
SIMATIC PCS 7
Technology

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

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Automation and Drives

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

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

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Automation and Drives

SIMATIC BATCH - Workflow


SIMATIC PCS 7 Plant Configuration Data
Technology SIMATIC
Manager
Introduction
Profibus
I/O
Controller
F-Engineering 5t
27.03.03
Communication
Operator System
Base Contol
Engineering System recipe recipe

System Functions St

Batch / Route Control Recipe AF1 AF2 Batch Batch Batch


editor planning control data report
MIS/MES Integration AF3

Add-ons
Migration
Summary
Charge
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Automation and Drives

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

Add-ons
Migration ...
Summary

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Automation and Drives

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

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

F-Engineering Technical Recipe


Technical Recipe
operation
equipment
Communication equipment operation

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

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Automation and Drives

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

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions Recipe operation (ROP)
Batch / Route Control
Library ROP Parallel branch
MIS/MES Integration
Recipe function Alternative branch
Add-ons
Migration Operator dialog Synch. line Loop
Summary Transition
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Automation and Drives

SIMATIC BATCH Unit-Independent Design


SIMATIC PCS 7 Plant Neutral Class Recipe
Technology
Class
Introduction Silo

Profibus
I/O
Controller Class
F-Engineering Reactor

Communication
Control Recipe
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary Class concept enables unit-independent recipes
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Automation and Drives

SIMATIC BATCH
Optimal Assignment of Units and Equipment
SIMATIC PCS 7 Configuration of strategies for dynamic allocation of units
Technology Preferred unit
Introduction
Least used unit
Process parameters
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary Automatic unit assignment during runtime
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Automation and Drives

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

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Automation and Drives

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

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

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

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Automation and Drives

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

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration Central editing
Summary Facilitates validation
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Automation and Drives

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

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

System Functions Basic


Basicrecipe
recipe#1
#1 Basic
Basicrecipe
recipe#2
#2 Basic
Basicrecipe
recipe#3
#3
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary Efficient engineering and simplified validation
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Automation and Drives

SIMATIC BATCH
Online Operation
SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System Stop point:
Block batch processing
System Functions
Resume after operator
Batch / Route Control input
MIS/MES Integration
Add-ons
Migration
Start Stop after step Stop immediately Resume End Cancel
Summary

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Automation and Drives

SIMATIC BATCH Fulfills 21 CFR Part 11


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

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

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Automation and Drives

p
SIMATIC BATCH cku
Reporting system based on XML data structures Ba

SIMATIC PCS 7 Reporting system with integrated browser


Technology

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

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Automation and Drives

SIMATIC ROUTE CONTROL SYSTEM (RCS)

SIMATIC PCS 7 CV1304A CV1306A


CV1341 CV1351

CV1326
Destination Source
Technology CV1325
CV1305 CV1307
CV1327
CV1328

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

CV1028 CV1030 CV1032


314 315

Controller

CV1038
CV1037
CV1036
CV1035
CV1031 CV1029 CV1033 FT311
F-Engineering
Main functions CV1034 VS

Communication 311 MASH PUMP


20-105
engineering/online tool for complex control
Operator System and supervision of transports
Engineering System
static defined partial routes are combined to a total
route dynamically
System Functions diagnosis and alarming tool for material routes
Batch / Route Control System environment
SIMATIC PCS 7
MIS/MES Integration
with and without SIMATIC BATCH
Add-ons Typical applications
Migration plants with fluid materials
parts of plants with complex product routes
Summary
tank farms
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Automation and Drives

SIMATIC ROUTE CONTROL SYSTEM (RCS)


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

Controller yeast

F-Engineering CO2

Communication CIP

Operator System
check valves
Engineering System water finishing

System Functions wort 1 fermentation tank group 3/4

Batch / Route Control execute several


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

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

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Automation and Drives

p
SIMATIC ROUTE CONTROL SYSTEM (RCS) cku
Integration in PCS 7 Ba

SIMATIC PCS 7
Technology

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

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

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Automation and Drives

MIS / MES Integration


SIMATIC PCS 7
Technology

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

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Automation and Drives

Easy Business and IT Integration Using Standard InterfacesSP-2


OPC .0
V6
SIMATIC PCS 7
OPC Clients
Technology

Introduction
Profibus OPC Server

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

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Automation and Drives

Interface to the IT World with @PCS 7


SIMATIC PCS 7 Process data available through
Technology company with @PCS 7
Introduction
Profibus Read access to OS data via
Internet/Intranet (process,
I/O archive data, messages)
Controller Write access to OS data
Communication with server
F-Engineering applications of @aGlance/ IT
Communication server add-ons
Company-wide availability of
Operator System process data; leverages C/S
technology; open for custom
Engineering System
C/S applications
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Migration
Summary

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Automation and Drives

Interface to the IT World with SIMATIC IT


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

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

Interface to the IT World with SIMATIC IT


Topology and Data Communication
SIMATIC PCS 7
Technology SAP R/3 ERP
Introduction
Profibus Planning level
I/O SIMATIC IT
MES MES
Production Suite MIS
Controller PCS 7 OS Server Client

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

Summary

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Automation and Drives

Tasks on the MES Level


SIMATIC PCS 7
Technology

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

MIS/MES Integration
Product data
Add-ons Interface to archiving
control level
Migration
(PCS 7)
Summary

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Automation and Drives

SIMATIC IT Product Family (Production Suite)


Based on S95
SIMATIC PCS 7
Technology

Introduction
PRM: Scheduli
Detailed
Detailed
production Report Manager
production
Profibus Product Resource ng
scheduling
scheduling
Manager Material
Production
Production
I/O tracking
Unilab:
POM: Tracking
tracking
Laboratory
Personne
Production
Production
Production Order
Controller resource
resource and
l
management
management Manager Information
F-Engineering Management
System
Communication
Production
Production
Planning
dispatching
KPI
Production
performance
Operator System dispatching performance
Analysis
analysis
analysis
Engineering System PPA:
Recipe
Product
Product PM: Production
System Functions definition
definition
Production Modeler
Mgt
management
management
Performance
(Base Application) Analyser
Batch / Route Control PrDefMan:
Production KPI
Production
MIS/MES Integration BATCH
Definition data
data
Manager Executio
Production
Production
Analysis
collection
collection
Historian
Add-ons
execution
execution
n
Migration PCS 7 / Batch

Summary

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Automation and Drives

up
PCS 7 Add-on Concept Ba
ck

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

Controller
F-Engineering PCS 7 Compatibility Test Add-on Contract
Certification
Communication
Operator System PCS 7 Add-on
Engineering System Catalog

System Functions
Order directly from partner
Batch / Route Control
MIS/MES Integration
Hotline / Support
Add-ons 1.) Simatic Hotline
2.) Partner Hotline
Migration
Summary

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Automation and Drives

SIMATIC PCS 7 - Add-ons


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

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

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Automation and Drives

Migration
From the installed basis to SIMATIC PCS 7
SIMATIC PCS 7 Step-by-step transition from the installed base to SIMATIC PCS 7
Technology Preserves previous investmests (conversion of proven application software; re-use of the I/O)
Integrated process management using common HMI
Introduction PCS 7 OS Clients PCS 7 ES PCS 7 OS Clients
Profibus
I/O
Controller
F-Engineering
Communication
Operator System
Engineering System
System Functions
Batch / Route Control
MIS/MES Integration
Add-ons
Minimal risk, quick transition period, no/minimal production downtime
Migration products and service from one source
Migration Migration integrates old plant innovative technologies (e.g. todays EDP infrastructure)
Summary 1 2 3 4 5 6 7
Consulting Offer Logistics Execution IBS Documentation Expansion
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Automation and Drives

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

p
SIMATIC PCS 7 cku
High Availability Redundancy at All Levels Ba

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

Sensor / Aktor
ET 200M

System Functions ~ Redundant connection of non-redundant PROFIBUS


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

MIS/MES Integration PROFIBUS PA


range (standard and failsafe)
Add-ons Increased availability on all levels
Y Link
Migration Minimal process down time
Summary COx,
NOx, ...
Increased productivity
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Automation and Drives

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

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

PROFIBUS-DP
PROFIBUS-DP
PROFIBUS-DP

DP/EIB DP/PA Link


MIS/MES Integration PROFIBUS-PA
ET 200M
PROFIBUS-PA
Add-ons
MODBUS DP/PA Link
DP/PA Link Y Link
PROFIBUS-DP PROFIBUS-PA
Migration ET
200iS COx,
Summary ET ET Zone 1 NOx,
200X 200S Zone 2 etc.
Copyright Siemens AG 2003
All Rights Reserved A&D AS PA PM / A&D AS SM MP PCS7_Technical_2004_E No. 166
Automation and Drives

SIMATIC PCS 7 Fulfills All Requirements


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

Batch / Route Control Communication


Fast Ethernet
AS, I/O modules, I/O
MIS/MES Integration Fiber optic switching technology Online reconfiguration and expansion
Redundancy (system and field bus)
Add-ons Redundancy (controller, modules and Profibus)
Online expansion
Integrated Safety Engineering
Migration
Integration of intelligent field devices / drives
Summary Large range of I/O modules
Copyright Siemens AG 2003
All Rights Reserved A&D AS PA PM / A&D AS SM MP PCS7_Technical_2004_E No. 167
Automation and Drives

SIMATIC PCS 7: worldwide more than 2,445 cku


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

System Functions
185 Installations South Africa 35

Batch / Route Control in America

MIS/MES Integration Argentina 7 48 Installations


Canada 11 Brazil 33
in Africa
Chile 1
Add-ons Colombia 2 Algeria 1
Costa Rica 1 Egypt 3 Australia 22
Ecuador 1
Migration Peru 3
Mauritius
Morocco
1
4 23 Installations
Trinidad 1 Mozambique 1 in Australia
Summary Venezuela 4 Namibia 2
Swaziland 1 New Zealand 1
Copyright Siemens AG 2003
All Rights Reserved A&D AS PA PM / A&D AS SM MP PCS7_Technical_2004_E No. 168
Automation and Drives

Automation made easy !


SIMATIC PCS 7
Technology

Introduction
Profibus
I/O
Totally
Integrated
Controller
F-Engineering
Communication
Operator System
Engineering System Automation
with
System Functions
Batch / Route Control
MIS/MES Integration

SIMATIC PCS 7
Add-ons
Migration
Summary

Copyright Siemens AG 2003


All Rights Reserved A&D AS PA PM / A&D AS SM MP PCS7_Technical_2004_E No. 169