PCS 7 Engineering System

s Preface, Contents

SIMATIC Process Control System PCS 7 Engineering System

Manual

Using the PCS 7 Documentation

1

Introduction to Plant Engineering with PCS 7

2

Planning the Plant Engineering

3

Configuraton of the PCS 7 Plant

4

Basic Concepts of Engineering

5

Configuration of the PCS 7 Engineering System

6

Configuring PCS 7

7

Compiling and Downloading

8

Testing

9

Comparing Project Versions with VXC

10

Archiving and Documenting

11

Service

12

Appendix

13

Index

Edition 07/2005 A5E00346923-02

Safety Guidelines This manual contains notices intended to ensure personal safety, as well as to protect the products and connected equipment against damage. These notices are highlighted by the symbols shown below and graded according to severity by the following texts:

! ! !

Danger indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken.

Warning indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken.

Caution indicates that minor personal injury can result if proper precautions are not taken.

Caution indicates that property damage can result if proper precautions are not taken.

Notice draws your attention to particularly important information on the product, handling the product, or to a particular part of the documentation.

Qualified Personnel Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and systems in accordance with established safety practices and standards.

Correct Usage Note the following:

!

Warning This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended.

Trademarks SIMATIC®, SIMATIC HMI® and SIMATIC NET® are registered trademarks of SIEMENS AG. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners. Copyright Siemens AG 2005 All rights reserved

Disclaimer of Liability

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed.

Siemens AG Bereich Automation and Drives Geschaeftsgebiet Industrial Automation Systems Postfach 4848, D- 90327 Nuernberg

Siemens AG 2005 Technical data subject to change.

Siemens Aktiengesellschaft

A5E00346923-02

Preface Purpose of the Manual This manual shows you how you can configure your plant optimally with the PCS 7 process control system. You will see the individual steps in configuration based on examples. You will learn, among other things: •

How to structure the process control configuration of a plant technologically and through various phases.

•

How to use the different views (Component view, Plant view, Process object view)

•

Which phases you work through during configuration

•

How to structure plants

•

How to create process tag types and models

There are no additional manuals dealing with the following aspects that are covered in detail in this ES configuration manual: •

Configuring a process control system

•

Working with the plant hierarchy (PH) and the process object view (POV)

•

Working with the import / export assistant (IEA)

The contents of the electronic manuals are largely identical to those in the online help. Due to technical reasons, there may nevertheless be minor differences between the online help and the electronic manuals. If there are discrepancies, the information in the online help can be considered more up to date. During installation of PCS 7, the ES Configuration Manual is copied to the PG or PC. You can open the manual with Start > SIMATIC > Documentation > English > PCS 7 Configuration Manual ES.

Process Control System PCS 7 - Engineering System A5E00346923-02

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Preface

Getting Started PCS 7 Getting Started – Part 1 is intended for newcomers to PCS 7. It provides an initial overview of the process control system PCS 7 and provides newcomers with the information they require to create a simple project alone. The project can be configured on an existing SIMATIC station. PCS 7 Getting Started – Part 2 is intended for users that have already worked through Getting Started – Part 1. It introduces you to functions of PCS 7 that you can use for fast and effective plant configuration. You can use these functions in particular when you configure large and complex systems. Both parts of Getting Started introduce the functions based on a concrete sample project called "COLOR". At the same time, the correct order for creating a configuration is outlined. Both parts of Getting Started are available under Start > SIMATIC > Documentation > English > ....

Required Experience This ES configuration manual is intended for personnel involved in configuring, commissioning, and service. Basic experience of working with the PC/programming device and working with Windows are assumed.

Validity The ES Configuration Manual is valid for the software on the DVD "Process Control System PCS 7 Engineering Toolset V6.1".

Readme File Please refer to the readme file for important general information:

iv

•

The readme file is on the DVD "Process Control System PCS 7 Engineering Toolset V 6.1".

•

You can also open the readme file after installing PCS 7 with the menu command Start > Simatic > Product Notes > General > PCS 7 Readme.


Preface

Changes Compared with the Previous Version Below, you will find an overview of the most important changes relating to ES configuration compared with the previous version: •

Expansion of the plant hierarchy to 8 levels

•

Updating of block types throughout a multiproject Refer to the section "How to Update Block Types"

•

Importing/exporting I/Os and messages in the POS Refer to the section "How to Import/Export I/Os and Messages"

•

Editing archive tags Refer to the section "How to Edit Measured Value Archives" and "How to Assign Parameters and Interconnect the Blocks"

•

Reading back and archiving block I/Os Refer to the section "How to Assign Parameters and Interconnect the Blocks"

•

Setting up a maintenance station Refer to the section "Diagnostics with a Maintenance Station"

•

Deriving the diagnostic pictures from the PH Refer to the section "Settings and Properties of the PH"

•

Trend display in the CFC test mode Refer to the section "How to Use the Trend Display in Test Mode"

•

Test mode in the process object view Refer to the section "How to Test in the Process Object View"

•

Shared declarations Refer to the section "How to Store Shared Declarations"

•

Synchronizing Hierarchy Folders in the Multiproject Refer to the section "Additional PH Functions in a Multiproject"

Guide to the Manual The ES Configuration Manual provides you with an overview of the essential functions of PCS 7. You can use the ES configuration manual as a source of reference and read the specific information you need at the time. The configuration steps are described in an order that is practical for the actual configuration. The manual provides you with important background information and relationships for all the configuration steps illustrating the interdependencies in the entire system. All activities are described uniformly based on the menu commands of the menu bar. For many functions, you can also use the alternative commands in the contextsensitive menu of the individual objects.


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Preface

Further Support If you have any technical questions, please get in touch with your Siemens representative or agent responsible. You will find your contact person at: http://www.siemens.com/automation/partner You will find a guide to the technical documentation offered for the individual SIMATIC Products and Systems here at: http://www.siemens.com/simatic-tech-doku-portal The online catalog and order system is found under: http://mall.automation.siemens.com/

Training Centers Siemens offers a number of training courses to familiarize you with the Process control System PCS 7 automation system. Please contact your regional training center or our central training center in D 90327 Nuremberg, Germany for details: Telephone: +49 (911) 895-3200. Internet:

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http://www.sitrain.com


Preface

Technical Support You can reach the Technical Support for all A&D products •

Via the Web formula for the Support Request http://www.siemens.com/automation/support-request

•

Phone:

+ 49 180 5050 222

•

Fax:

+ 49 180 5050 223

Additional information about our Technical Support can be found on the Internet pages http://www.siemens.com/automation/service

Service & Support on the Internet In addition to our documentation, we offer our Know-how online on the internet at: http://www.siemens.com/automation/service&support where you will find the following: •

The newsletter, which constantly provides you with up-to-date information on your products.

•

The right documents via our Search function in Service & Support.

•

A forum, where users and experts from all over the world exchange their experiences.

•

Your local representative for Automation & Drives.

•

Information on field service, repairs, spare parts and more under "Services".


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Preface

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Contents 1

Using the PCS 7 Documentation 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.2 1.2.1

2

3

Guidelines on Using the PCS 7 Documentation.......................................... 1-1 Options for Accessing Documentation ........................................................ 1-1 Documentation for the Planning Phase....................................................... 1-3 Documentation for the Realization Phase ................................................... 1-4 Documentation for Commissioning, Operation, Diagnostics and Servicing 1-7 Guide through the ES Configuration Manual............................................... 1-8 Guide to the PCS 7 Engineering System Configuration Manual................. 1-8

Introduction to Plant Engineering with PCS 7 2.1

2-1

Structure of a PCS 7 Plant .......................................................................... 2-1

Planning the Plant Engineering 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.5.1 3.5.5.2 3.5.5.3 3.5.5.4 3.5.5.5 3.5.5.6

1-1

3-1

Before Beginning the Engineering............................................................... 3-1 Components of a PCS 7 Plant..................................................................... 3-3 How to Find the Right Components ............................................................ 3-3 Important Criteria for Selecting Components .............................................. 3-7 With Which "Third-party Systems" Can PCS 7 Communicate? .................. 3-8 How Can the Plant Be Protected Against Unauthorized Access? .............. 3-9 How Can the Process Management Be Verified? ..................................... 3-11 How Can Project and Process Data be Archived?.................................... 3-13 What Sources Can Be Used in Planning the Plant Design? ..................... 3-15 What Service Support Does SIEMENS Offer for PCS 7? ......................... 3-17 Capacity Options for Configuring a PCS 7 Plant....................................... 3-18 How Can PCS 7 Be Scaled? ..................................................................... 3-18 How Many Process Objects Can Be Handled in a Project?...................... 3-19 How Many CPUs Are Needed for the Automation? .................................. 3-21 How Many Devices, Sensors and Actuators Can Be Integrated?............. 3-22 How Many Operator Stations Are Required? ............................................ 3-23 What are the Expansion Limits?................................................................ 3-24 Selecting Fault-Tolerant and Fail-Safe Components ................................ 3-25 Introduction ................................................................................................ 3-25 Redundancy Concept of PCS 7 ................................................................ 3-25 Safety Concept of PCS 7........................................................................... 3-28 Recommended Use of Components ......................................................... 3-31 Selecting the Network Components .......................................................... 3-32 Communication within PCS 7 .................................................................... 3-32 Which Networks / Bus Systems Are Used for Communication? ............... 3-33 Field of Application and Parameters of the Network/Bus Systems ........... 3-34 Maximum Transmission Rates of the Networks / Bus Systems................ 3-35 Terminal Bus and Plant Bus Ethernet ....................................................... 3-36 Management Level Scheme with Ethernet................................................ 3-36 Use of Switching Technology .................................................................... 3-38 Optical and Electrical Transmission Media ............................................... 3-40 Connecting Network Nodes to Ethernet .................................................... 3-40 Configuring Redundant Ethernet Networks............................................... 3-42 Planning Diagnostics for Ethernet ............................................................. 3-43


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Contents

3.5.6 3.5.6.1 3.5.6.2 3.5.6.3 3.5.6.4 3.5.6.5 3.5.6.6 3.5.6.7 3.5.6.8 3.5.7 3.5.7.1 3.5.7.2 3.5.7.3 3.5.8 3.5.8.1 3.5.8.2 3.5.8.3 3.5.8.4 3.5.8.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.7 3.7.1 3.7.2 3.7.2.1 3.7.2.2 3.7.2.3 3.7.3 3.7.4 3.7.5 3.7.6 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 3.8.7 3.8.8 3.9 3.9.1 3.9.2 3.9.3

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Field Bus with PROFIBUS......................................................................... 3-43 Planning the Field Level with PROFIBUS ................................................. 3-43 Electrical Transmission Media................................................................... 3-45 Optical transmission media ....................................................................... 3-46 Connecting PROFIBUS DP Nodes ........................................................... 3-48 Configuration of Redundant PROFIBUS DP Networks............................. 3-49 Connecting Non-redundant PROFIBUS DP Devices to Redundant PROFIBUS DP.................................................................... 3-50 Connecting PROFIBUS PA to PROFIBUS DP.......................................... 3-52 Planning Diagnostics for PROFIBUS ........................................................ 3-54 Data Links to Other Systems..................................................................... 3-56 Connecting the AS Interface to PROFIBUS DP ........................................ 3-56 Connecting Instabus EIB to PROFIBUS DP ............................................. 3-58 Connecting MODBUS to PROFIBUS DP .................................................. 3-59 Administration Level and Remote Access................................................. 3-60 Connecting to MIS/MES ............................................................................ 3-60 Connecting to the IT World - SIMATIC IT Framework............................... 3-60 Connecting HMI Systems via OPC ........................................................... 3-61 Connecting to the IT World with @PCS 7 ................................................. 3-62 Access to the PCS 7 OS over Web Client................................................. 3-65 Selecting the PC Components for ES, OS, BATCH and IT ...................... 3-66 Which PC Components Can Be Used?..................................................... 3-66 Preconfigured PCS 7 Systems (Bundles) ................................................. 3-68 Connecting PC Components ..................................................................... 3-68 Additional Components for Acoustic and Optical Signaling ...................... 3-69 Selecting AS Components......................................................................... 3-70 What are the Criteria for Selecting the AS? .............................................. 3-70 Overview of Automation Systems ............................................................. 3-71 Standard Automation Systems for PCS 7 ................................................. 3-72 Fault-tolerant Automation Systems for PCS 7........................................... 3-73 Fail-safe Automation Systems for PCS 7 .................................................. 3-74 Limits of the CPUs for PCS 7 Projects ...................................................... 3-75 Default Performance Parameters of the CPUs for PCS 7 Projects........... 3-76 Components for Fault-tolerant Automation Systems ................................ 3-77 Components for Fail-safe Automation Systems ........................................ 3-79 Selecting the I/O Components................................................................... 3-82 Introduction ................................................................................................ 3-82 Should Distributed or Central I/O Be Used?.............................................. 3-82 Which Devices Can Be Connected as Distributed Components?............. 3-84 Use in Fault-tolerant or Fail-safe Automation Systems?........................... 3-85 Overview of Usable Distributed I/O System ET 200.................................. 3-86 Connecting HART Devices to Distributed I/O............................................ 3-87 Can the Configuration Be Changed During Ongoing Operation? ............. 3-88 How Can Distributed I/O Be Integrated in Hazardous Zones?.................. 3-89 Preparation for Efficient Engineering......................................................... 3-91 Planning Objects/Functions for Efficient Engineering ............................... 3-91 Which Data and Data Formats Can Be Imported?.................................... 3-93 How Are Repeatedly Used Technological Functions Supported? ............ 3-94


Contents

4

Configuraton of the PCS 7 Plant 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.4.3 4.4.4

5

5.9.5 5.9.6 6

Basic Configuration of the PCS 7 Plant....................................................... 4-1 Configuration of the PC Stations ................................................................. 4-3 Engineering Station Configurations............................................................. 4-3 Operator Station Configurations .................................................................. 4-5 BATCH Station Configurations .................................................................... 4-7 Configuration of the Terminal and Plant Bus............................................... 4-9 Data Paths over the Terminal Bus and Plant Bus ....................................... 4-9 Terminal Bus and Plant Bus Configurations.............................................. 4-10 Configuration of the Automation systems and the Connected I/O ............ 4-12 Configurations of the Automation Systems ............................................... 4-12 Guideline in the installation instructions for the products .......................... 4-13 Supplements to the Assembly Instructions for PCS 7 Products ............... 4-16 Rules for Configuration in RUN (CiR)........................................................ 4-17

Basic Concepts of Engineering 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.5 5.6 5.7 5.8 5.8.1 5.8.2 5.9 5.9.1 5.9.2 5.9.3 5.9.4

5-1

Central, Plantwide Engineering ................................................................... 5-1 Creating Projects with the PCS 7 "New Project" Wizard............................. 5-3 Distributed Engineering ............................................................................... 5-5 Configuring in a Multiproject ........................................................................ 5-5 Branching and Merging Charts of a Project ................................................ 5-8 Configuration in a Network .......................................................................... 5-9 Typing, Reusability, and Central Modifiability of Engineering Data........... 5-10 Using Block Types, Faceplates, and Block Icons...................................... 5-11 Using Process Tag Types ......................................................................... 5-13 Application of SFC Types .......................................................................... 5-15 Using Models ............................................................................................. 5-16 Using the Master Data Library/Libraries.................................................... 5-17 Using Project-Specific Catalog Profiles..................................................... 5-18 Import and Reuse of Plant Data ................................................................ 5-19 Free Assignment between Hardware and Software.................................. 5-21 Deriving the Picture Hierarchy and OS Areas from the PH....................... 5-22 Generating Block Icons and Operator Texts ............................................. 5-23 Generating Block Icons ............................................................................. 5-23 Generating Operator Texts........................................................................ 5-23 The PCS 7 Message System .................................................................... 5-24 Basic Concept of the Message System..................................................... 5-24 Configuring Messages............................................................................... 5-26 Important Features of Message Configuration .......................................... 5-27 Acknowledgment Concept and Acknowledgment-triggered Reporting (ATR) ........................................................................................ 5-29 Time Stamp with 10 ms Accuracy ............................................................. 5-30 Acoustic/Optical Signaling ......................................................................... 5-30

Configuration of the PCS 7 Engineering System 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.2

4-1

6-1

Configuration of the Engineering System.................................................... 6-1 Central Starting Point - The SIMATIC Manager .......................................... 6-1 The Component View .................................................................................. 6-3 The Plant View ............................................................................................ 6-5 The Process Object View ............................................................................ 6-6 Relationships between the Views................................................................ 6-9 Cross-View Functions and How to Use Them............................................. 6-9 PCS 7 Applications and How They Are Used ........................................... 6-10


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Contents

7

Configuring PCS 7 7.1 7.2 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.8 7.5.9 7.5.10 7.5.11 7.5.12 7.6 7.6.1 7.6.2 7.6.3 7.6.4 7.6.5 7.6.6 7.6.7 7.6.7.1 7.6.7.2 7.6.7.3 7.6.7.4 7.6.7.5 7.6.7.6 7.6.7.7 7.6.7.8 7.6.8 7.6.9 7.6.10 7.6.11

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7-1

Overview of the Steps in Configuration ....................................................... 7-1 Setting up the PC Stations .......................................................................... 7-3 Creating the PCS 7 Project ......................................................................... 7-3 Overview of the Defaults and Individual Steps............................................ 7-3 How to Set the Defaults............................................................................... 7-4 How to Create a new Multiproject with the PCS 7 Wizard .......................... 7-5 How to Add Projects to the Multiproject ...................................................... 7-7 How to Insert an Existing Project in a Multiproject ...................................... 7-7 How to Remove a Project from the Multiproject .......................................... 7-8 How to Expand a Project by Adding Further Components.......................... 7-8 How to Store Shared Declarations .............................................................. 7-9 Configuration of the AS and PC Stations .................................................. 7-10 How to Insert the SIMATIC 400 Stations in the Projects of the Multiproject ...................................................................................... 7-10 How to Start Configuring SIMATIC 400 Stations....................................... 7-11 How to Insert CPs in the SIMATIC Stations and Assign Them to Networks................................................................................................ 7-12 Inserting and Configuring the Operator Stations ....................................... 7-13 Inserting and Configuring the BATCH Stations ......................................... 7-15 Inserting and Configuring the Engineering Station.................................... 7-16 How to Configure and Download the PC Stations..................................... 7-18 Creating the Plant Hierarchy (PH) ............................................................. 7-21 Structure of the PH .................................................................................... 7-21 Settings and Properties of the PH ............................................................. 7-23 How to Make the Settings for the PH ........................................................ 7-25 Rules for Naming in the PH ....................................................................... 7-26 How to Insert Further Hierarchy Folders ................................................... 7-27 How to Insert Objects in the Hierarchy Folder........................................... 7-28 Rules for Copying and Moving within the PH ............................................ 7-29 How to Specify the AS-OS Assignment .................................................... 7-30 How to assign objects to the PH................................................................ 7-31 How to Check the Consistency of the PH ................................................. 7-32 Additional PH Functions in a Multiproject.................................................. 7-34 S88 Type Definition of the Hierarchy Folders............................................ 7-35 Creating the Master Data Library .............................................................. 7-37 Introduction - Master Data Library............................................................. 7-37 Objects of the Master Data Library............................................................ 7-39 How to Create a Master Data Library........................................................ 7-41 Working with Libraries ............................................................................... 7-42 How to Copy Objects from other Libraries to the Master Data Library...... 7-43 How to Update Block Types ...................................................................... 7-44 Adjusting the Blocks .................................................................................. 7-45 Adapting Blocks to Project Requirements ................................................. 7-45 How to Modify Attributes of the Block I/Os ................................................ 7-45 How to Lock Message Attributes Against Changes in Block Instances .... 7-47 How to Compile Message Texts................................................................ 7-48 How to Set the Language for Display Devices .......................................... 7-48 How to Create your own Blocks for the Master Data Library .................... 7-49 Using Faceplates and Block Icons for OS Pictures................................... 7-49 How to Import/Export I/Os and Messages................................................. 7-50 Working with Process Tag Types .............................................................. 7-53 Working with Models ................................................................................. 7-55 How to Test Library Objects ...................................................................... 7-56 How to Document Library Objects............................................................. 7-56


Contents

7.7 7.7.1 7.7.2 7.7.3 7.7.4 7.7.5 7.8 7.8.1 7.8.2 7.8.3 7.8.4 7.8.4.1 7.8.4.2 7.8.4.3 7.8.4.4 7.8.4.5 7.8.4.6 7.8.4.7 7.8.4.8 7.8.4.9 7.8.4.10 7.8.4.11 7.8.5 7.8.5.1 7.8.5.2 7.8.6 7.8.6.1 7.8.6.2 7.8.6.3 7.8.6.4 7.8.6.5 7.8.6.6 7.8.6.7 7.8.7 7.8.7.1 7.8.7.2 7.8.7.3 7.8.7.4 7.8.7.5 7.8.7.6 7.8.7.7 7.8.7.8 7.8.7.9 7.8.7.10 7.8.8 7.8.8.1 7.8.9 7.8.9.1 7.8.10 7.8.10.1 7.8.10.2 7.8.10.3

Distributing the Multiproject for Distributed Editing (Multiproject Engineering).......................................................................... 7-57 Conditions for Further Editing in the Multiproject ...................................... 7-59 Overview of the Steps ............................................................................... 7-60 How to Store the Projects of the Multiproject ............................................ 7-61 How to Move Projects to Distributed Engineering Stations....................... 7-62 How to Continue Editing Projects on Distributed Stations ........................ 7-64 Configuring the Hardware.......................................................................... 7-65 Overview of Hardware Configuration ........................................................ 7-65 Defining a Project-specific Catalog Profile ................................................ 7-66 Exporting/Importing the Hardware Configuration ...................................... 7-68 Configuring the SIMATIC Station (CPU, CPs, Central I/Os) ..................... 7-68 Creating the Concept for Address Assignment ......................................... 7-68 Overview of the Steps in Configuration ..................................................... 7-70 How to Create a SIMATIC 400 Station...................................................... 7-72 How to Insert Modules in a SIMATIC 400 Station ..................................... 7-73 How to Insert a Communications Processor ............................................. 7-76 How to Assign Symbols to Input and Output Addresses........................... 7-77 Setting the CPU Properties ....................................................................... 7-78 Setting the Process Image ........................................................................ 7-82 Configuring Fault-tolerant Systems (H Systems) ...................................... 7-87 Configuring Fail-safe Systems (F Systems) .............................................. 7-87 Default Parameter Values for the CPUs.................................................... 7-87 Setting the Time-of-Day Sychronization.................................................... 7-88 Principle of Time-of-Day Synchronization ................................................. 7-88 How to Set Time-of-Day Synchronization on the AS................................. 7-90 Configuring the Distributed I/Os (Standard) .............................................. 7-91 How to Configure the Distributed I/O......................................................... 7-91 How to Configure PA Devices ................................................................... 7-95 How to Configure the Diagnostic Repeater ............................................... 7-96 How to Configure Intelligent Field Devices with SIMATIC PDM ............... 7-98 How to Configure HART Devices with SIMATIC PDM ............................ 7-101 How to Configure Y-Links and Y-Adapters.............................................. 7-102 How to Use the Diagnostics of SIMATIC PDM........................................ 7-103 Configuring the Distributed I/O for Configuration Changes in Run (CiR) 7-104 Principle of Configuration Changes in RUN ............................................ 7-104 Types of CiR Objects............................................................................... 7-107 Overview of the Permitted Configuration Changes ................................. 7-108 How to Define CiR Elements for Future Plant Expansion (CPU-STOP) . 7-109 How to Delete CiR Elements (CPU-STOP)............................................. 7-113 How to Convert CiR Elements into Real Objects (CPU-RUN) ................ 7-114 How to Undo Used CiR Elements (CPU-RUN) ....................................... 7-116 Changing the Parameter Settings for Existing Modules in ET 200M Stations (CPU-RUN) ................................................................ 7-117 ET 200M Modules that Allow New Parameter Settings and their Reactions.................................................................................. 7-120 How to Change the Parameter Settings of a Channel (CPU-RUN) ........ 7-122 10 ms Time Stamp .................................................................................. 7-124 How to Configure the Hardware for 10 ms Time Stamps........................ 7-124 Acknowledgment-triggered Reporting ..................................................... 7-125 How to Activate Acknowledgment-triggered Reporting (ATR) ................ 7-125 Downloading the Configuration to the CPU............................................. 7-126 How to Download the Configuration in CPU-STOP ................................ 7-126 How to Download Configuration Changes in CPU-RUN......................... 7-127 Reaction of the CPU after Downloading Configuration Changes with the CPU in RUN ............................................................................... 7-128


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Contents

7.9 7.9.1 7.9.2 7.9.3 7.9.4 7.9.5 7.9.6 7.9.7 7.9.8 7.9.9 7.10 7.10.1 7.10.2 7.10.3 7.10.4 7.10.5 7.10.6 7.10.7 7.11 7.11.1 7.11.2 7.11.2.1 7.11.2.2 7.11.2.3 7.11.2.4 7.11.2.5 7.11.2.6 7.11.2.7 7.11.2.8 7.11.2.9 7.11.2.10 7.11.2.11 7.11.2.12 7.11.2.13 7.11.2.14 7.11.3 7.11.3.1 7.11.3.2 7.11.4 7.11.4.1 7.11.4.2 7.11.4.3 7.11.4.4 7.11.5 7.11.5.1 7.11.5.2 7.11.5.3 7.11.5.4 7.11.5.5 7.11.5.6 7.11.5.7 7.11.5.8 7.11.5.9 7.11.5.10

xiv

Creating Network Connections................................................................ 7-133 How to Display Networked/Non-networked Stations............................... 7-133 How to Create and Assign Parameters for a New Subnet ...................... 7-134 How to Create and Assign Parameters for the Network Attachment of a Station............................................................................................... 7-135 How to Change the Node Address .......................................................... 7-136 How to Save the Network Configuration ................................................. 7-137 How to Check the Consistency of the Network ....................................... 7-138 Cross-project Networks ........................................................................... 7-139 Configuring Redundant Networks ........................................................... 7-140 Tips on Editing the Network Configuration .............................................. 7-140 Creating the SIMATIC Connections ........................................................ 7-142 Connection Types and Connection Partners........................................... 7-142 How to Configure Connections between Two SIMATIC 400 Stations .... 7-144 How to Configure a Connection between a PC and SIMATIC 400 Station (Named Connection) ..................................... 7-148 How to Work with the Connection Table ................................................. 7-152 Cross-Project Connections in a Multiproject ........................................... 7-153 How to Merge Cross-Project Connections .............................................. 7-155 Configuring Redundant Connections ...................................................... 7-156 Configuring AS Functions........................................................................ 7-157 Configuration by Several Users (Textual Interconnections).................... 7-158 Creating CFC Charts (General)............................................................... 7-161 Overview of the Steps in Configuration ................................................... 7-163 How to Create a new CFC Chart............................................................. 7-164 How to Insert Blocks into the CFC Chart................................................. 7-165 How to Assign Parameters and Interconnect the Blocks ........................ 7-167 Runtime Groups and Runtime Properties ............................................... 7-169 Runtime Properties of the Blocks ............................................................ 7-170 How to Adapt the Run Sequence ............................................................ 7-173 How to Optimize the Run Sequence ....................................................... 7-175 How to Define CFC Chart I/Os ................................................................ 7-177 How to Compile CFC Charts ................................................................... 7-179 How to Download CFC Charts to the CPU.............................................. 7-181 How to Test CFC Charts ......................................................................... 7-183 How to Use the Trend Display in Test Mode........................................... 7-184 How to Configure the AS Runtime Measurement ................................... 7-185 Programming SIMATIC Connections ...................................................... 7-188 Blocks for Different Connection Types .................................................... 7-188 How to Program the SIMATIC Connections............................................ 7-189 Programming the Connection to the I/O (Driver Blocks) ......................... 7-191 Concept of the Driver Blocks ................................................................... 7-191 List of Driver Blocks................................................................................. 7-192 How to Generate Module Drivers ............................................................ 7-193 How to Create Your Own Driver Blocks .................................................. 7-195 Creating Process Tags from Process Tag Types (Multiproject).............. 7-196 How to Create a Process Tag Type from a CFC Chart........................... 7-196 How to Modify a Process Tag Type ........................................................ 7-198 How to Add a Process Tag Type to a Project ......................................... 7-199 How to Assign an Import File to the Process Tag Type (Create an Import File) ............................................................................ 7-200 How to Create an Import File or Assign it to the Process Tag Type ....... 7-201 Automatic Creation of a Number of Process Tags .................................. 7-202 How to Edit a Process Tag ...................................................................... 7-203 How to Adopt Process Tags .................................................................... 7-203 How to Synchronize Process Tags with the Process Tag Type.............. 7-205 How to Restore Lost Process Tag Type Assignments ............................ 7-207 Process Control System PCS 7 - Engineering System A5E00346923-02

Contents

7.11.6 7.11.6.1 7.11.6.2 7.11.6.3 7.11.6.4 7.11.6.5 7.11.6.6 7.11.6.7 7.11.6.8 7.11.6.9 7.11.6.10 7.11.6.11 7.11.6.12 7.11.6.13 7.11.6.14 7.11.6.15 7.11.6.16 7.11.7 7.11.7.1 7.11.7.2 7.11.7.3 7.11.7.4 7.11.7.5 7.11.8 7.11.9 7.11.9.1 7.11.9.2 7.11.9.3 7.11.9.4 7.11.9.5 7.11.9.6 7.11.9.7 7.11.9.8 7.11.9.9 7.11.9.10 7.11.9.11 7.11.10 7.11.11 7.11.11.1 7.11.11.2 7.11.11.3 7.11.11.4 7.11.11.5 7.11.11.6 7.11.11.7 7.11.11.8 7.11.11.9 7.11.11.10 7.11.11.11 7.11.11.12 7.11.11.13 7.11.11.14

Creating Sequential Control Systems (SFC)........................................... 7-208 Advantages and Uses of SFC Types/SFC Instances ............................. 7-209 Overview of the Steps in Configuration ................................................... 7-211 How to Create a new SFC Chart............................................................. 7-212 How to Create the Topology of the Sequential Control System.............. 7-213 How to Specify the Sequencer Properties............................................... 7-215 How to Configure Steps........................................................................... 7-216 How to Configure Transitions .................................................................. 7-218 How to Adapt the Operating Parameters and Runtime Properties ......... 7-220 Working with Charts, Types, and Instances ............................................ 7-222 Configuring Messages in SFC................................................................. 7-224 How to Create an SFC Type ................................................................... 7-225 How to Create an SFC Instance.............................................................. 7-227 How to Modify an SFC Type (centrally)................................................... 7-228 How to Compile Charts and Types.......................................................... 7-229 How to Download SFC Charts................................................................. 7-232 How to Test the SFC Program ................................................................ 7-234 Creating Models (Multiproject)................................................................. 7-236 How to Create a Model............................................................................ 7-236 Textual Interconnections and Models...................................................... 7-239 Generating Replicas from Models ........................................................... 7-240 How to Work with Models in the SIMATIC Manager ............................... 7-241 How to Assign Replicas to a Model Later................................................ 7-243 Editing Mass Data in the Process Object View ....................................... 7-243 Working in the Process Object View ....................................................... 7-245 Filtering and Sorting ................................................................................ 7-245 Setting, Showing/Hiding, Resorting and Defining Columns .................... 7-246 Copying, Moving, and Deleting................................................................ 7-247 Search and Replace ................................................................................ 7-248 How to Edit the General Data.................................................................. 7-249 How to Edit Parameters........................................................................... 7-251 How to Edit Signals ................................................................................. 7-254 How to Edit Messages............................................................................. 7-257 How to Edit Picture Objects..................................................................... 7-259 How to Edit Measured Value Archives .................................................... 7-261 How to Test in the Process Object View ................................................. 7-263 Adopting the Data from the Plant Engineering ........................................ 7-266 Import/export of Process Tags/Models.................................................... 7-267 Identifying Repeated Functions ............................................................... 7-267 Working with the Import/Export Assistant................................................ 7-268 Working with Process Tags and Models ................................................. 7-269 Requirements and Steps in Configuration............................................... 7-269 Functions for Working with Process Tags and Models ........................... 7-272 What Happens during Import?................................................................. 7-276 How to Import Process Tag Types and Models ...................................... 7-278 What Happens during Export? ................................................................ 7-281 How to Export Process Tag Types and Models ...................................... 7-282 Restrictions with the IEA.......................................................................... 7-283 Data of the IEA File in the ES.................................................................. 7-284 Creating/Editing Import Files with the IEA File Editor ............................. 7-285 How to Exchange Data with Excel/Access.............................................. 7-287 Structure of the IEA File .......................................................................... 7-288


xv

Contents

7.11.12 7.11.12.1 7.11.12.2 7.11.12.3 7.11.12.4 7.11.12.5 7.11.12.6 7.11.12.7 7.12 7.12.1 7.13 7.14 7.14.1 7.15 7.15.1 7.15.2 7.15.3 7.15.4 8

Compiling and Downloading 8.1 8.2 8.3 8.4

9

11

How to Test with S7-PLCSIM ...................................................................... 9-2 How to Test a Plant During Operation......................................................... 9-3 How to Test Field Devices........................................................................... 9-4 10-1

Using the Version Cross Checker (VXC) .................................................. 10-2 How to Compare Project Versions ............................................................ 10-5

Archiving and Documenting 11.1 11.1.1 11.1.2 11.1.3 11.2 11.2.1 11.2.2

xvi

9-1

Comparing Project Versions with VXC 10.1 10.2

8-1

Requirements for Compiling and Downloading ........................................... 8-3 Downloading to All CPUs ............................................................................ 8-4 Options for Compiling and Downloading ..................................................... 8-8 Change Log ............................................................................................... 8-10

Testing 9.1 9.2 9.3

10

Import/Export of the Hardware Configuration.......................................... 7-291 How to Export a Station Configuration .................................................... 7-292 Structure and Content of the CFG File.................................................... 7-293 Expanding CFG Files .............................................................................. 7-295 How to Import a Station Configuration (First Import of an Entire Station) ............................................................ 7-297 How to Import an Expanded Import File (Extra Remote I/O, Field Device, Module)............................................... 7-298 How to Update an Imported Station Configuration (Change Attributes, Signal Assignments of Modules)............................. 7-299 Exporting to Synchronize with Planning Tools ........................................ 7-300 Configuring OS Functions ....................................................................... 7-301 Setting the AS/OS Lifebeat Monitoring.................................................... 7-304 Configuring BATCH Functions ................................................................ 7-306 Configuring the Interface to the Management Level (@PCS 7 and SIAMTIC IT) ..................................................................... 7-308 Configuring the Interface to the Management Level ............................... 7-308 Merging Projects after Distributed Editing (Multiproject Engineering)..... 7-309 How to Move Projects Edited on Distributed Stations to the Central Engineering Station .......................................................... 7-309 How to Merge Subnets from Different Projects into a Multiproject.......... 7-311 How to Merge Cross-Project Connections .............................................. 7-312 How to Configure New Cross-Project Connections between AS and OS ................................................................................ 7-313

11-1

Archiving/Retrieving Multiprojects and Project Master Data ..................... 11-2 How to Archive a Multiproject and the Project Master Data...................... 11-2 How to Retrieve a Multiproject and the Project Master Data .................... 11-3 Data Security and Backup ......................................................................... 11-3 Documentation .......................................................................................... 11-4 Creating Project Documentation ............................................................... 11-4 How to Convert Documentation to a PDF File .......................................... 11-4


Contents

12

Service 12.1 12.2 12.3

13

12-1 Diagnostics with a Maintenance Station.................................................... 12-1 Teleservice with PC Anywhere.................................................................. 12-3 Further Service Support and Diagnostics.................................................. 12-3

Appendix 13.1 13.2 13.3 13.4 13.5

13-1 Installation Guidelines for PCS 7............................................................... 13-1 Lightning Protection................................................................................... 13-4 Electrical Installation.................................................................................. 13-6 Basics of EMC-Compliant Installation of PCS 7...................................... 13-11 Degrees of Protection (Housing Protection)............................................ 13-13

Index


Index-1

xvii

Contents

xviii


1


1.1

Guidelines on Using the PCS 7 Documentation

1.1.1

Options for Accessing Documentation

Documentation for your support This section provides a global overview of the PCS 7 documentation that is available in addition to this manual. We differentiate between: •

PCS 7 system documentation: configuration manuals and introductory tutorials across the entire range of products providing a guideline for the complete system and explaining the interaction among the individual hardware and software components

•

PCS 7 product documentation: documentation for special hardware and software components providing detail information about these products

Access options The following options are available for accessing the PCS 7 documentation: •

PCS 7 computer: help menus in applications

•

PCS 7 computer: Windows Start menu

•

Internet: Customer Support (http://www.ad.siemens.com/meta/support)

•

Internet: at http://www.pcs7.de

•

Manual Collection "Process Control System PCS 7 – Electronic Manuals"

PCS 7 computer: help menus in applications Online help is available in the PCS 7 software through help menus of the individual applications. As of PCS 7 V6.0 SP3, SIMATIC Manager also offers access to: •

PCS 7 system documentation: menu command Help > Contents

•

PCS 7 Getting Started - Part 1: menu command Help > Getting Started


1-1


PCS 7 computer: Start menu All manuals (PDF) and readme files (WRI) for installed applications can be opened and printed from the Windows Start menu: •

Manual: menu command Start > Simatic > Documentation

•

Readme, What's new: menu command Start > Simatic > Product Information

Internet: Customer Support (ProdIS information system) You can download manuals and product information without charge from the Siemens Customer Support Internet site. The PCS 7 documentation is located in the following folders: •

System documentation: Product Information > Process automation > Process control systems > SIMATIC PCS 7 Process Control System > Electronic documentation

•

Product documentation: "Manuals" tab in the folders of the individual products

On the Internet: at http://www.pcs7.de The PCS 7 site provides convenient access to the complete PCS 7 documentation - the latest news about hardware and software components released for PCS 7 V6.1: •

http://www.pcs7.de > [Technical Documentation] > [Manuals V6.1]

Manual Collection "Process Control System PCS 7 – Electronic Manuals" Apart from the Internet, the entire PCS 7 V6.1 documentation is also available in a 3-language Manual Collection (German, English, French) with convenient navigation and text search functions. The Manual Collection is part of the DVD "Process Control System PCS 7 Engineering Toolset V 6.1" and can be copied from the DVD to your PCS 7 computer.

Preview Because the entire documentation of PCS 7 is extremely wide-ranging, you will find a guideline below that will help you to find the information you require during various phases:

1-2

•

Documentation for the planning phase

•

Documentation for the realization phase

•

Documentation for commissioning, operation, diagnostics and servicing



1.1.2

Documentation for the Planning Phase Below you will find the PCS 7 documentation that •

providing an overview of the systems and components for PCS 7 and

•

support for effectively planning your PCS 7 plant.

Documentation

Contents

Information about the range of services Catalog ST PCS 7

Ordering information and prices for all hardware and software components you may require for automating a PCS 7 plant

Catalog ST PCS 7.A

Ordering information and prices for SIMATIC PCS 7 add-ons that can be integrated in your PCS 7 plant to create a total solution

Interactive catalog CA 01

Catalog ST PCS 7 in electronic form

PCS 7 Product Brief

An introduction to the principles of communication and range of features in SIMATIC PCS 7; shows the technical possibilities and the suitable features for fulfilling you automation requirements.

Getting Started PCS 7 – First Steps

Uses a simple sample project to show you the fundamental procedures and the interaction of the software components of SIMATIC PCS 7 during engineering and in process operation. Time required for tutorial: approx. 1 hour

Selecting the components and systems for the PCS 7 plant Configuration manual Section "Engineering System": PCS 7 Engineering System • Capacity options in configuring a PCS 7 plant

Manual PC Configuration and Authorization

List PCS 7 - Released Modules

•

Selecting network components

•

Selecting PC components for engineering and operator control and monitoring

•

Selecting AS components

•

Selecting I/O components

•

Preparations for efficient engineering

Comprehensive overview of PC configurations for engineering and operator control and monitoring: •

Areas of application for the various PC configurations

•

Design and configuration of the PC networks

•

Required hardware and software for the PC components

•

Required authorizations and licenses

•

Installation instructions and settings for the operating system

•

Installation instructions and settings for PCS 7

List of modules released for PCS 7 versions


1-3


1.1.3

Documentation for the Realization Phase Below you will find the PCS 7 documentation that •

Provides support for the installation of the PCS 7 software

•

Provides support for configuring the wiring of the hardware

•

Explains the basic concept of engineering with PCS 7

•

Aids you in full configuration of your PCS 7 plant

Documentation

Contents

Installation PCS 7 readme

Latest information with notes about installation and using PCS 7 software

PCS 7 What's new?

Compact summary of the new or changed features in PCS 7 in comparison to previous versions

Manual PC Configuration and Authorization

Comprehensive overview of PC configurations for engineering and operator control and monitoring: • Which PC configuration can be used for specific purposes? • How can the PC network be designed and configured? • Which software and hardware are needed for specific PC components? • Which authorizations and licenses are required for the individual products? • Installation instructions and settings for the operating system and PCS 7 software

Configuration of components and systems Configuration Manual Section "Structuring a PCS 7 Project": PCS 7 Engineering System • Basic configurations of a PCS 7 plant • Guideline in the installation instructions for the productsauanleitungen der Produkte • Special considerations, differences between PCS 7 and specifications in the installation instructions of the productsauanleitungen der Produkte • Rules for plant changes during ongoing operation (CiR) • Configuration guidelines PCS 7: EMC and lightning protection Manuals for the automation • system S7-400H/FH • • • • Manuals for S7-300 I/O Modules

• •

Manuals for CPs and FMs (S7-400, S7-300)

• •

Manuals for ET 200 components ET 200M, ET 200S, ET 200iSP

•

Manuals for additional DP components: Diagnostic Repeater, DP/PA Link/Y Link, DP/AS-i Link

•

1-4

•

•

Instructions for configuring automation systems Memory concept and startup scenarios Cycle and reaction times of the S7-400 Technical specifications Operation lists Manual for hardware configuration and parameter assignment of components Technical specifications Manual for hardware configuration and parameter assignment of components Technical specifications Manual for hardware configuration and parameter assignment of components Technical specifications Manual for hardware configuration and parameter assignment of components Technical specifications



Documentation

Contents

Manuals for Industrial Ethernet and PROFIBUS networks

• •

Topologies and Network Configuration Configuration of the communication

Manuals for SIMATIC NET • components: CPs for • Industrial Ethernet and • PROFIBUS, OSM/ESM ...

Topologies and Network Configuration Installation instructions Technical specifications

Engineering Getting Started PCS 7 Part 1 (with video sequences)

Introduction to the basic functions of PCS 7 based on the PCS 7 project "COLOR". Contains the most important background information required to understand the individual engineering tasks and detailed instructions for step-by-step retro-engineering. On completion of configuration, the OS can be put into process mode. We recommend working through this Getting Started tutorial before beginning work with the PCS 7 Engineering System configuration manual. Time required for tutorial: approx. 16 hour

Getting Started PCS 7 Part 2 (with video sequences)

Introduction to using the functions for efficient engineering from PCS 7. This is based on the PCS 7 "COLOR" project configured in Getting Started PCS 7 - Part 1. PCS 7 Project "COLOR". We recommend working through this Getting Started tutorial if you plan to configure a large PCS 7 plant with a large number of process tags. Time required for tutorial: approx. 16 hour

Manual Software Update Without Using New Functions

Step-by step instructions on converting your PCS 7 project from PCS 7 V6.0 to V6.1 without subsequent use of the new functions of PCS 7 V6.1.

Manual SW-Update With Using New Functions

Step-by step instructions on converting your PCS 7 project from PCS 7 V6.0 to V6.1 and subsequently using the new functions of PCS 7 V6.1.

Manual Brief Instructions Describes how to update software from PCS 7 versions V5.1/V5.2 to V6.1. on Updating Software This documentation guides through the steps in the manuals for a software PCS 7 V5.1/V5.2 to PCS 7 update from V5.x to V6.0 and a software update from V6.0 to V6.1. V6.1 Configuration Manual Sections for configuring the engineering system: PCS 7 Engineering System • Basic concepts of engineering • Configuration of the engineering system • Creating the PCS 7 configuration • Compiling, downloading, testing, archiving and documenting project data Configuration manual PCS 7 Operator Station

Complete information about configuring the PCS 7 operator station, the HMI system of PCS 7: • Configuring OS data • Creating process pictures • Settings in the alarm system • Options for archiving • Downloading and project and configuration changes • Time synchronization and lifebeat monitoring • Using server-server communication • Using diagnostic functions (maintenance station)

Manual PCS 7 OS Web Option

•

Using the Web client


1-5


Documentation

Contents

Configuration Manual PCS 7 BATCH

Complete information about configuring the PCS 7 BATCH station, the system for automating batch processes: • Technological basis according to ISA S88.01 • Configuring batch plant data • Creating recipes • Planning and controlling batches • Managing and archiving batch data

Manual PCS 7 Faulttolerant Process Control Systems

Informs you about the basic solution concept, the method of operation and the most important configurations to be made when building fault-tolerant systems using the SIMATIC PCS 7 process control system. It presents faulttolerant solutions on all automation levels (control, process, field).

Manual PCS 7 10 ms Time Comprehensive overview of required components, the interaction among the components and their configuration for using 10 ms time stamps Stamps Manual PCS 7 Library

Description of method of operation, block I/Os and input/output field of the respective faceplates

Manual PCS 7 Programming Instructions Blocks

Explanation of how AS blocks and faceplates conforming to PCS 7can be created to ... • Monitor parameter values through a faceplate • Control parameter values and therefore the reactions of blocks through a faceplate • Report asynchronously occurring events and block states on the OS and display them in a faceplate or a WinCC message list

Manual PCS 7 Programming Instructions Driver Blocks

Help in creating driver blocks conforming to the system to fully exploit the functions in PCS 7 (not included with PCS 7; must be ordered extra from the PCS 7 Catalog)

@PCS 7

Configuring and using the PCS 7 interface for the plant operations level

Manuals for the individual engineering tools: CFC, SFC, STEP 7, SFC Visualization, PDM, WinCC, LT Options, SCL, DOCPRO

• • •

Basics of the engineering tool Working with the engineering tool Testing and commissioning the engineering tool

Readme and What's New for the individual engineering tools: CFC, SFC, STEP 7, SFC Visualization, PDM, SCL, DOCPRO

• •

Latest information with notes about installation of the engineering tool Compact summary of the new or changed features in comparison to previous versions

1-6



1.1.4

Documentation for Commissioning, Operation, Diagnostics and Servicing The following PCS 7 documentation contains information about •

Commissioning and operating in process mode

•

Support and performing servicing tasks

Documentation

Contents

Process Mode Manual PCS 7 OS Process • Control

Graphical user interface and operator input at the PCS 7 OS in process mode: -

Alarm system

-

Trend system

-

Group display

-

Controlling the process

•

Working at the maintenance station

Manual PCS 7 OS Web Option

•

Working with a Web client

Configuration Manual PCS 7 BATCH

•

Batch control

•

Managing and archiving batch data

Manual Service Support and Diagnostics

This manual is intended for trained service personnel (Service Level 1): PCS 7 users and SIMATIC S7 specialists The manual contains information providing support for: •

Ensuring the availability of your PCS 7 plant

•

Understanding the alarm concept of your PCS 7 plant

•

Finding the right diagnostic tools when a fault occurs

•

Using the right procedure when a fault occurs and providing qualified, detailed information about the state of the PCS 7 plant to service experts

Manuals for the automation • system S7-400H/FH •

Commissioning Maintenance

Manuals for CPs and FMs (S7-400, S7-300)

•

Diagnostics

Manuals for ET 200 components ET 200M, ET 200S, ET 200iSP

•

Commissioning

•

Diagnostics

•

Maintenance

Manuals for additional DP components: Diagnostic Repeater, DP/PA Link/Y Link, DP/AS-i Link

•

Commissioning

•

Diagnostics

Manual Programming with STEP 7

•

Hardware diagnostics and troubleshooting


1-7


1.2

Guide through the ES Configuration Manual

1.2.1

Guide to the PCS 7 Engineering System Configuration Manual

Basic Layout of the Configuration Manual for the PCS 7 Engineering System The PCS 7 engineering system configuration manual is divided into three sections: Section

Phase

Selecting the components and systems for the PCS 7 plant Planning the plant engineering

This contains all the information that you need to select the right systems and components based on the requirements of your PCS 7 plant. You are provided with a comprehensive overview of the configuration options for automation systems, distributed I/Os, bus systems and networks for PCS 7.

Configuration of components and systems Configuration of PCS 7 plants

A guide to manuals containing configuration instructions for the hardware components. You are also provided with notes and information about the ways in which PCS 7 deviates from other SIMATIC applications.

Engineering Basic Concepts of Engineering

This provides an introduction to the requirements for efficient engineering with PCS 7 (for example, type-defining, reusability, central editing).

Configuration of the PCS 7 engineering system

Introduction to the structure and use of the engineering software from PCS 7

Creating the PCS 7 configuration

Complete configuration of a PCS 7 project based on step-by-step instructions, contexts and background information.

Compiling and downloading

Information about how configuration data is compiled and downloaded to the PLCs (AS, OS, BATCH).

Testing

This section also provides and overview of the most important testing features prior to commissioning.

Comparing project versions

This offers instruction on how to use the Version Cross Checker to version and compare various project states.

Archiving and documenting

Information about data security and backing up project data

1-8


2


2.1

Structure of a PCS 7 Plant

PCS 7 - The Process Control System for Totally Integrated Automation As the process control system in the company-wide automation network called Totally Integrated Automation, SIMATIC PCS 7® uses selected standard hardware and software components from the TIA building block system. Its uniform data management, communication and configuration offer an open platform for modern, future-oriented and economical automation solutions in all sectors of the process industry, production industry and hybrid industry (mixture of continuous/batch processes and discrete production, e.g. in the glass or pharmaceuticals industries). Within the TIA network, SIMATIC PCS 7 not only handles standard process engineering tasks, it can also automate secondary processes (e.g. filling, packaging) or input/output logistics (e.g. material flows, storage) for a production location. By linking the automation level to the IT world, the process data become available throughout the company for the evaluation, planning, coordination and optimization of operational sequences, production processes and commercial processes.

Basic structure of a PCS 7 plant The modular architecture of SIMATIC PCS 7 is based on selected hardware and software components from the standard range of SIMATIC programs. The SIMATIC PCS 7 process control system can be seamlessly incorporated into the company-wide information network using interfaces based on international industrial standards for data exchange such as Ethernet, TCP/IP, OPC or @aGlance.


2-1


@

SIMATIC PCS 7

1

OS 4 Combined Single Station Engineering/ (Multi-VGA) Operator Station 4

PCS 7 BOX

2

3 4

Engineering Station Maintenance Station SIMATIC PDM Engineering Toolset

5

OS Clients

BATCH Clients

SIMATIC IT Framework Components

@PCS 7/OPC Server 6

Terminal Bus Industrial Ethernet Archive Server BATCH Server

OS Server 4

PROFIBUS DP

Plant Plant Information Maintenance

4

5

Industrial

Plant Bus Industrial Ethernet

INTERFACE

DP/EIB Link 00

00

00 7 00

s 6GK1415-0AA00 instabus EIB Power

00

PROFIBUS Addr.

DP/EIB-Link

DP/BF EIB/BF

24V

EIB

Phys. Adr.

instabus EIB

ET 200M Ex I/O HART

OP

PROFIBUS PA

Ex

DP/PA Link

7

Fault-tolerant Automation Systems

Fail-safe Automation Systems ET 200M Fail-safe

PROFIBUS DP

DP/AS Interface Link

PROFIBUS DP

Standard Automation Systems

OS

ET 200M

DP/PA Link

PROFIBUS DP/iS

8

ET 200M with CP 341

PROFIBUS DP

3

Internet/ Intranet

4

Ethernet

3

MODBUS, serial link, ... 9 DP/PA Link PROFIBUS PA

Y Link

PROFIBUS PA

0 1

S

ET 200iSP

o CAL oLIM oAR

o CODE

63,29 36,72 +/-

7

8

9

.

4

5

6

0

1

2

3

Clear

ESC

Enter

MEAS

Info

ULTRAMAT 6

P RO F I

Zone 1

PROCESS FIELD BUS

Zone 2

BUS

The system/components of PCS 7 No. 1

System/ components

Description

Additional section in this manual

@PCS 7

Processes can be monitored from anywhere around • the world per Intranet or Internet using the @PCS 7 server and the corresponding Web@aGlance / IT client.

Connecting to the IT World with @PCS 7

Upstream information systems featuring an @aGlance interface can be also connected to SIMATIC PCS 7 using @PCS 7. OPC can also be used as an interface to SIMATIC PCS 7. 2

2-2

SIMATIC IT Framework

SIMATIC PCS 7 can be integrated into the • company-wide information network with SIMATIC IT Framework.

Connecting to the IT World - SIMATIC IT Framework



No.

System/ components

Description


3

Engineering station

PC station with PCS 7 Engineering Toolset for centralized plant-wide engineering:

•

Installing the Engineering Station

•

Configuration of the hardware

•

•

Configuration of communication networks

Preconfigured PCS 7 Systems (Bundles)

•

Configuration of continuous and sequential process sequences using standard tools

•

•

Configuration of discontinuous process sequences (batch processes) with BATCH

Including Objects/Functions for Efficient Engineering in the Planning

•

Operator control and monitoring strategies

•

Compiling, downloading of all configuration data to the automation system (AS), operator station (OS), and BATCH station •

Further Service Support and Diagnostics

•

Installing Operator Stations

•


•

Installing the Engineering Station

•

Installing Operator Stations

•


•

BATCH Station Configurations

The communication between the servers (OS, BATCH)

•

Communication within PCS 7

•

•

Management Level Scheme with Ethernet

•

Communication within PCS 7

•


Maintenance station

PC station for checking the status of all PCS 7 components in hierarchically structured diagnostic pictures. A maintenance station can be set up in an MS client/MS server architecture. The diagnostics client is operated ideally on an engineering station.

4

Operator station

PC station with human-machine interface for operating and monitoring of your PCS 7 plant in process mode An operator station can be configured as a singleworkstation or multiple-workstation system with OS client / OS server architecture. For operator stations, it is also possible to use a central archive server on a separate PC station. The archive server is a node on the terminal bus.

(3 + 4) PCS 7 Box

PCS 7 Box is an industrial PC with integrated AS/ES/OS station. PCS 7 Box is used for autonomous small plants or combined AS/OS stations that can be integrated in the PCS 7 network. It allows centralized engineering.

5

BATCH station

PC station for operation and monitoring of discontinuous process sequences (batch processes) A BATCH station can be configured as a singleworkstation or multiple-workstation system with BATCH client / BATCH server architecture.

6

Terminal bus

and the engineering station is performed over the terminal bus.

Note: Single stations in all systems (ES, OS, BATCH) can have a connection to the terminal bus. 7

Plant bus

The plant bus is used for communication between • •

the servers (OS) and the automation systems (AS) the automation systems (SIMATIC connections)


2-3


No.

System/ components

Description


8

Automation sierungssystem

The automation system

•

What Are the Criteria for Selecting the AS?

•

Field Level Scheme with PROFIBUS

•

Which Devices Can Be Connected as Distributed Components?

•

Data Links to Other Systems

9

I/O / field bus

•

registers the process variables

•

processes the data according to the instructions in the user program

•

issues control instructions and setpoints to the process

•

supplies the operator station with the data for visualization

•

registers actions on the operator station and forwards them to the process

Connects classic and intelligent field devices. Intelligent field devices are connected by HART or PROFIBUS communication. The following can also be connected: •

Simple actuators and sensors via an AS interface

•

Components in building automation via an instabus EIB

•

Components with Modbus interface

Additional information – PCS 7 Product Brief If you are interested in additional introductory information about PCS 7, read our product brief for the PCS 7 process control system. It contains comprehensive information about the principles of communication and the range of features in SIMATIC PCS 7 as well as the technical possibilities and suitable functions for fulfilling your automation requirements. The following sections in this manual are based on the information in the PCS 7 Product Brief.

2-4


3


3.1

Before Beginning the Engineering The following is an overview with questions you should carefully work through to efficiently plan your plant. Under the heading "Related sections in this manual", you can jump to sections with further information and overviews that should help you to answer these questions.

Question

Related sections in this manual

What documentation is required?

Processing phase in which Quick location of • the documentation is sought after information needed: • • Planning

Options for Accessing Documentation

•

Configuration

•

•

Commissioning

Documentation for the Realization Phase

•

Documentation for Commissioning, Operation, Diagnostics and Servicing

•

Guide to PCS 7 Engineering System Configuration Manual

Selecting systems and determining requirements for the components

•

How to Find the Right Components

•

The Important Criteria for Selecting Components

•

Creating the plant hierarchy

•

•

Determining the areas; supporting • areas, for example the analysis of faults during plant • operation

How Many Process Objects Can Be Handled in a Project?

How should the plant be controlled and how should it react to disruptions?

What areas are contained in the plant?

•

Process types: continuous or discontinuous operation

•

Degree of automation

•

Controllability (central/local)

•

Availability

•

Technological areas

•

Type of systems

•

Local factors

Required knowledge for ...


•


Documentation for the Planning Phase

How Many Devices, Sensors and Actuators Can Be Integrated? How Many CPUs Are Needed for the Automation? What Sources Can Be Used in Planning the Plant Design?

3-1


Question

Related sections in this manual

Which components Configuring signal paths should be used?

Required knowledge for ...


Determining

•

Which Networks / Bus Systems Are Used for Communication?

•

What Are the Expansion Limits?

•

Which PC Components Can Be Used?

•

How Can the Plant be Protected Against Unauthorized Access?

•

Bus systems and conventional cabling

•

Transmission rates

•

Limits to distances

PC components (operator Determining control, monitoring, • Numbers of units configuration systems) • Availability

What preparations can be made for efficient engineering?

How can servicing be implemented in the PCS 7 plant?

3-2

•

Data security

•

Change documentation (validation)

•

How Can the Process Management Be Verified?

•

How Can Project and Process Data Be Archived and Compared?

Automation systems Determining (performance and areas of • Number of AS application) • Availability Planned or existing I/O • Failure safety devices, sensors and • Ex protection actuators

•

What Are the Criteria for Selecting the AS?

•


•

Number of process tags

•

Number and distribution of workplaces for engineering

•

Starting preparations for servicing

•

Planning diagnostics

•

Using diagnostic tools

•

Employed modules and software

•

Planning the engineering environment

•


•

Use of multiprojects and the Import/Export Assistant

•

Which Data and Data Formats Can Be Imported?

•

Use of appropriate resources to create lists (e.g. process tag lists)

Planning service What Service Support Does support and diagnostics SIEMENS Offer for PCS 7?



3.2

Components of a PCS 7 Plant

3.2.1

How to Find the Right Components PCS 7 offers a wide range of possibilities for realizing automation tasks. The large selection and variety of components enables you to •

Use appropriate components to fulfill special requirements

•

Select components that can be exactly configured to meet specific requirements

The following table lists optimally matched systems, components and functions for specific process control requirements.

Selecting systems, components and functions Select the systems, components and functions based on the requirements of your PCS 7 plant: Requirements

Specification

System, component, function for PCS 7

Check √

Process mode - OS Operation and monitoring Operation and monitoring in process mode

PCS 7 operator station with WinCC software

Lifebeat monitoring

Monitors systems connected on the terminal bus and plant bus

"Lifebeat monitoring" function of WinCC

Time-of-day synchronization

Central time synchronization from systems connected on the terminal bus, plant bus and field bus

Function "time synchronization" from WinCC

Long-term data acquisition

Using archive systems

Archive systems of WinCC

Controlling and operating Graphically displaying and operating sequential control configured sequential control systems systems

SFC visualization

Access protection

Central user administration, access protection and electronic signatures

SIMATIC Logon with electronic signature

Batch processes

Controlling discontinuous processes

SIMATIC BATCH

Swapping out process data

Viewing swapped out process data

StoragePlus

Process mode – AS and I/O Availability

Using fault-tolerant automation systems

S7-400H + Distributed I/Os (ET 200M, ET 200iSP)

Failure safety

Using fail-safe automation systems

S7-400F + Distributed I/Os (ET 200M, ET 200S)

Availability and failure safety

Using fault-tolerant and fail-safe automation systems simultaneously


S7-400FH + Distributed I/Os (ET 200M)

3-3


Requirements

Specification


Control modes

Modules with controller functions

S7-400 FM

Distributed I/O system

Connecting field device via PROFIBUSDP depending on the protection level, connections and Ex zone

ET 200M with S7-300 signal modules, CPs, FMs, HART and fail-safe S7-300 signal modules

Check √

ET 200S with electronic modules and fail-safe power modules ET 200iSP with electronic modules, HART e.g. Diagnostic Repeaters

Diagnostics (with hardware components)

Simple diagnostics for communication errors in PROFIBUS DP lines

Diagnostics (with software components)

Using and activating the PCS 7 diagnostic functions

Ex zone

Special I/O components for use in hazardous areas (zones 1 or 2)

S7-300-Ex I/O modules, ET 200iSP

Plant modifications

Changing the system during operation

CiR

"Further Service Support and Diagnostics" e.g. NCM S7 PROFIBUS Diagnostics

For more detailed information, refer to the section "Further Service Support and Diagnostics"

Process mode – communication/connection Terminal bus, plant bus

Ethernet

Support for communication through network components such as CPs, bus links etc.

Network components of SIMATIC NET

Connecting AS

Connecting automation systems to the plant bus

CP 443-1

Connecting OS/BATCH

Connecting PCS 7 operator/BATCH stations to the terminal bus or plant bus

CP 1612, CP 1613, CP 1512 or other Ethernet adapter

Connecting ES

Connecting the PCS 7 engineering station to the terminal bus or plant bus

CP 1612, CP 1613, CP 1512 or other Ethernet adapter

Point-to-point coupling

Communication between the AS and other stations via point-to-point link

S7-400 CPs

Communication (network)

S7-300 CPs (in ET 200M)

Sensors and actuators

Connecting actuators and sensors

PROFIBUS PA

Intelligent field devices

Connecting intelligent field devices with HART and PROFIBUS communication

PROFIBUS DP/PA

Coupling DP/PA

Gateway between PROFIBUS DP and PROFIBUS DP

DP/PA coupler DP/PA Link

Non-redundant PROFIBUS DP devices

Connecting non-redundant PROFIBUS Y Link DP devices to redundant PROFIBUS DP

3-4



Requirements

Specification


Check √

Engineering Scalability

Licenses for various numbers of process License objects

Basic engineering

Basic engineering of hardware, communication

STEP 7 with HW Config, NetPro

Continuous automation functions

Graphical configuration of automation functions

CFC

Discontinuous automation functions

SFC Graphical configuration of sequential control systems with stepping conditions

Repeatedly used technological functions

Using the PCS 7 library

Library PCS 7

User function blocks, custom

Creating custom user function blocks based on IEC 61131-3

SCL

Batch processes

Configuring recipes and batches (production jobs)

SIMATIC BATCH

Availability with S7-400H

Engineering for redundant automation systems

S7 H Systems

Failure safety with S7-400F

F programming tools with F function blocks

Optional package S7 F Systems

Controller optimization

System-aided optimization of control circuits with PCS 7

PCS 7 PID Tuner

Plant pictures for PCS 7 OS

Creation of plant pictures for the OS in process mode and interconnection of picture objects with process tags (dynamic display)

Graphics Designer from WinCC

Faceplates for PCS 7 OS

Creating faceplates for PCS 7 OS process pictures

Faceplate Designer

Intelligent field devices

Configuration, parameter assignment and commissioning of field devices

SIMATIC PDM

Functions for efficient engineering

Multiproject, SFC type, process tag type, models, process object view

Efficient engineering

Mass data processing

•

Working with the several project engineers

•

Type definitions with reusability and centralized modification capability

Creating •

Process tags from process tag types

•

Storing models

Import/Export Assistant

Comparing project versions

Determining differences between various Version Cross Checker (VXC) versions of a project

Versioning

Versioning of multiprojects, projects or libraries

Version Trail

Testing

Functional testing of the configuration with a simulated SIMATIC S7 station

PLC-SIM

Plant documentation

Documenting plants in PCS 7 projects in DOCPRO conformance with standards


3-5


Further information

3-6

•

Section "Capacity Options in Configuring a PCS 7 plant"

•

Section "Selecting network components"

•

Section "Selecting PC Components for ES, OS, BATCH and IT"

•

Section "Selecting AS components"

•

Section "Selecting I/O components"

•

Section "Preparations for Efficient Engineering"



3.2.2

Important Criteria for Selecting Components The selection of components for a process control system involves a variety of factors. The most important are: •

The type of process (continuous or discontinuous)

•

The reaction of a plant to disruptions (availability and safe state)

Type of process •

Continuous process Process sequence in plants in which "the same product" is produced "unchanged" (e.g. water desalination plants). Such processes can be automated by PCS 7 using sequential control charts (SFC). The automation can implemented for small plant units as well as for the entire plant.

•

Discontinuous process Process sequence in plants in which "different products" are produced (e.g. various recipes for producing tablets or mixing paints). Such processes can be automated by PCS 7 using SIMATIC BATCH. With the recipe-based control strategies in SIMATIC BATCH, the process sequences of a PCS 7 plant can be flexibly adapted to changing products, material properties, plant conditions, product stages, etc.

Reaction of a plant to disruptions (availability and safe state) The consequences of disruptions are often difficult to judge. Planned reactions to faults are therefore very important. This can be achieved by: •

Using fault-tolerant components

•

Using fail-safe components

•

Using fault-tolerant and fail-safe components

•

Implementing the appropriate configuration measures, for example: -

Interlocks between measuring points (defining targeted response in the system)

-

Sequential control charts for startup and shutdown (automatic control of entire systems)

-

Higher-level calculation and management functions (reacting directly to the effects of an event)

-

Control functions for targeted control of units and plants (e.g. control using fail-safe systems in a defined state)

Further information •

Section "Selecting fault-tolerant and fail-safe components"

•

Manual Process Control System PCS 7; Fault-tolerant Process Control Systems


3-7


3.2.3

With Which "Third-party Systems" Can PCS 7 Communicate?

Communication with "Third-party Systems" You can link up with numerous systems within the framework of Totally Integrated Automation with PCS 7 (TIA components can be used in PCS 7 without additional applications): •

Administration level and remote access PCS 7 can be seamlessly incorporated into the company-wide information network using standardized interfaces for data exchange such as Ethernet, OPC and @aGlance (@PCS 7). This makes process data available at any time and at any location throughout the company

•

Data links to other communication systems Communication can also be established using adapters for: -

instabus EIB AS interface MODBUS

Note Please contact your Siemens representative for more information about communication options.

Selecting components Select the components that you need for the data link to the third-party systems: Requirements

Specification


Process mode – communication/connection IT world PCS 7 can be integrated in SIMATIC IT Framework with an adapter.

SIMATIC IT

Access to MIS/MES process data

Company-wide access to process data in PCS 7 based on @aGlance or OPC

@PCS 7 (@aGlance) or OPC from WinCC

Simple actuators and sensors

Connection of simple (usually binary) actuators and sensors on the lowest field level Used to connect components in building automation Used to connect components with the Modbus interface

AS-i Link

Configuration, parameter assignment and commissioning

HW Config or specific component software

Building automation MODBUS devices Engineering Links and couplers

Check √

DP/EIB link CP 341 with MODBUS driver

Further information

3-8

•

Section "Administration Level and Remote Access"

•

Section "Data Links to Other Communication Systems" Process Control System PCS 7 - Engineering System A5E00346923-02


3.2.4

How Can the Plant Be Protected Against Unauthorized Access?

Protection against unauthorized access in an automated plant A great number of components are networked together in modern industrial plants. A variety of bus systems and protocols (such as TCP/IP, COM/ DCOM etc.) are used to form the network. In networked automated plants, it is important to protect against unauthorized access to the plant, for example from "office networks", and thereby ensure that there are no negative effects on the plant.

Plant protection in PCS 7 In addition to the standard resources from Windows (user logon) and the usual network components (bridges and firewalls), PCS 7 provides a variety of options to prevent unauthorized access in a plant.

Selecting components and functions Select the components/functions from PCS 7 that you need for access protection: Requirements

Specification

Operator permissions for Access protection using smartcards the PCS 7 OS containing operator permissions Configuring operator permissions


Check √

Smartcard reader Function "User administrator" from WinCC

Central user management in PCS 7 User management with User management with access access protection control protection control for engineering and process mode, determination of application-specific user roles for engineering and operator control and monitoring

SIMATIC Logon

Access protection on the Password protected access to tasks for AS changing data in the automation system (user program, HW Config)

Function "Password protected access to the CPU" from STEP 7

Electronic signature

Electronic signature based on SIMATIC Logon

Password protected execution of functions, e.g. for controlling batches with BATCH


3-9


Principle of central user management with SIMATIC Logon SIMATIC Logon from PCS 7 is based on the basic user management mechanism in Windows: 1. Users and user groups (available on the relevant Windows server) and passwords are defined centrally in Windows. 2. The definition of user roles for the engineering system, operator station and BATCH station and their assignment to defined Windows user groups is performed with the SIMATIC Logon software. 3. Additional limits to user roles and user rights can be defined within the application. For example, the following can be specified in SIMATIC BATCH: -

Limits to the user rights in a user role (global)

-

Permitted user roles per computer (for each specific computer)

-

Permitted user roles per plant unit (for each specific unit)

Response in active operation: The components contained in PCS 7 are supplied with the data for the user currently logging on via the central logon service and are informed about changing logons.

Principle of electronic signatures PCS 7 supports the "electronic signature" function conforming to FDA or 21 CFR Part 11 requirements. The engineering contains definitions of the actions or conditional transitions of objects that should be activated by the "electronic signature" function based on the user role. When such an event occurs, there is a dialog prompt for one or more signatures based on the usual logon dialog in Windows. Requirements: The SIMATIC Logon Service software verifies the login data. This means that the SIMATIC Logon Service must be installed on the PC in order to use the "electronic signature" function.

3-10



3.2.5

How Can the Process Management Be Verified?

What is the purpose of process and process management verification? Legal and business requirements play a decisive role for many plants, especially in regard to: •

Verifying conformity to quality standards

•

Documenting the status of a plant

•

Verifying that only authorized personnel have access to the plant and verifying the operator input

•

Verifying that only authorized personnel can make changes to the plant

An additional requirement for a process control system is often complete automatic documentation of all critical plant data and process operation in an automated plant.

Food & Drug Administration (FDA) The US Food & Drug Administration (FDA) has defined guidelines for these areas. The GMP laws 21 CFR Part 210, 211, 11 are based on these guidelines. The most important, internationally valid requirements for automation engineering (in regard to validation) are summarized in 21 CFR Part 11.

Validation with PCS 7 in conformity to 21 CFR Part 11 PCS 7 and SIMATIC BATCH support validation in conformity to 21 CFR Part 11.


3-11


Selecting components and functions Select the components/functions from PCS 7 that you need for validating the process management: Requirements

Specification

Logging of performed modifications

Logging of protected actions


BATCH: Logging of any change to •

recipes

•

user rights BATCH recipe log

BATCH: Logging of any changes during batch production (including operator input)

BATCH batch log

ES: Logging of

ES change log

Entire program or changes to the CPU

•

Switchover to test mode (CFC, SFC)

√

BATCH change log

BATCH: Logging of recipes

•

Check

Logging of delete actions BATCH: Documentation of all delete actions in a separate log

BATCH log

Versioning

BATCH: Versioning recipes, recipe operations and formulas

Automatically when a new batch object is created

System access

Central user management based on Windows

SIMATIC Logon

User identification

The log book is automatically amended with the identification of the user.

Automatic in the change logs

Electronic signature

Password protected execution of functions, e.g. for controlling batches with BATCH

Electronic signature based on SIMATIC Logon

Logging of electronic signatures

BATCH: Documentation of the performed electronic signatures

Automatically in the recipe/batch log and in the log book BATCH

Consistency of the AS codes

Version comparison of engineering data with graphic display of differences

Version Cross Checker (VXC)

Logging of AS access

Logging of changes made in the AS

Access protection with SIMATIC Logon Logging with the Change log

Proof for validation

BATCH: Logs and archives - completed batches can be archived in the XML format

Function "Archiving a Batch" in BATCH

Further information

3-12

•

Manual Process Control System PCS 7; SIMATIC BATCH

•

Online help Version Cross Checker

•

Online help SIMATIC Logon and Electronic Signature



3.2.6

How Can Project and Process Data be Archived? SIMATIC PCS 7 provides a variety of functions for archiving project data and process values.

Archiving of project data The central database organization for plant-wide configuration data is performed on the engineering system. To avoid loss of data, it is recommended to regularly backup your project. Archiving involves saving configuration data in the compressed form of an archive file. This is possible on the hard disk or transportable data media (for example CD, DVD). You can select the required archiving tool in the SIMATIC Manager. Tip: Use the Version Cross Checker to determine differences between various versions of a project.

Archiving of process data Process data (measured values and alarms) can be saved in the following archives: •

WinCC archives These are "circular" archives, meaning that the archives have a certain limited capacity. As soon as the maximum capacity has been reached, the oldest values are deleted so that further new values can be saved. This corresponds to the FiFo principle. To avoid loss of these oldest values, you can swap out these archives (see "Swapping out Archived Information".

•

BATCH archives Batch data archiving in the XML format: Batch data accessible to authorized personnel or systems can be saved in the XML format. These archives are used for long-term storage of batch data as required by the FDA.


3-13


Components, functions for archiving Archiving of

Specification


Configuration data

Function "Archiving" in the The multiproject can be archived with all projects and the master data SIMATIC Manager from STEP 7 library.

Process data (in circular archives)

The operator station saves measured values and alarms in archives to be able to have access to the data over a long period of time.

Batch data

The batch logs of completed batches can be archived: •

in XML format

•

in a database

√

WinCC archives

WinCC archives must be configured • and adapted with editors from • WinCC. • SIMATIC PC station as a central archive server (WinCC)

Check

Tag logging: Process values Alarm Logging: Alarms Report Designer: Print layout

•

Central archive server with integrated StoragePlus

•

Tag logging, alarm logging

Function "Archiving Batches" in SIMATIC BATCH

Swapping out archived information You can swap out the information (tag and alarm logs) in OS archives to external media (e.g. CD, DVD).

Note Swapped out OS archives can be viewed with the software product StoragePlus (optional package).

Further information

3-14

•

Section "Archiving/Retrieving Multiprojects and Project Master Data"

•

Manual Process Control System PCS 7; Operator Station

•




3.2.7

What Sources Can Be Used in Planning the Plant Design?

What is a plant design? A plant design involves •

Construction and arrangement of plant areas, the methods and location used and

•

The capability it should have.

Planning the plant design Note No general recommendations can be made for the plant design. The designs involved in engineering a plant for process automation depend on: •

Laws, standard specifications, norms

•

Process and production engineering factors

•

Local conditions (location, expansion possibilities, environmental conditions, etc.)

•

Miscellaneous requirements (such as the sensors and actuators employed).


3-15


Sources for planning the plant design You can gather important information from the following sources: Source

Topic

Description of process

•

Type of process engineering Plant (e.g. power station):

•

Type of location

•

•

Central/distributed configuration of automation systems

Plant with subunits (e.g. heating unit with burner control)

•

Relationship of units to the entire process (e.g. failure of unit = failure of plant or reduced quality/performance)

•

Information about hazards (e.g. danger of explosive gasses)

•

•

Process tag lists

Example

Central/distributed configuration of HMI systems

Number of workplaces depending on the degree of • automation

Central or distributed configuration possible; note in this regard:

•

Information about units (e.g. pressure control) and components (e.g. pressure sensor, pumps, valves) Types of sensors and actuators and their technical parameters - for examples:

•

Distance and distribution

-

Fill level sensor: 0 to 20 l

•

Maintenance

-

•

Environment (e.g. Ex zone, local operator input, heat, dust)

Pumps: with motor, temperature sensor, overload protection

-

•

Configuration, operating and • monitoring

Valves: with drive and position feedback signal

•

Process tag types

Planned location of the sensors/actuators in the plant

•

Signal from sensors and actuators: acquisition and processing in an automation system

•

Process tag assignment to a process tag type (e.g. "fill level")

Importing data for the engineering Electronic plant information can be imported into the engineering system to display the plant structure in PCS 7: process tag information, plant pictures etc.

Further information

3-16

•

Section "Capacity Options in Configuring a PCS 7 plant"

•

Section Which Data and Data Formats Can be Imported?



3.2.8

What Service Support Does SIEMENS Offer for PCS 7? The following table shows the services offered by Siemens for PCS 7 plants: Service

Description

Availability

Helpline

You are not sure whom you should contact. You will be directed to the right specialists in your area.

Tel.: +49 (0) 180 50 50 111

Online support

An information system in the Internet http://www.siemens.de/automa covering the topics Product Support, tion/service&support Services & Support and SupportTools Helpful programs and software products about SIMATIC Card

Technical support

Technical telephone support:

Europe:

•

Tel.: +49 (0) 180 50 50 222

FREE CONTACT (free of charge)

Fax. +49 (0) 180 50 50 223 E-mail: [email protected]

•

Field service

FAST CONTACT (charge): with Tel.: +49 (0)911 895 7777 guaranteed return of call within Fax. +49 (0)911 895 7001 the next two hours

Fast local help

Tel.: +49 (0) 180 50 50 444

Personalized service contracts Replacement parts

Replacement parts and repairs


Tel.: +49 (0) 180 50 50 448

3-17


3.3

Capacity Options for Configuring a PCS 7 Plant

3.3.1

How Can PCS 7 Be Scaled?

Scalability SIMATIC PCS 7 can be flexibly adapted in a variety of ways for different plant requirements and sizes. Add-ons and reconfiguration are no problem if the plant is later expanded or technological changes are made. SIMATIC PCS 7 covers all plant sizes. Depending on the requirements, for example, you can: •

Select a variety of powerful automation systems: -

from applications with few control tasks (for example with SIMATIC PCS 7 BOX) etc.

-

to automation solutions for very large production facilities with integrated process data control

•

Install distributed or central I/Os step-by-step

•

Configure and scale the display and control components: -

from small single-workstation systems and approximately 160 process tags, for example for laboratory automation etc.

-

to distributed multiple-workstation systems with client/server architecture with around 60,000 process tags, for example for automation of large production facilities

•

Scale the number of configurable process objects (software for a variety of PO quantities)

•

Select network components and configure communications networks

•

Enhance the functionality by selectively adding a variety of hardware and software components (for example operator stations with SIMATIC BATCH or a separate archive server)

•

Integrate applications for connecting SIMATIC PCS 7 to the IT world

Capacity options The following sections provide information about planning for PCS 7 plant capacity:

3-18

•


•

How Many CPUs Are Needed for the Automation?

•

How Many Devices, Sensors and Actuators Can Be Integrated?

•

How Many Operator Stations Are Required?

•

What Are the Expansion Limits?



3.3.2


Process objects A process object is a process tag that is displayed in a CFC chart. A process object is therefore a functional unit of a process control system.

Plant size The configurable size of a PCS 7 plant can be scaled to the number of process objects (PO). The software product licenses for Engineering, Operator Stations and SIMATIC BATCH are offered for a various number of configurable process objects (PO). This number can be increased at any time with additional PowerPacks. The licenses for SIMATIC PDM are offered for a various number of configurable devices.

What is regarded as a process object? All the blocks that can be controlled monitored by the operator count as process objects in PCS 7: The block has the attribute S7_m_c. This attribute is in the block properties in CFC. Such a function unit can include: •

Blocks for operator control and monitoring of a plant (for example motors, valves)

•

Objects for automation (for example level control)

•

Objects for signal acquisition and signal processing (not channel driver blocks, for example MEAS_MON)

Plant capacity limited by process objects The following table shows the plant capacities suited for PCS 7 and the plant capacity levels that can be achieved (determined for each component of the process control system). Components of the process control system

Level of the license Remarks

Engineering System (ES)

Max. PO:

Number of configurable process objects in the CFC

•

250

•

1000

•

2000

Note: Take the limit for the OS into consideration. When compiling the OS, approximately 30 external tags are acquired per process object for the operator stations.

•

3000

•

5000

•

unlimited


3-19


Components of the process control system

Level of the license Remarks

Operator Stations (OS)

Max. PO:

•

Limited to 5,000 PO per single-workstation system

•

250

•

Limited to 8,500 PO per OS server

•

2000

•

Max. 12 servers each with max. 5,000 PO = 60,000 PO

•

3000

•

5000

Note: Consider the additional limit to the number of tags (one process object has approx. 30 tags on the average).

•

8500

Archiving

Max. PO:

(archive server and OS server)

•

< 512

•

512 < 1500

•

1500 < 5000

•

5000 < 30000

•

30000 < 80000

BATCH Stations (batch processes)

Route control station

PDM

Max. PO: •

150

•

300

•

600

•

1800

•

unlimited

Max. paths: •

30

•

31 to 100

•

101 to 300

Max. devices: •

4

•

128

•

512

•

1024

•

2048

•

unlimited

SIMATIC PCS 7 Box Max. PO: •

250

•

2000

•

A maximum of 1,000 process values can be archived on the OS server.

•

A maximum of 10,000 process values can be archived on the archive server.

The license for <512 archive tags is included in all OS server licenses. If more process values need to be archived, all additional licenses are required up to the desired capacity. Depends on the load on the BATCH server

Number of paths activated in process mode (material transport) The basis of 30 active paths can be expanded to the next higher-level with an upgrade. Number of configurable devices

Refer to the notes on the engineering system (ES), operator station (OS), and PDM

Further Information •

3-20

Manual Process Control System PCS 7; PC Configuration and Authorization



3.3.3

How Many CPUs Are Needed for the Automation?

Criteria for required number of CPUs The number of required CPUs in a PCS 7 plant depends on: •

The number of sensors and actuators – the more sensors and actuators, the more automation systems required: See section How Many Devices, Sensors and Actuators Can Be Integrated?

•

The CPU type - the more powerful the CPU, the fewer CPUs required: See section "Overview of Automation Systems"

•

The workload and the desired expandability - the more reserve demanded, the more CPUs required

•

The limits of the CPUs: See section "Limits of the CPUs for PCS 7 Projects"

•

The expansion of the plant: See section What Are the Expansion Limits?

•

Environmental requirements

•

The desired optimization of the CPU for fast program execution and less required CPUs: -

Optimization of the execution cycle for program sections

-

Optimization of the execution sequences

No multicomputing for PCS 7 Note Multicomputing (synchroneous operation of more than one CPU) is not possible in PCS 7!


3-21


3.3.4

How Many Devices, Sensors and Actuators Can Be Integrated?

Mixed capacities The following provides an example mixed capacities for automation systems in a PCS 7 plant.

Caution The values shown in the following table are not maximum values for each item specific to the automation system. They represent an example of a typical distribution of total available automation system capacity in which all items are operated together in a contingent block.

Example: Mixed capacity for automation systems in a PCS 7 plant: Object

AS 416-3

AS 417-4/AS 417H

Analog value measurements

125

150

Digital value measurements

300

400

Dosing

10

15

Motors

125

150

PID controllers

100

130

Valves

125

150

SFC

30

50

Steps

300

500

AS 416-3

AS 417-4/AS 417H

675

850

or: Object Digital inputs DI

3-22

Digital outputs DO

260

315

Analog inputs AI

210

275

Analog outputs AIO

100

130



3.3.5

How Many Operator Stations Are Required?

Capacity of the PCS 7 OS SIMATIC PCS 7 supports both single-workstation and multiple-workstation systems with an OS client/OS server architecture. The following table shows the most important factors for planning operator stations in a multiple-workstation system. Property

Limit

Maximum number of OS server/redundant OS server pairs

12

Maximum number of OS clients in multiclient 32 per multiple-workstation system mode (when each OS client has access to all 12 OS servers/redundant server pairs) Number of process tags

Approx. 5,000 per OS server Approx. 60,000 per multiple-workstation system

Number of process value/s that can be archived

Approx. 1,000 process value/s with OS server Approx. 10,000 process value/s with central archive server (SQL server)

OS areas

64 OS areas in 5 levels per OS server

Maintenance station

1 maintenance station for monitoring diagnostic variables

Note Each monitor counts as an OS client when multiple monitors are used.


3-23


3.3.6

What are the Expansion Limits? The limits to expanding a plant depend on the: •

Networks used between the PCS 7 components

•

Distance to be bridged between the sensors and actuators (taking into consideration the potential transmission rates).

Since almost all of the sensors and actuators for PCS 7 are integrated in the distributed I/O, the length of the communications network is a critical factor.

Maximum length The following bus systems are used in PCS 7 with the following maximum lengths: Bus system

Application in PCS 7

Maximum length

Industrial Ethernet (Fast Ethernet)

Communications network for LAN and cell area with components especially developed for use in commercial systems

1.5 km electrical coupling

PROFIBUS DP

Communications network for the cell and field 10 km electrical coupling area 100 km optical coupling

PROFIBUS PA

PROFIBUS for process automation (PA)

150 km optical coupling (global)

1.9 km electrical coupling

HART Sensors and actuators that use the HART communication protocol for data exchange can communicate with the automation system over special modules.

3 km

Point-to-point coupling

Communication between two nodes with special protocols

Depends on the selected network

MPI

Multi-Point-Interface for testing and diagnostics

15 m

AS interface (ASI)

Communication network on the lowest automation level for connecting to (usually binary) actuators and sensors to the programmable controller

100 m

instabus EIB

Used to connect components in building automation

1000 m

MODBUS

Used to connect components with the Modbus Depends on component interface

TIA solution

Further information

3-24

•

Section "Which Networks / Bus Systems Are Used for Communication?"

•

Section "Maximum Transmission Rates of the Networks / Bus Systems"



3.4

Selecting Fault-Tolerant and Fail-Safe Components

3.4.1

Introduction The reaction of the plant to faults is an important aspect in process control engineering. Since the report of a fault is often not enough, the following components are an important part of process control engineering: •

Fault-tolerant components

•

Fail-safe components

Investment costs The high investment costs for fault-tolerant and fail-safe components are negligible in comparison to the costs and losses involved in the loss of production. The higher the costs resulting from production stoppage, the more advisable the use of faulttolerant and fail-safe components.

3.4.2

Redundancy Concept of PCS 7 The use of fault-tolerant components in a process control system can minimize the risk of production loss. A redundant design guarantees fault tolerance in a control system. This means that all components involved in the process have a backup in continuous operation. When a fault occurs or one of the control system components fails, the correctly operating redundant component takes over the continuing control task.


3-25


Redundancy concept The components of the PCS 7 enable you to assign any degree of fault tolerance to all automation levels, from operator stations (control level) to the bus system, from the automation system (process level) to the distributed I/O (field level). Redundant OS Clients and SIMATIC BATCH Clients

1

Terminal Bus, Segment 1

Terminal Bus, Segment 2 T

2

3

OS Server

BATCH Server

OSM Double Redundanter Plant Bus

5

PROFIBUS DP

Fault-tolerant Automation Ssystem AS 414H / AS 417H (optionally with redundant power supply)

ET 200M 7

ET 200M

Sensor / Actuator

8

ET 200M Fail-safe Redundant DP/PA Link PROFIBUS PA 9

Y Link

PROFIBUS DP S o CAL oLIM oAR

o CODE

63,29 36,72 +/-

7

8

9

.

4

5

6

0

1

2

3

ULTRAMAT 6

3-26

Clear

ESC

Enter

MEAS

Info

10

Connection non-redundant PROFIBUS DP devices to redundant PROFIBUS DP



No. in illustration

Description

1

Several OS/BATCH clients can access data on an OS/BATCH server. An OS/BATCH client can access data on up to 12 OS/BATCH servers or redundant OS/BATCH server pairs.

2

The terminal bus in ring form is used for the client-server and server-server communication. This avoids communication failures, for example if the cable is damaged or broken. The availability can also be increased by building a redundant terminal bus and segmenting the terminal bus.

3

The OS server and BATCH server itself can be installed with redundancy if required. A maximum of 32 OS/BATCH clients can access data on an OS/BATCH server or redundant OS/BATCH server pair.

5

The redundant plant bus (Industrial Ethernet in a ring structure) ensures reliable communication between automation systems, engineering stations and OS/BATCH servers.

6

The redundant S7-400H automation system (AS 414H or AS 417H) is connected with an Ethernet communication processor (CP) to each automation subsystem via the plant bus. Each automation subsystem can be connected to several PROFIBUS DP lines. The internal PROFIBUS DP interfaces or additional communication processors can be for connections.

7

The connection of the ET 200M distributed I/O to the redundant PROFIBUS-DP lines is made using two 153-2 IMs on a special bus module.

8

You can evaluate the sensor signals with redundant digital or analog input/output modules. If one of the two input modules fails, the sensor signal continues to be evaluated by the remaining operational input module.

9

The PROFIBUS-PA I/O is connected to the redundant PROFIBUS-DP by DP/PA Link and two 157 IMs.

10

The Y-link enables you to connect non-redundant PROFIBUS DP device to a redundant PROFIBUS DP.




3-27


3.4.3

Safety Concept of PCS 7 Fail-safe automation systems are employed for PCS 7 when a fault could endanger human life, damage the plant or the environment. They detect errors in the process, even their own internal errors, and automatically bring the plant to a safe state when a fault occurs.

Safety concept The fail-safe automation systems from PCS 7 can be configured single-channel (F system with one CPU) or redundant (FH system). Configuration variants for fail-safe and fault-tolerant systems F system

FH system

1

FH system with redundant I/O 3

2

AS 414FH/ AS 417FH

AS 414FH/ AS 417FH

AS 414F/ AS 417F

ET 200M

IM 153 Isolation module

No. in illustration

3-28

ET 200M

2x IM 153

PROFIBUS DP

F module

PROFIBUS DP

PROFIBUS DP

F module redundant ET 200M

Isolation module redundant

Description

1

The fail-safe S7-300 signal modules are connected via the ET 200M to the fail-safe S7-400F automation system (AS 414F or AS 417F).

2

Fail-safe automation system can also be configured redundantly. The use of the fail-safe and fault-tolerant S7-400FH automation system (AS 414FH or AS 417FH) for PCS 7 provides optimum safety and availability.

3

Fail-safe S7-300 signal modules (F modules) can also be redundantly connected to increase availability even further.



Safety mechanisms •

The PROFIsafe profile is used for safety-related PROFIBUS DP communication between the F CPU and distributed I/O. Based on this safety frame, the fail-safe automation systems and signal modules can recognize corrupt user data and trigger appropriate error responses.

•

Following programming (F program), the configured safety functions are processed twice in different processor sections of the CPU. Potential errors are detected in a subsequent comparison of the results.

•

Programming errors such as division by zero or a value overflow are intercepted by special fail-safe CFC blocks (F blocks).

•

Additional safety is provided by functions such as the comparison of F programs, detection of F program changes per checksum and access authorization per password.

Note An error detected in the F program does result in a CPU STOP; it triggers a definable reaction that brings the affected F runtime group or the entire F program to a safe state.

Using standard components Standard modules can also be used in fail-safe automation systems in addition to fail-safe S7-300 signal modules. A user program may contain both F programs and standard programs. The decoupling is ensured with special conversion blocks.

Certificates for S7-400F/FH (AS 414F/FH and AS 417F/FH) The fail-safe S7-400F/FH automation system used with PCS 7 has the following certification: •

German Technical Inspectorate (TÜV) certificate for the safety classes SIL1 to SIL3 from IEC 61508

•

Requirement classes AK1 to AK6 from DIN V 19250/DIN V VDE 0801

•

Categories 2 to 4 from EN 954-1

Using ET 200S ET 200S can also be centrally connected to a fail-safe S7-400F/FH automation system by using a fail-safe power module. The fail-safe power module brings the electronic modules from ET 200S to a safe state. ET 200S supports the PROFIsafe profile on the PROFIBUS DP.


3-29


Add-ons for PCS 7 Note Refer to the catalog Add Ons for the Process Control System SIMATIC PCS 7 (Catalog ST PCS 7.A) to learn which selected standard components can be integrated into a fail-safe automation system.

Further Information

3-30

•

Manual SIMATIC Programmable Controllers S7 F/FH

•

Manual S7-300 Fail-safe Signal Modules

•

Manual SIMATIC ET 200S Distributed I/O System



3.4.4

Recommended Use of Components The safety and availability requirements are also decisive factors in the selection of fault-tolerant and fail-safe components for a plant. The following table provides recommendations for components based on the level of requirements for systems.

Requirements

Low/none or none

Medium

High/large

Availability

Default

Proportion:

SIMATIC H Systems

Safety aspects

Default

Proportion:

Availability and safety aspects

Default

Proportion:

AS SIMATIC H Systems SIMATIC F Systems

SIMATIC F Systems SIMATIC FH Systems

SIMATIC FH Systems

Distributed I/O Availability

ET 200M

Two IM 153 in ET 200M

Two IM 153 in ET 200M Redundant signal modules in ET 200M

Safety aspects

Availability and safety aspects

DP/PA Link

Two IM 157 in DP/PA Link Two IM 157 in DP/PA Link

ET 200M

Fail-safe signal modules in ET 200M


ET 200S

Fail-safe power modules

Fail-safe power modules

ET 200M




Redundant fail-safe signal modules in ET 200M

Bus systems Availability on the terminal bus and plant bus

Industrial Ethernet: standard ring configuration

Industrial Ethernet: Industrial Ethernet: standard ring configuration redundant ring configuration

Availability on field bus

PROFIBUS DP/PA

Redundant PROFIBUS DP/PA

Redundant PROFIBUS DP/PA

Redundant servers for PCS 7 OS and SIMATIC BATCH

Redundant servers for PCS 7 OS and SIMATIC BATCH

HMI systems Availability – data security PCS 7 OS and SIMATIC BATCH


3-31


3.5

Selecting the Network Components

3.5.1

Communication within PCS 7 The communication within PCS 7 is based on SIMATIC NET network components that conform to worldwide accepted standards. SIMATIC NET includes powerful and robust components especially developed for industrial use that: •

Allow reliable data exchange amongst all levels and components in the PCS 7 plant

•

Can be enhanced and expanded by standard components

SIMATIC NET SIMATIC NET includes •

Communication network consisting of transmission medium, corresponding connection and transmission components and the respective transmission methods

•

Protocols and services used for data communication between the components

•

Communication modules of the automation systems that establish the connection to the communication network (e.g. communication processors (CP)).

Further information Refer to the following SIMATIC NET manuals for additional information about network architecture, network configuration, network components:

3-32

•


•

Manual SIMATIC NET NCM S7 for Industrial Ethernet

•

Manual SIMATIC Net PROFIBUS Networks

•

Manual SIMATIC NET; Triaxial Networks

•

Manual SIMATIC Net Twisted Pair and Fiber-Optic Networks

•

Manual Industrial Ethernet OSM/ESM; Network Management

•

Manual SIMATIC NET; AS Interface – Introduction and Basic Information



3.5.2

Which Networks / Bus Systems Are Used for Communication? The following table shows you the network / bus systems used for the communication between components in a PCS 7 plant.

Communication Operator BATCH between station station

Engineering AS station

Distributed I/O

Intelligent field devices, sensors and actuators

Operator station

Ethernet Ethernet Ethernet

Ethernet

None

None

BATCH station


Ethernet via OS None

None

Engineering station


Ethernet

Ethernet via AS Ethernet via AS

AS

Ethernet Ethernet Ethernet via OS

Ethernet

PROFIBUS DP

PROFIBUS DP PROFIBUS PA HART, AS-i, EIB, Modbus via PROFIBUS DP

Distributed I/O

None

None

Ethernet via AS

PROFIBUS DP

PROFIBUS DP via AS

via AS

Intelligent field devices, sensors and actuators

None

None

Ethernet via AS

PROFIBUS DP

via AS

None


PROFIBUS PA HART, AS-i, EIB, Modbus via PROFIBUS DP

3-33


3.5.3

Field of Application and Parameters of the Network/Bus Systems The following table provides an overview of the most important decision criteria for the use of network / bus system:

Bus

Plant bus and terminal bus

Field bus

Network / bus system

Industrial Ethernet

PROFIBUS DP

PROFIBUS PA

HART

AS-i

Standards

IEEE 802.3

EN 50170-1-2

IEC 1158-2 ISA S50.2 DIN EN 61158-2

Conforming to Bell 202 standard

IEC 62026 EN 50295

Transmission rate

100 Mbps*

Up to 12 Mbps depending on distance

31.25 Kbps

1.2 Kbps (PTP) Max. cycle time: 19.2 Kbps 5 ms (for 31 (Bus) AS-i slaves)

Network size: • Electrical

Up to 100 m*

Up to 10 km *** Up to 1.9 km (with repeaters)

•

Optical

Up to 150 km**

Up to 100 km

•

Global

WAN with TCP/IP

Topologies

-

3 km (PTP) 100 m (bus)

max. 100 m

-

-

-

-

-

-

Ring, line, star, tree, redundant

Ring, line, star, tree, redundant

Number of nodes: • Typical

1023 per segment

32 per segment 32 per segment 1 node 64 per DP/PA Link

15

•

(unlimited)

max. 125

max. 125

1 node

max. 32 (31 slaves with max. 124 binary elements)

Address and protocol; no bus parameters

Data throughput and connection parameters

Data throughput and connection parameters

Parameter assignment for devices with SIMATIC PDM

Connected by S7 configuration

-

-

Maximum

Specific parameter assignment Special field of application * **

***

3-34

Line, star, tree

Ex zone

Line - direct connection to special input modules

-

Line, star, tree

Analog sensors slave profile 7.3/7.4

Applies to ITP cable. The use of triaxial cables allows a transmission rate of 10 Mbps for lines lengths up to 1.5 km. Network with optical connection between nodes: • Up to 150 km ring length with up to 50 OSMs in single mode • More OSMs or > 150 km with hierarchical rings • Max. 3 km distance between 2 adjacent OSMs (optical switch modules) PROFIBUS DP segment with repeaters: see section "Electrical Transmission Media"



3.5.4

Maximum Transmission Rates of the Networks / Bus Systems The following table lists the maximum transmission rates of the network / bus systems. The transmission rate depends on the network physics: •

Electrical network: Network installed with electrical conductive connections (copper cable)

•

Optical network: Network installed with fiber-optic cables (FO)

Network / bus system

Electrical network

Optical network

Recommendation

Industrial Ethernet

Max. 100 Mbps between • CPU • OS • ES • BATCH Transmission rate for max. segment lengths: • 12 Mbps max. 60 m • 6 Mbps max. 60 m • 3 Mbps max. 100 m • 1.5 Mbps max. 200 m • 500 Kbps max. 400 m • 187.5 Kbps max. 700 m • 93.75 Kbps max. 900 m • 45.45 Kbps max. 900 m • 19.2 Kbps max. 900 m • 9.6 Kbps max. 900 m 25 Kbps

Max. 100 Mbps between • CPU • OS • ES • BATCH max. 12 Mbps • Used with plastic FO max. 400 m • Used with glass fiber FO max. 10 m

Only use components with Fast Ethernet (100 Mbps).

PROFIBUS DP

PROFIBUS PA

HART

1.2 Kbps (PTP) 19.2 Kbps (Bus) Max. cycle time: 5 ms (for 31 AS-i slaves)

AS-i

-

-

Optical networks should be used when importance is placed on interference immunity and electrical isolation. Relationship between transmission rate and distance for electrical networks: see section "Electrical Transmission Media".

Communication is over PROFIBUS DP: Refer to the section "Connecting PROFIBUS DP to PROFIBUS PA". Communication is over PROFIBUS DP: Refer to the section "Connecting AS-Interface to PROFIBUS-DP"

Gigabit Ethernet for PCS 7 SCALANCE components enable Gigabit Ethernet for PCS 7: •

SCALANCE X414-3E offers a modular configuration of 2 x 10/100/1000 Mbps and 12 x 10/100 Mbps. Via Gigabit ports (electrical or optical, depending on the media module used), the SCALANCE X414-3E-components can be configured in the redundant ring.

•

The DTEs are connected to the 10/100 Mbps ports.


3-35


3.5.5

Terminal Bus and Plant Bus Ethernet

3.5.5.1


Isolation of the terminal bus and plant bus Note Isolation of the plant bus and terminal bus is always recommended but not an absolute necessity. The connection to the MES layer should always be made through a router to protect against unauthorized access to the process control system (e.g. by computer viruses in office applications).

Fast Ethernet technology The network components used in PCS 7 are Industrial Ethernet components using modern Fast Ethernet technology. This means: •

Communication speeds of 100 Mbps

•

Use of switching technology

•

Redundancy using optical/electric rings

Connection of 10 Mbps Ethernet Components and units with 10 Mbps Ethernet (triaxial cable, OLM, star coupler) can be integrated into communication network with 100 Mbps through switch modules (OSM).

Components used for PCS 7 Network nodes are connected to switches by network cables. The following components from the SIMATIC NET product range are used: •

Optical Switch Module (OSM)

•

Electrical Switch Module (ESM)

Used for data transmission:

3-36

•

Twisted Pair cables (ITP or TP)

•

Fiber-optic cable (FO)

•

Coaxial and triaxial cables



1

3

2

3

1

OLM OSM TP62

OLM

OSM TP62

OSM

OSM

OSM

OSM Network 1

OSM in RM mode

4

OSM TP62

OSM

Network 2 OSM TP62

OSM

OSM

OLM

2

6

ESM

ESM

Network 3

5

ESM 6

6

1

3

ELM 1

ITP standard 9/15

4

Fiber optic (FO)

2

TP XP cord

5

Triaxial cable

3

TP cord 9/RJ45

6

Spur line 727-1 (drop cable)

Further information Section "Data Paths over the Terminal Bus and Plant Bus"


3-37


3.5.5.2

Use of Switching Technology

Use of optical switch modules (OSM) OSMs allow the configuration of "switched networks" with 100 Mbps that meet stringent requirements for availability and comprehensive diagnostics. The load on a network can be reduced and the performance thereby increased by forming segments (i.e. dividing a network into subnetworks) and connecting each segment to an OSM. An OSM provides additional ports (with RJ45, ITP or BFOC interfaces as options) to which terminals and additional network segments can be connected.

Use of optical media converters (OSM) An OMC converts an electrical twisted pair interface into an optical interface. OMCs allow nodes to connect to one of the 8 ports provided by an OSM BC08 via an RJ45-TP interface.

Use of electrical switch modules (ESM) ESMs are used to form electrical rings: •

The data rate in a ring is 100 Mbps.

•

Up to 50 ESMs can be used in each ring.

An ESM provides additional ports to which terminals and additional network segments can be connected.

3-38



Selecting OSM, OMC and ESM variants Switch

Port type and number

OSM TP22

sub D (ITP)

RJ45 (TP)

-

2

Preference

Multi- Singlemode- modeOC OC 2

-

High EMC load

Plant bus

Terminal bus

x

x

x

x

x

x

x

x

x

TP cable in switchgear cubicle OSM ITP62 (standard)

6

-

2

-

OSM TP62

-

6

2

-

OSM ITP62-LD

6

-

-

2

x

OSM ITP53

5

-

3

-

x

OSM BC08

-

-

8

-

x

x

x

X

Building-wide coupling

Building-wide coupling

x

x

TP cable TP cable TP cable (max. 6 m) in (max. 6 m) in (max. 6 m) in the switchgear the switchgear the switchgear cubicle cubicle cubicle OMC TP11

-

1

1

-

x

ESM ITP62

8

-

-

-

x

x

x

x

x

Within buildings ESM TP40

-

4

-

-

x

x

Within switchrooms ESM TP80

-

8

-

-

X

x

Within switchrooms




3-39


3.5.5.3

Optical and Electrical Transmission Media

Optical transmission media Glass fiber-optics are preferably used as the optical transmission media. PCS 7 offers standard cables with a compatible connector set (4 BFOC connectors) that are suitable for indoor and outdoor overhead lines.

Electrical transmission media The terminals are connected with Industrial Twisted Pair (ITP). Prefabricated cable or meterware (ITP standard cable) in a variety of designs are offered with sub D connectors to allow direct connection between the nodes and network components. Terminals can be optionally connected with twisted pair (TP) using TP cord cables.

3.5.5.4

Connecting Network Nodes to Ethernet

Bus connection to AS, OS, BATCH and ES PC Station for ES/OS/BATCH

Ethernet

Network Module

Industrial Ethernet

Industrial

Automation System

CP 443-1

Connection of the AS The automation systems are connected to Industrial Ethernet via TCP/IP, ISO and UDP using the CP 443-1 communication processor.

3-40



Connection of the OS, BATCH and ES The operator stations, BATCH stations and engineering stations are connected to Industrial Ethernet by communication cards. The communication cards use a slot in the PC/PG. Various types of communication are employed depending on the requirements: •

•

Communication cards without onboard processor (Basic Communication Ethernet - BCE) are sufficient for connecting up to 8 (one operator station) underlying automation systems. The connection can be optionally made via the: -

Ethernet supplied with the PC/PG

-

CP 1612 with SOFTNET-S7/Windows software

-

CP 1512 with SOFTNET-S7/Windows software

If the maximum number of 8 automation systems per operator station is not enough or if fault-tolerant automation systems are connected, communication cards with onboard processor can be used: -

CP1613 with S7-1613 software or

-

CP 1613 with S7-REDCONNECT software for redundant communication with S7-400H/FH

Note Communication can be established with up to 64 automation systems (including redundant systems) via the CP 1613.

Time-of-day synchronization CP 443-1 and CP 1613 support time synchronization over Industrial Ethernet (Fast Ethernet). A PC with a CP 1613 can receive time-of-day frames from the following time-of-day transmitters: •

SIMATIC S7-400/H/FH with CP 443-1

•

SIMATIC NET time transmitter for Industrial Ethernet (see catalog IK PI)

•

SIMATIC SICLOCK

•

PC with CP 1613

Further information Section Data Paths over the Terminal Bus and Plant Bus


3-41


3.5.5.5

Configuring Redundant Ethernet Networks

Redundant plant bus/terminal bus The following communication solutions are offered to increase the system availability: •

Redundant electrical network with ESM

•

Redundant optical network with OSM

•

Combined redundant network with OSM and ESM

Use of ring structures Redundancy can also be implemented by configuring a ring structure: •

Simple ring (see example of a redundant plant bus)

•

Double ring: An additional ring with OSM/ESM and two interface cards for each connected component (e.g. AS, OS) increases the availability.

Example of a redundant plant bus The following illustration shows a redundant plant bus in ring structure with OSMs. This architecture can also be built with ESMs. The plant bus is configured redundantly with OSM. A fault in the bus line (a wire break, for example) has no effect on the communication occurring throughout the entire bus. One of the two OSMs to which the OS servers are connected may fail without it affecting the complete system. If one OSM fails, the redundant OS partner server can continue to communicate through the operational OSM. Redundant OS Server Pair


Fault-tolerant automation system S7-400H with CPU AS 414FH/AS 417FH

Optical Switch Module (OSM) with integrated redundancy properties

Spacially separated racks each with two CP 443-1

Synchronization Lines

3-42



OSM and ESM All OSM and ESM variants feature 2-ring ports to connect the OSMs and ESMs to double Ethernet ring structures. The OSM/ESM are synchronized over a synchronization line.

Further information

3.5.5.6

•

Section "Use of switching technology"

•


Planning Diagnostics for Ethernet The use of OSM/ESM allows segment-by-segment examination of the state of an Ethernet network. OSM/ESM detects communication errors, reports them to other SIMATIC NET network components and sets its own fault LED. Additional tools are available for network diagnostics. Refer to the configuration manual Process Control System PCS 7; Operator Station and the manual Process Control System PCS 7; Service Support and Diagnostics to see which other diagnostic tools you require for commissioning and process mode.

3.5.6

Field Bus with PROFIBUS

3.5.6.1

Planning the Field Level with PROFIBUS

PROFIBUS in a PCS 7 plant PROFIBUS is used exclusive on the field level of PCS 7. The following PROFIBUS profiles are used: •

PROFIBUS DP - for communication between the AS and distributed I/O

•

PROFIBUS PA (according to IEC 61158) - for direct connection bus-capable intelligent field devices

Components used for PCS 7 PROFIBUS can be operated with the following combinations of transmission media for a wide variety of applications: •

Shielded two-wire cable - for electrical data transmission

•

Fiber-optic cable (FO) - for optical data transmission


3-43


PROFIBUS networks can be built using the following components based on the transmission medium used and the devices to be connected: •

Optical Link Module (OLM)

•

Optical Bus Terminal (OBT)

•

Y Link

•

DP/PA coupler and DP/PA Link

•

Diagnostic repeater

•

RS 485 repeater

•

RS 485 terminating element

Plant Bus Industrial Ethernet Automation System Long distances with fiber optic

PROFIBUS DP ET 200M

OLM

OLM

s SIMATIC PANEL PC POWER

TEMP

A G

B H

C

D

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PROFIBUS PA

Ex

DP/PA Link

Ex isolation and repeater

ET 200iSP 0

PROFIBUS DP/iS

3-44

ENTER

Integrated: - Power supply - Terminal resistor - Ex isolation

1

PROFIBUS DP

SHIFT FN CTRL ALT

Ex



3.5.6.2

Electrical Transmission Media

Electrical transmission media Shielded, twisted pair cables are used as the transmission media for electrical PROFIBUS networks. PROFIBUS nodes are connected to bus lines via a bus terminal with a spur line or bus cable connectors.

PROFIBUS segment A PROFIBUS segment is formed by a bus cable terminated at both ends with surge impedance. The individual PROFIBUS segments are connected together with repeaters. The maximum cable length of a segment depends on the: •

Transmission rate

•

Type of cable

The maximum cable length of a PROFIBUS segment is limited: see section "Maximum Transmission Rate of the Networks / Bus Systems").

RS 485 repeater The RS 485 repeater is a signal amplifier. It allows the cable length to be increased. A maximum of 9 RS 485 repeaters can be connected in series. The following cable lengths are possible when RS 485 repeaters are used between two nodes: Transmission rate

Max. cable length between 2 nodes (with 9 RS 485 repeaters connected in series)

9.6 to 187.5 Kbps

10,000 m

500 Kbps

4,000 m

1.5 Mbps

2,000 m

3 to 12 Mbps

1,000 m

RS 485 terminating element All PROFIBUS segments are terminated at both ends based on the transmission rate. An RS 485 terminating element is used as a permanent line termination to terminate the PROFIBUS segments.




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3.5.6.3

Optical transmission media

Note Recommendation: Fiber-optic cable should be the preferred for long distances and when connecting between buildings.

Glass fiber-optics or plastic fiber-optics are used as the transmission media for optical PROFIBUS networks.

Glass fiber optics PCS 7 offers standard cables for glass fiber-optics with a compatible connector set (20 BFOC connectors) that are suitable for indoor and outdoor lines.

Plastic fiber optics PCS 7 offers standard cables for plastic fiber-optics with compatible plug adapters that are suitable for indoor lines: •

The maximum cable length between two PROFIBUS DP devices is 400 m.

Optical Link Module (OLM) OLM allows configuration of optical and combined (electrical/optical) networks: •

The OLM features an RS 485 interface and 2 fiber-optic interfaces.

•

The maximum distance between two OLMs is 15 km.

•

The length of the fiber-optic cable can reach up to 3 km.

Optical Bus Terminal (OBT) The OBT allows a PROFIBUS DP node with integrated optical interface to be connected to an RS 485 segment or PROFIBUS DP node without integrated optical interface.

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Use of fiber-optics and OBTs for S7-400F/FH Fiber-optics and OBTs are recommended for fail-safe automation systems (with F modules only) to fulfill the requirements of safety level SIL 3. ET 200M is connected to the electrical bus line of the PROFIBUS DP through an OBT using fiber-optics. Safety level SIL 3 has the advantage that no isolation module to isolate signals between IM 153-2 and F modules when a direct, electrical connection is made. Fail-safe Automation System AS 414F/AS 417F

PROFIBUS DP Copper Cable

IM 153-2 ET 200M with standard I/O modules

IM 153-2 FO

OBT

ET 200M with fail-safe I/O modules

IM 153-2 FO OBT ET 200M with fail-safe I/O modules Plastic Fiber Optic Cable


Manual SIMATIC NET; PROFIBUS Networks

•

Manual SIMATIC Net; Twisted Pair and Fiber-Optic Networks


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3.5.6.4

Connecting PROFIBUS DP Nodes

Bus connection of AS, ET 200M, ET 200S, and ET 200iSP DP Interface in the CPU

CP 443-5 Extended

ET 200M

PROFIBUS DP

Automation System

ET 200M

Connection of the AS The connection of the automation systems to the PROFIBUS DP is made via: •

CP 443-5 Extended or

•

Internal DP interface of the CPU

The PROFIBUS DP lines can be connected to up to 4 internal DP interfaces per automation system (with add-on modules depending on the CPU) and also to up to 10 CP 443-5 Extended. IF 964-DP interface modules are available for the DP interfaces. These can be installed in available module slots of the CPU.

Connection of ET 200M, ET 200S, and ET 200iSP Bus cable connectors in a variety of designs are used to connect ET 200M, ET 200S, and ET 200iSP to PROFIUS-DP. They can be ordered together with the ET 200 components.

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3.5.6.5

Configuration of Redundant PROFIBUS DP Networks

Redundant PROFIBUS DP The fault-tolerant S7-400H automation system features a PROFIBUS-DP master interface on each CPU for connecting to PROFIBUS-DP. For switched distributed I/O, the connection to the I/O device is made through two IM 153-2 interface modules. The following fault-tolerant communication configurations are offered for PROFIBUS-DP: •

Redundant PROFIBUS-DP as an electrical network

•

Redundant optical network with OLM with line, ring and star structure

Example of redundant PROFIBUS DP The following illustration shows an electrical network with redundant PROFIBUS-DP. The communication from the sensor to the fault-tolerant system is taken over by the redundant bus connection when the active bus connection fails.

PROFIBUS DP

Automation Syystem AS 414H/AS 417H PROFIBUS DP Master Interface on each H CPU

ET 200M

ET 200M

Dual channel switched I/O ET 200M, consisting of 2 x IM 153-2 and 2 x SM

Redundant I/O module

Sensor




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3.5.6.6

Connecting Non-redundant PROFIBUS DP Devices to Redundant PROFIBUS DP

Y Link To implement the changeover from a PROFIBUS master system to a singlechannel PROFIBUS master system, the Y-Link is preferred as the gateway.

Configuration of the Y Link The Y-Link consists of two IM 157 interface modules and a Y-adapter. The Y coupler is a component of the Y Link and is used to connect the underlying PROFIBUS DP to the DP master in the IM 157.

Fault-tolerant Automation System AS 414H / AS 417H

PROFIBUS DP

2 x IM 157 Y Link

Lower-level DP Master System S o CAL oLIM oAR

o CODE

63,29 36,72 +/-

7

8

9

.

4

5

6

0

1

2

3

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ESC

Enter

MEAS

Info

ULTRAMAT 6

Y Coupler Connection non-redundant PROFIBUS DP device to redundant PROFIBUS DP

Note Use only the active backplane bus module when configuring the Y Link.

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Properties of the Y Link •

When a fault occurs, the Y Link bumplessly switches the complete I/O line to the active PROFIBUS DP of the redundant H system.

•

From the perspective of the programmable controller, the Y-Link is a DP slave, and from the perspective of the underlying DP master system, it is a DP master.

•

Transmission rates:

•

-

For the connection to the H system: from 9.6 Kbps to 12 Mbps

-

For the switched PROFIBUS DP: from 187.5 Kbps to 1.5 Mbps

Capacity: -

The number of Y Links on an S7-400H is only limited by the maximum number of bus nodes, 126.

-

The number of nodes in each underlying DP master system is limited to 64.

•

Supports configuration changes in RUN (CiR)

•

Modular design mounted on an S7-300 rail with an active backplane bus

•

Isolation between the underlying DP master system and power supply over the RS-485 repeater

•

Degree of protection IP 20


Manual DP/ PA Link and Y Link Bus Connections


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3.5.6.7

Connecting PROFIBUS PA to PROFIBUS DP

DP/PA Link The DP/PA Link is the preferred gateway between PROFIBUS-DP and PROFIBUS-PA.

Configuration of the DP/PA Link DP/PA Link consists of two IM 157 interface modules and up to 5 DP/PA couplers. A DP/PA Link can be connected to the redundant PROFIBUS DP using two IM 157 modules.

DP/PA coupler The DP/PA coupler is the physical link between the PROFIBUS-DP and PROFIBUS-PA. The DP/PA coupler is available for hazardous and non-hazardous areas. When few numbers are involved, the real-time requirements are not important and no redundant PROFIBUS DP is used, the DP/PA coupler can also be operated stand-alone (without IM 157).

Automation System

PROFIBUS DP

DP/PA Coupler PROFIBUS PA

IM 157 DP/PA Link (max. 5 DP/PA Coupler) PROFIBUS PA

Communication via PROFIBUS PA PROFIBUS PA uses the same communication protocol as PROFIBUS DP; communication services and frames are identical. Each PROFIBUS PA segment must be terminated by a SpliTConnect terminator.

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Properties of the DP/PA Link •

When a fault occurs, the DP/PA Link bumplessly switches to the active PROFIBUS DP of the redundant H system.

•

Modules can be "hot swapped" during online operation when a special bus module is used.

•

Capacity: -

Up to 5 DP/PA couplers can be connected to a DP/PA Link.

-

The number of nodes in each underlying PROFIBUS PA is limited to 64.

•

Supports configuration changes in RUN (CiR)

•

Isolation of the higher-level DP master system

•

Suitable for connecting sensors/actuators in the areas with explosion danger (hazardous zones)

•

Configuration, commissioning and diagnostics of DP/PA Link and connected field devices with the SIMATIC PDM tool integrated in the ES

DP/PA Link or DP/PA coupler The use of DP/PA Link or DP/PA couplers depends on the size of the plant, the desired performance and the automation system employed: Components

DP/PA coupler

Structure

•

Use and performance Transmission rate Function

Housing safety level

Redundancy Diagnostics

DP/PA Link

Stand-alone operation without additional components possible Integrated power supply and bus terminal for PROFIBUS PA

DP/PA Link is built from a combination of • Interface module IM157 and • • DP/PA coupler (max. 2 with standard model or max. 5 for hazardous zone) For small number of devices and low For extensive addressing volumes and real-time requirements high cycle time requirements • at DP end: 45.45 Kbps • at DP end: from 9.6 Kbps up to max. 12 Mbps • at PA end: 31.25 Kbps • at PA end: 31.25 Kbps When using the DP/PA, the field Field devices are addressed by the devices are addressed directly by the automation system indirectly through the automation system; in other words the DP/PA Link (DP slave). DP/PA coupler is transparent. Designs for hazardous zones are Designs for hazardous zones are available. available. Only sensors and actuators can be Only sensors and actuators can be used in the hazardous zone! used in the hazardous zone! A configuration with two IM 157 modules allows use in an H system. via LED via diagnostic frame and LED


Manual DP/ PA Link and Y Link Bus Connections


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3.5.6.8

Planning Diagnostics for PROFIBUS

Diagnostic Repeater We recommend the use of diagnostic repeaters to provide detailed diagnostics for PROFIBUS DP segments (copper cable). When a fault occurs it sends a diagnostic alarm to the DP master with detailed information about the type of fault and the location. Principle: To be able to localize a problem in the network, the diagnostic repeater must know the topology of the PROFIBUS subnet to which it is attached. With the function "Prepare Line Diagnostics", the diagnostics repeater determines the distances to all nodes and saves the data internally in a table. By calculating the distance to a line fault, the repeater can then identify the nodes between which the fault is located based on the table.

Plant Bus Industrial Ethernet Standard Automation System

PROFIBUS DP line not monitored

PROFIBUS DP line monitored subnet

Fault

Long distance with fiber optic Diagnostic Repeater

PROFIBUS DP OLM

OLM

s SIMATIC PANEL PC POWER

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Ex isolation and repeater

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Properties The diagnostics repeater has the following features: •

Diagnostics function for two PROFIBUS segments: The diagnostics function reports the location fault and cause line faults such as wire break or missing terminal resistors.

•

Repeater function for three PROFIBUS segments: The diagnostics repeater amplifies data signals on bus lines and connects the individual RS 485 segments.

•

Transmission rate: from 9.6 Kbps to 12 Mbps See also section Maximum Transmission Rates of the Networks / Bus Systems"

•

Cable length: When standard cables are used, the diagnostics repeater can monitor a maximum of 100 meters of cable in each PROFIBUS segment.

Note Only use the active backplane bus module.


Manual SIMATIC Diagnostics Repeater for PROFIBUS-DP

•

Manual Process Control System PCS 7; Service Support and Diagnostics


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3.5.7

Data Links to Other Systems Within the context of PCS 7, Totally Integrated Automation (TIA) provides solutions for configuring a wide range of communication tasks.

Potential communication partners TIA solutions are available for devices and plants that communicate with the following protocols:

3.5.7.1

•

AS Interface

•

Instabus EIB

•

MODBUS

Connecting the AS Interface to PROFIBUS DP

AS interface The actuator sensor interface (AS interface) is a heterogeneous network system for simple, usually binary actuators and sensors at the lowest field level. The AS interface is an international standard based on EN 50 295. The AS interface allows you to address all connected sensors and actuators on a common 2-wire cable while at the same time supplying them with the required power.

Connecting the AS Interface to PROFIBUS DP The AS interface is connected to PCS 7 through a DP/AS interface link to the PROFIBUS DP. The AS interface is connected to PCS 7 as an underlying bus through the DP/AS interface link. This does not permit use of the full range of PCS 7 features (no diagnostics capability, for example). The AS interface operates according to the master slave principle. The sensors/actuators connected through the AS interface line are treated as slaves by the master DP/AS interface link. DP/AS interface link is a DP slave from the point of view of the PROFIBUS DP master system.

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The PROFIBUS DP and AS interface are electrically isolated.

Plant Bus Industrial Ethernet Automation System

PROFIBUS DP

ET 200M

AS Interface DP/AS-i Link

M

M

AS-i Power Supply

INTERFACE

Branch

M

M

Actuators/ Sensors

M

DP/AS interface link The following DP/AS interface links can be used: •

DP/AS Interface Link 20 with IP20 protection

•

DP/AS Interface Link 20E with IP20 protection

•

DP/AS-i Link with IP66/67 protection

All DP/AS interface links can be operated on the PROFIBUS DP with transmission rates up to 12,000 Kbps. A power supply, PROFIBUS plug connector and AS interface connector sockets are needed for installation.

Connection of ET 200M to the AS interface An ET 200M (on the PROFIBUS DP) can also be connected to the AS interface through the AS interface master module, CP 343-2.


Manual SIMATIC Distributed I/O Device DP/AS-i Link

•

Manual SIMATIC NET DP/AS Interface Link 20

•

Manual SIMATIC NET DP/AS Interface Link 20E


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3.5.7.2

Connecting Instabus EIB to PROFIBUS DP

Instabus EIB Instabus EIB (European Installation Bus) is an open standard for building automation.

Connecting Instabus EIB to PROFIBUS DP The connection to PCS 7 is made through a DP/EIB Link to the PROFIBUS DP. Instabus EIB is integrated as a lower-level bus in PCS 7 through the DP/EIB link and therefore does not allow the full range of PCS 7 features (no diagnostics capability, for example). The DP/EIB link is a DP slave from the point of view of the PROFIBUS DP master system.

Plant Bus Industrial Ethernet Automation System

DP/EIB Link

00

00

00 7 00

s 6GK1415-0AA00 instabus EIB Power

00

PROFIBUS Addr.

DP/EIB-Link

DP/BF EIB/BF

24V

EIB

Phys. Adr.

Station

Area Coupler

0

PROFIBUS DP

instabus EIB

1

Bus line

DP/EIB link The following DP/EIB links can be used: •

DP/EIB Link with IP20 protection


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Manual SIMATIC NET DP/EIB Link



3.5.7.3

Connecting MODBUS to PROFIBUS DP

MODBUS MODBUS is an open serial communication protocol. The Modbus protocol is used to network third-party systems. Due to the transmission rate of a maximum of 38.4 Kbps, MODBUS is recommended when there are few bus nodes and low real-time requirements.

Connecting MODBUS to PROFIBUS DP The connection to PCS 7 is made through a CP 341 installed in the ET 200M distributed I/O device. The CP 341 allows faster data exchange through a point-topoint link using the MODBUS protocol.

CP 341 The CP 341 is available in the following 3 models (interface physics): •

RS 232C (V.24)

•

20 mA (TTY)

•

RS 422/RS 485 (X.27)

Special drivers are needed for Modbus master and Modbus slave to implement the Modbus link. These need to be ordered separately.


Manual SIMATIC CP 341 Point-to-Point; Installation and Parameter Assignment

•

Manual SIMATIC Loadable Drivers for PtP CPs; MODBUS Protocol RTU Format; S7 is Master

•

Manual SIMATIC Loadable Drivers for PtP CPs; MODBUS Protocol RTU Format, S7 is Slave


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3.5.8

Administration Level and Remote Access

3.5.8.1

Connecting to MIS/MES The following options are available to connect MIS/MES systems to SIMATIC PCS 7:

3.5.8.2

•


•

Connecting HMI Systems via OPC

•

Connecting to the IT world with @PCS 7


SIMATIC IT SIMATIC IT is an engineering platform for e-manufacturing based on the ISA S95 standard. According to this standard, explicit business and production rules coordinate functionality to achieve optimal workflow. The main elements of SIMATIC IT are: •

SIMATIC IT Framework

•

SIMATIC IT components

SIMATIC IT Framework SIMATIC IT Framework connects the automation level to the operational management and production control levels, as well as to the company management and planning levels. SIMATIC IT Framework is cross-industry integration and coordination platform for operating processes, data and functions and possesses the facility for plant and production modeling in addition to the basic functions for internal sequence control, user administration etc.

SIMATIC IT components SIMATIC IT components are standard products made available to various industrial sectors by IT functions defined in line with ISA S95, for example:

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•

Production Suite (basic MES functions such as material management, production order management)

•

SIMATIC IT Historian (plant performance analysis)

•

SIMATIC IT Unilab (laboratory information management system)

•

SIMATIC IT Interspec (product specification management system)

•

Detailed Production Scheduler

•

SIMATIC IT Suite Libraries



Connecting to PCS 7 The SIMATIC PCS 7 process control system can be integrated into SIMATIC IT Framework through the CP 443-1 IT.

Further information Refer to the following for more information: http://www.ad.siemens.de/mes/simatic_it/index_00.htm

3.5.8.3

Connecting HMI Systems via OPC

OPC OLE for Process Control (OPC) provides a standard mechanism for communicating with numerous data sources. It does not matter whether these sources are machines in your factory or a database in your control room. OPC is based on the OLE/COM technology from Microsoft. For detailed information about OPC, refer to the documentation "OLE for Process Control Data Access Standard, Version 2.0" published by the OPC Foundation.

Connecting HMI systems The OPC interfaces of PCS 7 conform to the specification from the OPC Foundation. Data exchange can be performed in PCS 7 using process tags (data access).

PCS 7 OS server with OPC data access server The applications of the OPC interface are based on the client-server model. An OPC data access server is installed together with the PCS 7 software. The PCS 7 OS server provides the industrial communication capability of data access as an interface to the systems. Each OPC client application can access the process data (tag management) from this OPC server. The PCS 7 OS server can be used as a •

OPC data access server or

•

OPC data access client

OPC is used to connect one or more operator stations on the PCS 7 OS server. You can connect to the operator station via a network (e.g. local data network).


Documentation OLE for Process Control Data Access Standard, Version 2.0

•

You can contact the OPC Foundation in the Internet at: http://www.opcfoundation.org


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3.5.8.4

Connecting to the IT World with @PCS 7

@PCS 7 @PCS 7 is software based on @aGlance that provides access to process data acquired with SIMATIC PCS 7. @PCS 7 provides access to the following PCS 7 data: •

WinCC archives (message, measured value and user archives)

•

WinCC data management

Each @aGlance-compliant client application of MIS/MES is therefore capable of accessing the data of PCS 7.

@aGlance @aGlance is communication software for the exchanging information between a variety of industrial data sources such as Scada packages, process control systems and programmable controllers. The Web technology of web@aGlance provides a standard for visualization and analysis of process data via the Internet. Using the standards provided by @aGlance, the visualization and analysis of the data can be performed on any computer regardless of the operating system - and also via Intranet and Internet. You can analyze, process and evaluate data using tools such as Excel or Visual Basic applications.

Connecting to PCS 7 @aGlance is already integrated in every PCS 7 OS in the form of an @PCS 7 server. A Web@aGlance packages and a normal Web browser are the only things needed for read access on the target PC. An additional license for @PCS 7 needs to be installed on the PCS 7 OS to activate write access and communication with other @aGlance servers. When @PCS 7 is started on the PCS 7 OS, the @PCS 7 system desktop opens. It allows access to the @PCS 7 system and a variety of @PCS 7 editors in which you can perform a range of tasks for communication with the plant operations level. An administration tool is available to configure logon activities with access permission.

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Because you can freely select operating systems and applications for the server and clients, you can implement @aGlance regardless of the existing hardware and software architecture. You are therefore not limited to specific providers or systems that are installed or will be installed in the future in your company.

Web-Browser - Internet-Explorer - Netscape

Client Applications - Microsoft Excel - InfoPlus.21 - MATLAB - Application with Visual Basic C++ @aGlance/IT Client Add-ons

Internet/ Intranet

Web-Server Web@aGlance

Network

@PCS 7 Server @PCS 7 Web Read Access @PCS 7 Web Write Access @PCS 7 Full Client Access @PCS 7 Server To Server SIMATIC CS 7 Operator Station


@aGlance/IT Server Add-Ons Server Applications - Other PLS - Process histories

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Available versions of @PCS 7 You do not need an additional authorization for the basic features (first point). However, WinCC must be installed with the basic process control option and its authorization: •

@PCS 7 Web Read Access is already integrated in the OS software and permits read access to OS data (process data, alarms, archive data) via the Internet/Intranet.

Authorizations are required for additional features. Each authorization level upgrade contains the features of the lower authorization levels (optional package 3 therefore includes all of the features): •

Optional package 1: @PCS 7 Web Write Access permits read and write access to OS data

•

Optional package 2: @PCS 7 Full Client Access permits communication with @aGlance/IT client applications such as the information management system, InfoPlus.21

•

Optional package 3: @PCS 7 Server to Server Communication permits communication with server applications in the @aGlance/IT server add-ons


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Manual SIMATIC @PCS7 V6.0; Interface to Plant Operations Level



3.5.8.5

Access to the PCS 7 OS over Web Client

Web Server and Web Client PCS 7 provides the option of using operator control and monitoring functions of the PCS 7 OS in process mode over the Internet or Intranet. This requires the following components: •

Web server: A separate Web server is set up that provides the Web client with all necessary OS pictures.

•

Web client: The Web client is a computer capable of operating over the Internet with the Internet Explorer from which the users can log on. Up to 50 Web clients can access a Web server.

How the Web Client Works Users log in with the Web server in the Internet Explorer and can then use all the functions according to their user rights (setting in the WinCC-Editor "User Administrator"). All operations made on the Web client are logged automatically with the name of the plant operator. The Web client offers, for example, the following functions: •

Execution of all operator control and monitoring functions that can also be used on an OS client

•

Message list calls Message lists can be called up user-specific, just as on an OS client, and the messages acknowledged user-specific.

•

Display of the picture hierarchy according to the plant hierarchy

•

Use of group display functions including the loop-in-alarm function.

•

Use of the expanded status display

Note Not all functions are available. You will find more detailed information on the availability of the functions in the function manual Process Control System PCS 7; OS Web Option.


Manual Process Control System PCS 7; PCS 7 OS Web Option


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3.6

Selecting the PC Components for ES, OS, BATCH and IT

3.6.1

Which PC Components Can Be Used?

PC components for ES/OS/BATCH/IT A wide range of basic devices is available for engineering stations (ES), operator stations (OS), BATCH stations (BATCH) and for connecting SIMATIC PCS 7 to the IT world. They consist of: •

Basic hardware (PC basic unit)

•

Color monitor

Recommended equipment for the basic hardware We recommend the following hardware for PC components (a more powerful configuration is an advantage): The minimum requirements should be met for smaller, new projects created with PCS 7: PC Station Engineering station OS Single Station OS server Central archive server OS client OS Web Server Maintenance Server BATCH Single Station BATCH server BATCH client BATCH and OS client Route Control Single Station Route Control Server Route Control Client

CPU speed

RAM

Hard disk

2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz 2.8 GHz

1 GB 1 GB 1 GB 1 GB 512 MB 1 GB 1 GB 1 GB 1 GB 512 MB 1 GB 1 GB 1 GB 512 MB

120 GB 120 GB 120 GB 120 GB 80 GB 120 GB 120 GB 120 GB 120 GB 80 GB 80 GB 120 GB 120 GB 80 GB

Note • PCs with higher CPU speeds, more RAM and larger hard disks are an advantage for engineering stations when working with multiprojects. Faster hard disks are also advantageous in such circumstances.

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•

More RAM is recommended for archive servers.

•

We also recommend CPU speeds above 2 GHz or dual processor systems for BATCH servers.



Minimum equipment for the basic hardware For smaller new projects created with PCS 7 V6.1, we recommend the following minimum configurations (a more powerful configuration is an advantage): PC Station Engineering station OS Single Station OS server Central archive server OS client OS Web Server Maintenance Server BATCH Single Station BATCH server BATCH client BATCH and OS client Route Control Single Station Route Control Server Route Control Client

CPU speed

RAM

Hard disk

1 GHz 1 GHz 1 GHz 2.8 GHz 866 MHz 1 GHz 2 GHz 2 GHz 2 GHz 866 MHz 2 GHz 2 GHz 2 GHz 866 MHz

768 MB 768 MB 768 MB 1 GB 512 MB 768 MB 1 GB 1 GB 1 GB 512 MB 1 GB 768 MB 768 MB 512 MB

40 GB 40 GB 40 GB 120 GB 40 GB 40 GB 40 GB 60 GB 60 GB 40 GB 40 GB 40 GB 40 GB 40 GB

Creating system partition C Partition C (for the operating system and PCS 7) should be at least 8 GB.

Color monitor We recommend monitors with a resolution of 1280 x 1024 or higher in order to fully exploit the graphic potential of the PCS 7 software.

Network The network for PCS 7 systems must be isolated using switches, routers or gateways to prevent disruption to the PCS 7 network from office networks, for example.

Latest information in PCS 7 readme files Please read the latest information provided for every new version or service pack of PCS 7 in the readme file on the DVD "Process Control System PCS 7 Engineering Toolset".




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3.6.2


Basic hardware Special versions of the basic hardware (bundles) are available for engineering stations (ES), operator stations (OS), BATCH stations (BATCH) and for connecting SIMATIC PCS 7 to the IT world. The bundles are optimized for special applications.

SIMATIC PCS 7 BOX basic hardware SIMATIC PCS 7 Box is an industrial PC with integrated AS/ES/OS station. The AS is based on the standard CPU 416-2 PCI. SIMATIC PCS 7 BOX is used for separate small plants or combined AS/OS stations that can be integrated in the PCS 7 network. Features: see manual Process Control System PCS 7; SIMATIC PCS 7 Box

Color monitors The Siemens industrial monitor range SCD, SCM and CRT are available for the PCS 7 process monitors. These are selected based on the ambient temperature of the plant. Up to 4 monitors can be connected to a workstation (OS client) via a multi-VGA card. Plant areas divided in such a way can be operated with 1 keyboard and 1 mouse.

Further Information

3.6.3

•

Catalog ST PCS 7

•

Catalog ST PCS 7.A (add-ons for SIMATIC PCS 7)

Connecting PC Components See section "Connecting Network Nodes to Ethernet"

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3.6.4

Additional Components for Acoustic and Optical Signaling

Signal module (I/O modules) PCS 7 OS single-workstation system and OS clients can be expanded with signal modules. These signal modules can control a horn and up to 3 different lamps or buzzer tones that represent a variety of message classes. Using a hardware timer (watchdog), the signal modules can detect and signal the failure of an operator station. A hardware acknowledgment button can also be connected. The signal modules are installed in a PCI slot in the operator station.

Sound card You can also use a standard sound card installed in the operator station.


For more information about the features and installation of signal modules, refer to the manual Process Control System PCS 7, WinCC Basic Process Control

•

For more information about the configuration of audible signal devices, refer to the configuration manual Process Control System PCS 7; Operator Station


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3.7

Selecting AS Components

3.7.1

What are the Criteria for Selecting the AS? Selected components from SIMATIC S7-400 form the basis of the PCS 7 process control system. The following can be configured by selecting hardware and suitable software: •

Standard automation systems

•

Fault-tolerant automation systems (H systems)

•

Fail-safe automation systems (F systems)

•

Fail-safe and fault-tolerant automation systems (FH systems)

SIMATIC PCS 7 Box SIMATIC PCS 7 Box is an industrial PC with integrated AS/ES/OS station. SIMATIC PCS 7 BOX is used for separate small plants or combined AS/OS stations that can be integrated in the PCS 7 network. The automation system integrated in SIMATIC PCS 7 is a standard automation system. Refer to the manual Process Control System PCS 7; SIMATIC PCS 7 Box to find all of the required information about the use of SIMATIC PCS 7 Box.

Criteria for Selecting the Automation Systems The highly varied requirements for automation systems do not permit a simple statement about the system to be employed. Below you will find a summary of the most important information about selecting automation systems that is described in detail elsewhere in the manual: •

Section "How Many CPUs Are Needed for Automation?"

•

Section "How Many Devices, Sensors and Actuators Can Be Integrated?"

•

Section "Redundancy Concept of PCS 7"

•

Section "Safety Concept of PCS 7"

The sections below contain additional information regarding the actual selection of automation systems and the I/O components to be connected.

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Configuration in RUN The automation systems released for PCS 7 support the "Configuration in RUN" function: Automation system

Configuration in RUN

Functionality for all automation systems:

•

Add/remove new slave

•

Add/remove new module

•

Reconfigure installed module

•

Changing the memory capacity

•

Changing the CPU parameters (labeled blue in HW Config: e.g. CPU Properties > Protection > Password Protection)

•

Add/remove S7-400 modules

Additional functionality for faulttolerant automation systems:

List of Usable Components Note A list of all the modules that can be used for a PCS 7 version is available in the document PCS 7 - Released Modules.

3.7.2

Overview of Automation Systems

Components in an Automation System The automation system is available as a preassembled complete system. An automation system essentially consists of the following components: •

Module rack with 9 or 18 slots

•

Power supply

•

S7-400 CPU

•

Connector for Industrial Ethernet

•

Memory card


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3.7.2.1

Standard Automation Systems for PCS 7 The following systems are available as standard automation systems:

Consisting of ...

AS 414-3

AS 416-2

AS 416-3

AS 417-4

CPU

CPU 414-3

CPU 416-2

CPU 416-3

CPU 417-4

DP interface

2 integrated

2 integrated

2 integrated

2 integrated

+ 1 DP module

+ 2 DP modules

Ethernet interface

+ 1 DP module CP 443-1

CP 443-1

CP 443-1

CP 443-1

Work memory CPU <= V3.1 (each code + data)

384 Kb

800 Kb

1600 Kb

2 Mb

Work memory CPU > V3.1 (each code + data)

700 Kb

1400 Kb

2800 Kb

10 Mb

Memory card RAM

1 Mb

2 Mb

4 Mb

4/8 Mb

Runtime license PCS 7 Library

1

1

1

1

Backup battery

2

2

2

2

Power Supply

PS 407; 10 A for AC 120/230V

PS 407; 10 A for AC 120/230V

PS 407; 10 A for AC 120/230V

PS 407; 10 A for AC 120/230V

or

or

or

or

PS 405; 10 A for DC 24V

PS 405; 10 A for DC 24V

PS 405; 10 A for DC 24V

PS 405; 10 A for DC 24V

Expandable: 10 Mb

Number of slots

9 or 18

9 or 18

9 or 18

9 or 18

Slots reserved for PS, CPU and CP

5

4

5

5

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3.7.2.2

Fault-tolerant Automation Systems for PCS 7 The fault-tolerant automation systems are: •

Equipped with two CPUs = ...-2H: The redundant subsystems are mounted in a single rack.

•

Equipped with only one CPU = ...-1H: These automation system are used when the redundant subsystems have to be spatially separated due to safety reasons, for example.

The following systems are available as fault-tolerant automation systems: Consisting of ...

AS 414-4-2H

AS 417-4-2H

AS 414-4-1H

AS 417-4-1H

CPU

2 * CPU 414-4H

2 * CPU 417-4H

CPU 414-4H

CPU 417-4H

DP interface

2 integrated in each

2 integrated in each

2 integrated

2 integrated

Ethernet interface

2 * CP 443-1

2 * CP 443-1

CP 443-1

CP 443-1

Work memory CPU <= V3.1 (each code + data)

384 Kb

2 Mb

384 Kb

Work memory CPU > V3.1 (each code + data)

700 Kb

10 Mb

700 Kb

10 Mb

Memory card RAM

1 Mb each

4 Mb each

1 Mb

4 Mb

Runtime license PCS 7 Library

1

1

1

1

Backup battery

4

4

2

2

Sync modules

4

4

-

-

Sync cable

2

2

-

-

Power Supply

PS 407; 10 A for AC 120/230V

PS 407; 10 A for AC 120/230V

PS 407; 10 A for AC 120/230V

PS 407; 10 A for AC 120/230V

or

or

or

or

PS 405; 10 A for DC 24V

PS 405; 10 A for DC 24V

PS 405; 10 A for DC 24V

PS 405; 10 A for DC 24V

Number of slots

2 * 9 (UR2-H)

2 * 9 (UR2-H)

9, 18

9, 18

Slots reserved for PS, CPU and CP

2*5

2*5

5

5


2 Mb Expandable: 10 Mb

Expandable up to 10 Mb

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Example Configuration AS 414/417-4-2H with UR2-H Rack UR2H

Rack S7 400H Rack 0

2 PS

2 CPU 2 Fiber optic and cables 2 CP 443-1

Rack 1

4 Synchronization modules

Rack UR2-H The UR2-H is a compact, special rack with a split backplane bus and therefore suitable for configuring a complete fault-tolerant automation system.

Synchronization Modules Synchronization modules are used to link the two central processing units. They are installed in the central controller module and interconnected with fiber-optic cable. Two synchronization modules are installed in each central controller.

3.7.2.3

Fail-safe Automation Systems for PCS 7 The fault-tolerant automation systems are used as the hardware for the fail-safe automation systems AS 414F and AS 417F. The following H systems are available depending on the type and configuration of the fail-safe automation system: •

For fail-safe systems (F systems): one AS 414-4-1H each or AS 417-4-1H

•

For fail-safe and fault-tolerant automation systems (FH systems) -

The two subsystems in a single rack: one AS 414-4-2H each or AS 417-4-2H

-

The two subsystems in separate racks: two AS 414-4-1H each or AS 4-417-1H

The safety functions are implemented by the installing F runtime licenses and programming tools / block libraries for fail-safe user programs (F programs).

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3.7.3

Limits of the CPUs for PCS 7 Projects The following table provides an overview of the limits for the most important performance specification of the CPUs used in PCS 7 projects:

Parameters

Limit

Limit

Limit

PCS 7

PCS 7

PCS 7

CPU 414-3

CPU 416-2

CPU 417-4

CPU 414-4H

CPU 416-3

CPU 417-4H

Local data area in bytes

16,384

32,768

65,536

Process image in bytes (I+O each)

8,192

16,384

16,384

I/O address space of the CPU in bytes (I+O each)

8,192

16,384

16,384

I/O address space of MPI/DP in bytes (I+O each)

2,048

2,048

2,048

I/O address space of DP/MPI in bytes (I+O each)

6,144

8,192

8,192

I/O address space of DP module in bytes (I+O each)

6,144

8,192

8,192

I/O address space of CP443-5 ext in bytes (I+O each)

4,096

4,096

4,096

600

1,800

10,000

Instances for alarms and communication calls Number of FBs

2,048

2,048

6,144

Number of FCs

2,048

2,048

6,144

Number of DBs

4,096

CPU <= V3.1 Work memory integrated in Kb

384

4,096 416-2:

8,192 800

416-3: 1,624

Expandable: 10,240

416-2: 1,400

10,240

(code + data each) CPU > V3.1 Work memory integrated in Kb

700

2,048

416-3: 2,800

(code + data each) RAM integrated load memory in Kb

256

256

256

(code + data each)


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3.7.4

Default Performance Parameters of the CPUs for PCS 7 Projects The following table shows the default parameters regarding the performance of the CPUs for PCS 7 projects. These values are set as defaults in the configuration of the CPU with PCS 7 software. They suffice for typical applications but can be changed within limits as required for configuration.

Parameters

Cycle load from communication [%] cycle

Default value PCS 7 Default value PCS 7 Default value PCS 7 CPU 414-3XJ00

CPU 416-2XK02

CPU 417-4XL00

CPU 414-4HL01

CPU 416-3XL00

CPU 417-4HL01

20

20

20

OB85 call for process update on the Only for incoming and Only for incoming and Only for incoming and system outgoing errors outgoing errors outgoing errors Cycle monitoring time [ms] cycle Minimum cycle time [ms] cycle Local data: priority class:

6,000

6,000

6,000

0

0

0

1,024

1,024

1,024

256

256

256

16,384

17,000

32,768

416-2: 2,048

3,072

1-2, 9-12, 16, 24-28 Local data: priority class: 3-8, 13-15, 17-23, 29 User local data area (bytes) Process image

768

(I+O each) (bytes) Diagnostics buffer number of elements

416-3: 3,072 3,000

3,000

3,000

Instances for alarms and communication calls

600

1,800

3,000

Module finished message monitoring time [100] ms

650

650

650

Parameter monitoring time [100] ms

600

600

600

QTM

out

out

out

in

in

in

Warm restart

Warm restart

Warm restart

Reasons for STOP message Startup mode Clock memory

None

None

None


None

None

None

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3.7.5

Components for Fault-tolerant Automation Systems

How the H System Works The automation system consists of two redundantly configured subsystems that are synchronized through fiber-optic cables. The two subsystems form a faulttolerant automation system that operates according to the principle of active redundancy. Active redundancy means that all the redundant equipment is permanently in operation and also takes part in the execution of the control task. The user programs loaded in both CPUs are fully identical and are run synchronously by both CPUs. If the active CPU fails, the automation system automatically switches to the redundant CPU. The failover has no effect on the ongoing process because it is bumpless.

Example Configuration for an H System

Ethernet

Engineering Station inlcuding license S7 H System Operator Station (plant visualization)

Plant Bus Industrial Ethernet Industrial

PROFIBUS DP

Fault-tolerant automation systems AS 414H / AS 417H (optionally with redundant power supply)

ET 200M

ET 200M

Dual channel switched I/O ET 200M, consisting of 2 x IM 153-2 und 2 x SM

Redundant I/O module

Sensor


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Components in a Basic Configuration of an H System The following components can be used to configure a complete fault-tolerant automation system with connected I/O: •

License for S7 H systems for configuring and programming the H system

•

Fault-tolerant automation system (AS 414-4-1H, AS 414-4-2H, AS 417-4-1H or AS 417-4-2H) with interface for connecting to the Industrial Ethernet plant bus and PROFIBUS DP field bus. Selecting the AS: see section "Overview of Automation Systems"" Connecting to the plant bus: see section "Connecting Network Nodes to Ethernet" Connecting to the field bus: see section "Connecting PROFIBUS DP Nodes"

•

Redundant PROFIBUS DP for connecting distributed I/Os: See section "Configuration of Redundant PROFIBUS DP Networks"

•

Distributed I/Os with ET 200 components: ET 200M with S7-300 signal modules (also with redundant signal modules) Refer to the section "Overview of Usable Distributed I/O System ET 200"

Connecting other Components •

PROFIBUS DP devices that can be configured non-redundant: See section "Connecting Non-redundant PROFIBUS DP Devices to Redundant PROFIBUS DP"

•

Intelligent field devices to PROFIBUS PA: See section "Connecting PROFIBUS PA to PROFIBUS DP"

Combined Operation Note It is possible to operate the fault-tolerant and standard automation systems in combination.


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3.7.6

Components for Fail-safe Automation Systems

How the F System Works Fail-safe automation systems detect errors in the process, even their own internal errors, and automatically bring the plant to a safe state when a fault occurs. The fail-safe automation systems (F/FH systems) based on the AS 414-4-H and AS 417-4-H automation systems combine standard production automation and safety technology in a single system. They are certified by the German Technical Inspectorate (TÜV) and conform to safety requirement category SIL 1 to SIL 3 according to IEC 61508, requirement category AK 1 to AK 6 according to DIN V 19250/DIN V VDE 0801 and categories 2 to 4 according to EN 954-1.

Safety Mechanisms of the F Systems: See section "Safety Concept of PCS 7""

FH Systems Fail-safe automation systems can be configured as single-channel (F system with one CPU) or as redundant (FH system). The redundancy of the FH systems is not relevant for failure safety. It is not used for fault detection; it serves only to increase the availability of fail-safe automation systems.


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Example Configurations for F/FH Systems

Ethernet

Engineering Station inlcuding option package S7 F system S7 H system Operator Station (plant visualization)


F system

PROFIBUS DP

IM 153 Isolation Module

PROFIBUS DP

PROFIBUS DP

F Module ET 200M

AS 414FH/ AS 417FH

AS 414FH/ AS 417FH

AS 414F/ AS 417F

ET 200M

2x IM 153

FH system

ET 200M

FH system with redundant I/O

Components in a Basic Configuration of an F System The following components can be used to configure a complete fail-safe automation system with connected I/O: •

F runtime license for editing fail-safe user programs

•

Optional package F systems for configuring and programming the H system

•

Fault-tolerant automation system (AS 414-4-1H or AS 417-4-1H) with interface for connecting to the Industrial Ethernet plant bus and PROFIBUS DP field bus. Selecting the AS: see section "Overview of Automation Systems" Connecting to the plant bus: see section "Connecting Network Nodes to Ethernet" Connecting to the field bus: see section "Connecting PROFIBUS DP Nodes"

•

Distributed I/Os with ET 200 components: -

-

ET 200M with fail-safe S7-300 signal modules (F modules) Isolation module for protecting against overvoltage between standard S7-300 signal modules and fail-safe S7-300 signal modules in the ET 200M ET 200S with fail-safe power modules

Refer to the section "Overview of Usable Distributed I/O System ET 200"

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Components for FH Systems The following fault-tolerant automation systems are available depending on the type and configuration of the FH system: •

The two subsystems in a single rack: AS 414-4-2H or AS 417-4-2H

•

The two subsystems in separate racks: AS 414-4-2H or AS 417-4-2H

In addition to the configuration of F systems, see section "Components for Faulttolerant Automation Systems" for all possible configurations of an H system that can be used in combination. The S7 H Systems license must be installed in the engineering station in addition to the optional package S7 F Systems.



•

Manual Automation System S7-300; Fail-safe Signal Modules


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3.8

Selecting the I/O Components

3.8.1

Introduction PCS 7 offers a wide range of options for connecting I/O devices and for recording and outputting process signals via sensors and actuators: •

Analog and digital input/output modules of the S7-400 operated centrally in the automation system

•

ET 200M, ET 200S, ET 200iSP distributed I/O systems connected to the automation system via PROFIBUS DP with a comprehensive range of signal and function modules

•

Direct connection of intelligent, distributed field/process devices and operator terminals via PROFIBUS DP/PA (also redundant or in hazard zones 0, 1 or 2)

Signal and Function Modules for PCS 7 Note PCS 7 only supports diagnostics for the signal and function modules listed in the document PCS 7 - Released Modules. All other signal modules from the current S7-400 and S7-300 product range can also be used. When these other signal modules are used, however, the integration is limited to process data, which means the full diagnostics capability of PCS 7 is not automatically available.

3.8.2

Should Distributed or Central I/O Be Used?

Using Central I/O Central I/O is primarily used for small applications or plants with a small, distributed structure.

Note The following PCS 7 functions cannot be used with central S7-400 signal modules:

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•

Configuration in RUN

•

Signal modules redundancy

•

Fail-safe signal modules



Using Distributed I/O PCS 7 plants are for the most part configured with distributed I/Os. The main advantages of this are: •

Modularity and uniformity

•

Low cabling and commissioning costs

•

Low space requirements

•

No need for terminal boards, sub-distribution boards and hazardous area buffer stages

•

Can increase availability using redundant configuration of signal modules

•

Safe states using fail-safe signal modules

•

Can be expanded and reconfigured in CPU RUN

•

Easy fault location using self-diagnostics with detailed information


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3.8.3


Connecting Field Systems to PCS 7 PCS 7 is optimized for the integration of distributed field systems in the process control system and uses PROFIBUS technology to accomplish this.

Ethernet

Engineering Station/Operator Station with SIMATIC PDM (local configuration of field devices for PROFIBUS DP, PROFIBUS PA and HART)


Automation System

ET 200M

HART

c

1

PROFIBUS DP connection via ET 200M

ET 200iSP HART

0

PROFIBUS DP

COMMUNICATION FOUNDATION

Ex

PROFIBUS DP connection via ET 200iSP

DP/PA Link PROFIBUS PA

PROFIBUS DP connection via DP/PA Link

Field devices on PROFIBUS DP

S o CAL oLIM oAR

o CODE

63,29 36,72 +/-

7

8

9

.

4

5

6

0

1

2

3

Clear

ESC

Enter

MEAS

Info

ULTRAMAT 6

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Devices that can be Connected as Distributed Components The following table shows: •

The field devices, sensors and actuators that can be connected as distributed components in a PCS 7 plant

•

The components used for communicating with these field devices, sensors and actuators

Device

I/O

Further Information

Sensors and actuators

Direct connection to the distributed I/O systems ET 200M, ET 200iS, or ET 200iSP

Overview of Usable Distributed I/O System ET 200

Intelligent PROFIBUS DP Direct connection to PROFIBUS DP (DP capable field devices master system) Intelligent PROFIBUS PA Direct connection to PROFIBUS PA capable field devices and

Connecting PROFIBUS PA to PROFIBUS DP

Simultaneous coupling of PROFIBUS PA to the PROFIBUS DP (DP master system) using DP/PA Link or DP/PA Coupler HART field devices

Direct connection to special I/O Connecting HART Devices to components of the distributed I/O systems Distributed I/Os ET 200M or ET 200iSP

Non-redundant PROFIBUS DP devices

Indirect connection of a device to a redundant PROFIBUS DP

3.8.4

Connecting Non-redundant PROFIBUS DP Devices to Redundant PROFIBUS DP

Use in Fault-tolerant or Fail-safe Automation Systems? The following table shows the automation systems in which the distributed I/O system ET 200 can be used. Automation system

ET 200M

ET 200S

ET 200iSP

Standard (AS 400)

X

X

X

Fault-tolerant (AS 400H)

X

Fail-safe (AS 400F)

X

Fail-safe and fault-tolerant (AS 400FH)

X

X X

Further information Section "Overview of Usable Distributed I/O System ET 200 "


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3.8.5

Overview of Usable Distributed I/O System ET 200 The following table provides an overview of the most important properties of the distributed I/O system from ET 200 used in PCS 7.

Property Protection level Digital modules

Analog modules Modules for motor starter Controller and counter modules hazardous digital/analog modules Fail-safe modules

Redundancy capable digital/analog modules Modules have enhanced diagnostic capability HART field devices can be connected

"Hot swapping" function in ongoing operation Configuration and parameter assignment Configuration in RUN (CiR) Can be used in hazardous areas (hazardous zones)

Max. n modules per station Electrical bus connection

Optical bus connection

Bus connected via connection modules Transmission rate Interfacing PROFIBUS DP devices to redundant PROFIBUS DP

3-86

ET 200M IP20 x

x x x (Analog module also for HART) x (+ isolation module)

ET 200iSP IP30 x (with counter/frequency measurement function) x x

ET 200S IP20 x

-

x x -

x

-

x (+ ET 200S SIGUARD) -

x

x

x

x (Parameter assignment via PDM)

x (Parameter assignment via PDM) x

-

x

HW Config and PDM

HW Config

x (+ active bus module) HW Config

Refer to the section "Can the Configuration be Changed During Ongoing Operation?" x x x ET 200M: Zone 2 ET 200iSP/ HART: Zone 2 (except motor (+ hazardous area Zone 1, 2 starter) partition) Acturator/sensor: Actuator/sensor/ Zone 0 HART: Zone 1 n=8 n = 32 n = 63 x x x (IM 153-2 (IM 152) (IM 151-1 High Feature) High Feature) x (IM 153-2 FO High Feature) x x x max. 12 Mbps Y Link

max. 1.5 Mbps -

max. 1.5 Mbps -



3.8.6

Connecting HART Devices to Distributed I/O

What is HART? HART (Highway Addressable Remote Transducer) is serial transmission method used to transmit additional parameter data such as measurement range, damping etc. to connected measuring transducers and actuators over a 4-20 mA current loop.

Use in PCS 7 •

HART devices can be connected to the distributed I/O system ET 200M in both standard environments as well as hazardous areas. Special S7-300 hazardous area signal modules with HART enable connection to HART devices certified for use in hazardous areas. The S7-300 hazardous area modules with HART are diagnostics capable (with channel and module diagnostics).

•

HART devices can be connected to special analog HART electronic modules of the distributed I/O system ET 200iSP.

All transducers and HART actuators certified for digital communication using the HART protocol can be connected through the ET 200M and ET 200iSP.

Example Configuration

Ethernet

Engineering Station / Operator Station with SIMATIC PDM (centralized configuration of field devices an PROFIBUS DP, PROFIBUS PA and HART)


ET 200M

HART

c

1


ET 200iSP

0

PROFIBUS DP

Automation System

HART

PROFIBUS DP Link via ET 200M

Ex PROFIBUS DP/iS Link via ET 200iSP


3-87


Use in Hazardous Zones •

On an ET 200M in hazardous zone 2 or

•

On an ET 200iSP in hazardous zone 1 or 2

Configuration of HART Field Devices HART field devices are configured for PCS 7 with SIMATIC PDM.

3.8.7

Can the Configuration Be Changed During Ongoing Operation? The following table provides an overview of the permitted configuration changes that can be made to the distributed I/O during ongoing operation (CPU RUN).

Components

Permitted configuration changes

ET 200M

•

Add/remove ET 200M stations

•

Add/remove new I/O modules

•

Parameter assignment for I/O modules

•

Configuration of connected HART field devices via SIMATIC PDM

Note: Only when IM 152-2 HF or IM 153-2 HF-FO is used ET 200S, ET 200iSP

PROFIBUS DP, PROFIBUS PA

•

Add/remove ET 200S/iSP stations

•

ET 200iSP: Parameter assignment for I/O modules as well for HART field devices connected to HART modules via SIMATIC PDM

•

Add/remove PROFIBUS DP nodes

•

Add/remove DP/PA links and DP/PA field devices

•

Parameter assignment for field devices with SIMATIC PDM

Further information Section Rules for Configuration Changes in RUN (CiR)

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3.8.8

How Can Distributed I/O Be Integrated in Hazardous Zones?

Integrating I/O in hazardous zones The following illustration shows an overview of the various possibilities for integrating distributed I/Os in hazardous zones:


PROFIBUS DP

Standard Automation Systems

OS

Intrinsically safe HMI device

ET 200M HART

c


M

Acuators/ Sensors PROFIBUS DP/iS ET 200iSP M

HART

Ex

Acuators/ Sensors

M

c


DP/PA Link

PROFIBUS PA

Zone 0

Zone 1 Zone 2


3-89


Legend to illustration Components

Use in Hazardous Zones

ET 200M

ET 200M can be operated in hazardous zone 2. The actuators/sensors can be located in hazardous zone 1 when the appropriate hazardous area I/O modules are used. Hot swapping of I/O modules is permissible in hazardous zone 2 with appropriate permission (e.g. fire certificate).

ET 200iSP

ET 200iSP can be installed directly in hazardous zones 1 or 2 (EEx de ib [ia/ib] IIC T4). Sensors/actuators also in Zone 0. Individual modules can be hot swapped under hazardous conditions.

PROFIBUS PA capable field devices

Field and process devices can be integrated directly in hazardous zones 1 or 2 per PROFIBUS PA. Sensors/actuators also in Zone 0.

Intrinsically Safe Operator Panel If required, an intrinsically safe PC operator panel (PCS 7 add-on) can be used in hazard zones 1 or 2. The panel is connected to an operator station, and distances up to 750 m are possible.

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3.9

Preparation for Efficient Engineering

3.9.1

Planning Objects/Functions for Efficient Engineering The following table provides an overview of the objects/functions for efficient engineering that you should take into consideration when planning the plant engineering with PCS 7.

Function

Brief Description

Tool

Process control library

PCS 7 offers a library with a wide range of Standard preconfigured and tested blocks, faceplate and PCS 7 symbols for graphic configuration of automation software solutions. These library elements can contribute considerably to minimize engineering requirements and project costs.

Additional section in this manual How Are Repeatedly Used Technological Functions Supported?

The comprehensive range of blocks includes simple logic and driver blocks, technological blocks with integral operation and signaling response such as PID controllers, motors or valves, and blocks for integration of PROFIBUS field devices. Multiproject engineering

Multiproject engineering enables an extensive Standard plant project to be divided into several functions of subprojects based on technological factors. The PCS 7 subprojects can then be work upon simultaneously by several project engineers.

Configuring in a Multiproject

Advantage: •

The individual projects can be added or removed from a multiproject at any time.

•

The subprojects in a multiproject are stored on a central server and moved to the local engineering stations for editing.

•

Once the subprojects are assembled back into the multiproject, the cross-project functions (such as compiling and downloading) are implemented for the entire plant.

Master data library

A custom library can be created for a project to improve efficiency.

Standard functions of PCS 7

Objects of the master data library

Branching and merging projects

Branch & merge is a function for multiproject engineering and is used to separate and reassemble project parts based on technological factors. Charts or plant units can be copied into another project to be modified there.

Standard functions of PCS 7

Branching and Merging Charts of a Project


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Function

Brief Description

Tool


Importing configured plant data

Configured plant data such as process tag lists or charts from the higher-level CAD/CAE world can be imported into the engineering system and used for almost fully automatic generation of process tags.


Which Data and Data formats Can Be Imported?

Automatic generation of process tags

Adopting the Data from the Plant Engineering

Based on the imported process tag lists and Import/Export custom defined process tag types, a great many Assistant process tags (CFC charts in PCS 7) are generated automatically and store in the correct location in the plant hierarchy.

Working with Process Tags and Models

Exporting configuration data

During the configuration and commissioning, parameters optimized with PCS 7 can be exported back into the CAD/CAE world.

Working with Process Tags and Models

Automatic expansion/modifica tion of hardware configurations

Station configurations can be exported from HW Config HW Config, modified and adapted outside of the project, and then imported back in again. The symbolic names of the inputs and outputs are also exported and imported again.


Using Process Tag Types

Import/Export of the Hardware Configuration

This function can be used for efficient engineering of plants with repeatedly used hardware structures.

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3.9.2

Which Data and Data Formats Can Be Imported? The following table shows: •

The work phases in which data can be imported

•

The data formats that can be imported

•

The application in which the data can be generated

Work phase in engineering

Available import formats

Application for generation

Creation of process tags

Lists in the format:

(CFC charts in PCS 7)

•

csv

Application that can export lists as csv files (e.g. Excel, Access)

Hardware configuration

•

cfg

HW Config (Standard PCS 7)

Create pictures for OS

Imported graphics in the format:

(non-dynamic screen elements)

•

emf

•

wmf

Any graphics application

Imported graphic objects in the format:

Foreign language texts

•

emf

•

wmf

•

dib

•

gif

•

jpg

•

jpeg

•

ico

•

txt

•

csv

Text editors (e.g. Excel, Wordpad)


Section "Import and Reuse of Plant Data"

•

Section Adopting the Data from the Plant Engineering"


3-93


3.9.3

How Are Repeatedly Used Technological Functions Supported?

Introduction •

Templates (standard types, standard solutions) are provided to support you in the configuration of a PCS 7 plant. They are contained in the PCS 7 Process Control Library.

•

It is also recommended to assemble similar function to improve the efficiency of the plant engineering. The configuration of similar functions can be achieved by implementing repeatedly used objects (such as process tag types and models).

Templates in the PCS 7 process control library Templates are available for the following technological functions in the PCS 7 Library: •

Controls for measured value displays

•

Binary value acquisition with monitoring

•

Analog value acquisition with monitoring

•

Manual adjustment

•

Fixed setpoint control

•

Cascade control

•

Ratio control

•

Split range control

•

Dosing

•

Motor control manual/automatic

•

Motor control (variable speed)

•

Valve control manual/automatic

•

Valve control continuous

•

Sequence control

If you wish to become better acquainted with the individual blocks and the way they are used, read the manual Process Control System PCS 7 Library.

3-94



Recommendation for configuring a large number of process tags Create a process tag list that contains all process tags. Give some thought about which process tags are to be assigned to a process tag type. Use this list during the engineering to generate the CFC charts with the corresponding process tags based on the process tag types in the Import/Export Assistant. The import file must have a specific format. The exact format is described in the section "Creating/Editing Import Files with the IEA File Editor". In preparation, you should create a process tag list containing the following information (example): Components

Measurement

Measurement

Motor

Block

1

2

1

Plant area

Plant area 1

Plant area 2

Plant area 1

Plant area 1

Subarea

Dosing plant

Oil heating

Mixer

Gas heating

Type

3 (PT 100 – temperature measurement)

3 (method of measurement, e.g. square-root)

10

etc.

Property 1

Measuring range start Measuring range start in (e.g. 263 °K)

Property 2 Property 3

Limit 1:300 °K

Property 4 Property 5

Property 6

Limit 4:400 °K

Property 7

etc.

Property ...

etc.

etc.

(e.g. 0 mA)

Measuring range end Measuring range end out (e.g. 473 °K)

....

etc.

(e.g. 100 mA) Feedback in

etc.

Limit 2:320 °K

Feedback out

etc.

Limit 3:390 °K

Temperature sensor (type 1 - PT 100)


Section "Adopting the Data from the Plant Engineering"


3-95


3-96


4


4.1

Basic Configuration of the PCS 7 Plant The following figure shows the basic components of a PCS 7 plant. Operator Station

1

BATCH Station

2

3

Ethernet

Engineering Station

Industrial Ethernet Industrial

Central I/O

4

PROFIBUS DP

Automation System AS 400


Distributed I/O

4-1


Legend to illustration Station

No. in Figure

Engineering station

1

Function The engineering station is used for centralized engineering of all PCS 7 system components: operator stations, BATCH stations, automation systems, central and distributed I/O. The configuration data is downloaded to the PCS 7 system components when the engineering is completed. Changes can only be made on the engineering station. This is followed by a new download.

Operator station

2

Your PCS 7 plant is controlled and monitored in process mode on the operator station.

BATCH station

3

Discontinuous processes (batch processes) are controlled and monitored in process mode on the BATCH station.

Automation system

4

The automation system •

registers and processes process variables from the connected central and distributed I/O and outputs control information and setpoints to the process

•

supplies the operator station with the data for visualization

•

registers actions on the operator station and forwards them to the process

Further information

4-2

•

Section "Connecting Network Nodes to Ethernet"

•

Section "Connecting PROFIBUS DP Nodes"



4.2

Configuration of the PC Stations

4.2.1

Engineering Station Configurations

Engineering Station Engineering stations are PCs on which the PCS 7 engineering software for configuring a PCS 7 project is installed. An engineering station must be connected to the plant and terminal bus to download the configuration data to the PLC (OS, BATCH, AS) and test in process mode. OS Clients

BATCH Clients

PCS 7 ES Terminalbus Industrial Ethernet

OS Server

Redundant BATCH Server Ethernet

Redundant OS Server


PC Configuration Options for the Engineering Station The following PC configurations are possible for engineering stations in a PCS 7 plant: •

Engineering of a PCS 7 project on a single PC

•

For small plants: -

Combination of engineering station and operator station on a single PC

-

Combination of engineering station, operator station and automation system on a single PC This solution is provided by SIMATIC PCS 7 Box.


4-3


•

For large plants - PCS 7 project engineering with several engineering stations:

Configuration

Method

Note

With common server (standard office network)

The engineering stations of the individual employees work on the multiproject in a PC network.

An employee works on a single project on a local engineering station.

Without a common server

•

The multiproject is saved on a central engineering station and the cross-project connections are created.

This method allows distributed engineering (for example at several locations).

•

The individual projects are moved to distributed PCs for engineering.

•

When the projects are completed, they are copied back to the central engineering station and the cross-project functions are finalized.

Further information

4-4

•


•

For detailed information about configuring engineering stations and installing the operating system and PCS 7 engineering software including the required authorizations, refer to the manual Process Control System PCS 7; PC Configuration and Authorizations.

•

Configuration manual Process Control System PCS 7; SIMATIC PCS 7 BOX



4.2.2

Operator Station Configurations

Operator station Operator stations are PCs on which the PCS 7 OS software is installed. The operator station is connected to the plant bus to allow data exchange with the automation system. The architecture of the operator station is highly variable and can be flexibly adapted to a variety of plant sizes and customer requirements. The operator station can be configured as a single workstation or multiple workstation system with client/server architecture. When installing a multiple workstation system, a terminal bus (separate from the plant bus) is recommended for data communication between OS clients and the OS server. The process values archive can be stored on separate archive servers to improve performance. To increase availability, operator stations can be set up redundantly. Archive Server

OS Clients (max. 32 in Multi-client Mode)

Terminal Bus Industrial Ethernet

Ethernet

OS Servers max. 12 (redundant) Plant Bus Industrial Ethernet Industrial

PC configuration options for operator stations The following PC configurations can be created for operator stations in a PCS 7 plant: •

OS as single workstation system on a single PC: Complete operator control and monitoring capability for a PCS 7 project (plant/unit ) on one station. The OS single workstation system can be used on the plant bus at the same time as other single workstations or multiple workstation systems. Two OS single workstation systems can also be operated redundantly with the software WinCC/Redundancy. The operator station can also be used in combination with an engineering station and an automation system on a single PC. This solution is provided by SIMATIC PCS 7 Box.


4-5


•

OS as multiple workstation system with client/server architecture: Consists of OS clients (operator stations) that are supplied with data (project data, process values, archives, alarms and messages) by one or more OS servers via a terminal bus (OS LAN). OS client can simultaneously access data on several OS servers (multiclient mode). OS servers are also capable of client functions that allow them to access data (archives, messages, tags, variables) on other OS servers. This allows process pictures on one OS server to be interconnected with tags on other OS servers. The OS Redundant Server Pack software enables OS servers to be operated redundantly. Up to 4 monitors can be connected to a workstation (OS client) via a multi-VGA card. Plant areas divided in such a way can be operated with 1 keyboard and 1 mouse.

•

OS with central archive server: For operator stations, it is also possible to use a central archive server on a separate PC station. The archive server is a node on the terminal bus and is not connected to the plant bus.

Maintenance Station (MS) As of PCS 7 V6.1, an operator station (an OS area) can also be configured and used as a maintenance station. With the maintenance station, it is possible to call up information on the status of all PCS 7 components in hierarchically structured diagnostic pictures. A maintenance station can be set up in an MS client/MS server architecture. The MS client is operated ideally on an engineering station. The MS server is an OS server.

Further information

4-6

•


•

Section "How Many Operator Stations Are Required?"

•

For detailed information on the structure of operator stations or maintenance stations and on installing the operating system and the PCS 7 OS software including the necessary authorizations, refer to the manual Process Control System PCS 7; PC Configuration and Authorization.

•

Configuration manual Process Control System PCS 7; PCS 7 Box



4.2.3

BATCH Station Configurations

BATCH station BATCH stations are PCs on which the SIMATIC BATCH is installed. The BATCH station is connected to the terminal bus to allow data exchange with the operator station. In process mode, the BATCH station communicates with the automation system only over the operator station. The architecture of the BATCH station is highly variable and can be flexibly adapted to a variety of plant sizes and customer requirements. The BATCH station can be configured as a single workstation or multiple workstation system with client/server architecture. Typical batch process automation features one BATCH server and several BATCH clients that process the plant project together. BATCH servers can be configured redundantly to increase the availability. BATCH servers and OS servers should always be operated on separate PCs. BATCH clients and OS clients can be operated on a common PC.

OS Clients

BATCH Clients

Engineering Station Terminal Bus Industrial Ethernet Redundant BATCH Server Ethernet

Redundant OS Server Plant Bus Industrial Ethernet

Industrial

Automation Systems


4-7


PC configuration options for BATCH stations The following PC configurations can be created for BATCH stations in a PCS 7 plant: •

•

For small plants: -

BATCH station and operator station as a single workstation system on a single common PC

-

BATCH station separate from an operator station as a single workstation system on a single PC

For large plants: -

BATCH station as multiple workstation system with client/server architecture: Consists of one BATCH server and several BATCH clients (workstations) BATCH clients and OS clients can be operated on separate PCs or on a common PC. BATCH servers can also be operated redundantly. Up to 4 monitors can be connected to a workstation (BATCH client) via a multi-VGA card. Plant areas divided in such a way can be operated with 1 keyboard and 1 mouse.

Further information For detailed information about the configuration of BATCH stations and the installation of the operating system and PCS 7 BATCH software including the required authorizations, refer to the manual Process Control System PCS 7; PC Configuration and Authorizations.

4-8



4.3

Configuration of the Terminal and Plant Bus

4.3.1

Data Paths over the Terminal Bus and Plant Bus The following illustration shows the communication paths over the terminal bus and plant bus.

OS Clients

SIMATIC BATCH Clients

Engineering Station

Terminal Bus Industrial Ethernet OS Servers

BATCH Server


Automation Systems

Legend for Figure Bus

Data exchange and Communication between ... communication of the following processes

Terminal bus

Download of the configuration data Engineering station and

Plant bus

•

operator stations (OS server, OS clients)

•

BATCH stations (BATCH server, BATCH clients)

Communication between the servers

•

the OS servers

•

BATCH servers and OS servers relevant to BATCH

Transmission of data processed by the servers to the operator control and monitoring stations (clients)

•

OS server and OS clients

•

BATCH server and BATCH clients

Download of the configuration data Engineering station and automation system Operating and monitoring of the processes

Automation systems and OS server (CPU -> CP -> BUS -> network card (CP) -> OS) Note: Communication for SIMATIC BATCH is from the OS server to the BATCH server over the terminal bus.

Communication between automation systems (SIMATIC communication)


The automation systems (CPU -> CP -> BUS -> CP -> CPU)

4-9


4.3.2

Terminal Bus and Plant Bus Configurations

Topology Options The plant bus and terminal bus can be configured as: •

Industrial Ethernet (10/100 Mbps)

•

Bus, tree, ring, star or redundant ring structures

Properties of Industrial Ethernet: see section "Areas of Application and Parameters of the Network/Bus Systems"

Available SIMATIC NET Components Purpose PC (OS, BATCH and ES)

Components of SIMATIC NET

Connection components • for Ethernet

CP 1613

•

BCE with CP 1612

•

Integrated Fast

Further Relevant Sections Connecting Network Nodes to Ethernet

Ethernet adapter AS

Connection components • for Ethernet

Connection path Electrical transmission path

•

ITP cable (Industrial Twisted Pair)

Planning the Management Level with Ethernet

•

TP cable (twisted pair)

Optical and Electrical Transmission Media

•

Coaxial cable

Optical transmission path • Network coupler

Electrical transmission path

4-10

Glass fiber

•

ESM

Planning the Management Level with Ethernet

•

Star coupler, ELM

Use of Switching Technology

OSM, OMC

Planning the Field Level with PROFIBUS

Optical transmission path •

Optical and/or electrical transmission path

CP 443-1

•

OLM

•

SCALANCE X



Installing Redundant Buses See section "Configuration of Redundant Ethernet Networks"

Further information Refer to the following documentation for additional information about network architecture, network configuration, network components and installation instructions: •

List PCS 7 - Released Modules: contains SIMATIC NET components released for a PCS 7 version

•

Manual SIMATIC NET NCM S7 for Industrial Ethernet

•


•

Manual SIMATIC NET; Triaxial Networks

•

Manual SIMATIC Net Twisted Pair and Fiber-Optic Networks

•


•



4-11


4.4

Configuration of the Automation systems and the Connected I/O

4.4.1

Configurations of the Automation Systems The following automation systems can be configured by selecting hardware and suitable software:

Automation systems

Further Relevant Sections

•

Standard automation systems

•

Fault-tolerant automation systems (H systems)

Redundancy Concept of PCS 7

Fail-safe automation systems (F systems)

Safety Concept of PCS 7

Fail-safe and fault-tolerant automation systems (FH systems)

Redundancy Concept of PCS 7 and

• •

Recommended Use of Components Recommended Use of Components Safety Concept of PCS 7

Available S7-400 Components Purpose

Components

Further Relevant Sections

Automation system

•

Overview of Automation Systems Limits of the CPUs for PCS 7 Projects Default Performance Parameters of the CPUs for PCS 7 Projects Components for Fault-tolerant Automation Systems Components for Fail-safe Automation Systems Connecting Network Nodes to Ethernet

Fault-tolerant automation system •

AS 400H/F/FH

AS 400H

Fail-safe automation system

•

AS 400F/FH

Connection components for Ethernet Connectivity device for PROFIBUS

•

CP 443-1

• •

CP 443-5 Extended or DP interface

Connecting PROFIBUS DP Nodes

SIMATIC PCS 7 Box SIMATIC PCS 7 Box with integrated AS/ES/OS station: The AS is based on the standard CPU 416-2 PCI.

Further information

4-12

•


•


•


•

Manual S7-300 Fail-safe Signal Modules

•

Configuration manual Process Control System PCS 7; SIMATIC PCS 7 BOX Process Control System PCS 7 - Engineering System A5E00346923-02


4.4.2

Guideline in the installation instructions for the products This section provides orientation through the installation instructions in the individual product documentation manuals.

Note Information relating to installation in the project documentation manuals for SIMATIC components is also valid when PCS 7 is used. The few exceptions relating to installation are described in the section "Supplements to the Assembly Instructions for PCS 7 Products". Information relating to programming and parameter assignment in the project documentation manuals for SIMATIC components is of limited validity when PCS 7 is used. PCS 7 offers many additional tools and functions. You should follow the procedures described in the section "Creating the PCS 7 Configuration" in this manual when programming and setting the parameters of the SIMATIC components.

Guideline in the installation instructions for the products Components

Information relating to installation can be found in the following product documentation (• Chapter ...)

Communication Industrial Ethernet

Manual SIMATIC NET; NCM S7 for Industrial Ethernet Manual SIMATIC NET; Triaxial Networks Manual SIMATIC Net; Twisted Pair and Fiber-Optic Networks

PROFIBUS

Manual SIMATIC NET; PROFIBUS Networks

AS interface


OSM/ESM

Manual SIMATIC NET; Industrial Ethernet OSM/ESM Network Management

CP 443-1

Device manual SIMATIC NET S7-CPs for Industrial Ethernet/Part B4; CP 443-1 •

CP 443-5 Extended

• CP 1613

Installation and Commissioning (steps 1 to 3)

Device manual SIMATIC NET; S7-CPs for PROFIBUS / Part B4; CP 443-5 Extended: Installation and Commissioning (steps 1 to 2)

Installation instructions SIMATIC NET; CP 1613 Manual SIMATIC NET; Time-of-Day Functions of the CP 1613

CP 1612

Installation instructions SIMATIC NET; CP 1612

CP 1512

Installation instructions SIMATIC NET; CP 1512

RS-485 Repeater

Manual S7-400, M7-400 Programmable Controllers; Module Specifications: •

RS-485 Repeater

PC Stations PC stations (ES, OS, BATCH, PCS 7 BOX)

Manual Process Control System PCS 7; PC Configuration and Authorization •

Configurations

•

Structure

•

Installation


4-13


Components


Automation systems S7-400 (AS 414-3, AS 416-2, AS 416-3, AS 417-4)

Manual S7-400, M7-400 Programmable Controllers; Hardware and Installation: •

Installing the S7-400

•

Wiring the S7-400

•

Commissioning

Manual Programmable Controller S7-400; CPU Data

S7-400H (AS 414-4-H and AS 417-4-H)

•

Installation of a CPU 41x

•

Technical specifications

Manual Process Control System PCS 7; Fault-tolerant Process Control Systems: •

Fault-tolerant Solutions in PCS 7

Manual SIMATIC S7-400H Programmable Controllers; Fault-tolerant Systems:

S7-400F/FH (AS 414-4-H and AS 417-4-H)

•

S7-400H Installation Options

•

Getting Started

•

Installation of a CPU 41x-H

•

Using I/O on the S7-400H

•

Changing the system during operation

System Description Safety Engineering in SIMATIC S7: •

Overview of Fail-Safe Systems

•

Configurations and Help with Selections

Manual SIMATIC Programmable Controllers S7 F/FH •

Safety Mechanisms

Manual SIMATIC S7-400H Programmable Controller; Fault-tolerant Systems: •

S7-400H Installation Options

•

Getting Started

•

Installation of a CPU 41x-H

•

Using I/O on the S7-400H

S7-400-Signal Modules

Manual S7-400, M7-400 Programmable Controllers; Module Specifications:

FM 455 S

Manual FM 455 Controller Module:

FM 455 C

•

Controller Settings

•

Installing and Removing the FM 455

•

Wiring

•

CP 441

CP 444

4-14


Manual Point-to-Point Communication CP 441; Installation and Parameter Assignment: •

Basic Principles of Serial Data Transmission

•

Mounting

•

Wiring

Manual CP 444 Communication Processor; Installation and Parameter Assignment: •


•

Mounting

•

Wiring



Components


Distributed I/O ET 200M

Fail-safe Signal Modules

Manual SIMATIC; ET200M Distributed I/O Device: •

Configuration Options with the ET 200M

•

Mounting

•

Wiring

Manual SIMATIC; S7-300 Programmable Controller Module Specifications: •

Manual for hardware configuration and parameter assignment of components

•


S7-300 Signal Modules for Manual Distributed I/O Device ET 200M Signal Modules for Process Process Automation Automation:

S7-300 Fail-safe Signal Modules

S7-300-Ex Signal Modules

•


•


Manual Automation System S7-300; Fail-Safe Signal Modules: •


•


Manual S7-300, M7-300, ET 200M Programmable Controllers, I/O Modules with Intrinsically-Safe Signals: •


•


FM 355 S

Manual FM 355 and FM 355-2 Controller Modules :

FM 355 C

•

Controller Settings

•

Installing and Removing the FM 455

•

Wiring

CP 340 CP 341

ET 200iSP

ET 200S

DP/PA Link and DP/PA Coupler

Manual CP 340 Point-to-Point Communication and CP 341 Installation and Parameter Assignment: •


•

Mounting

•

Wiring

Manual SIMATIC; ET200iSP Distributed I/O Device: •

Configuration Options

•

Mounting

•

Wiring and Fitting

Manual SIMATIC; ET200S Distributed I/O System: •


•

Mounting

•

Wiring and Fitting

Manual SIMATIC; DP/PA Link and Y Link Bus Couplers: •

Description of the Components

•

Installation

•

Wiring


4-15


Components


Y Link

Manual SIMATIC; DP/PA Link and Y Link Bus Couplers:

Diagnostic repeater

4.4.3

•

Description of the Components

•

Installation

•

Wiring

Manual Diagnostic Repeater for PROFIBUS-DP: •


•

Mounting

•

Wiring

Supplements to the Assembly Instructions for PCS 7 Products

ET 200S diagnostics for load voltage failure Note The digital input/output modules of the ET 200S do not feature diagnostics for load voltage failure. This means no QBAD is reported when the load voltage fails on the channel drivers. The outputs can no longer be switched by the user program and the last valid value is displayed at the inputs when there is no load voltage.

The following configuration variants offer a remedy: •

Use of DC 24 V digital input/output modules with a PM-E DC 24 V power module: A power supply for the entire station (IM 151 and power module) from a single DC 24 V sources means that a station fails when the voltage fails. The failure is reported in PCS 7 and results in passivation of all involved modules, in other words, all channel drivers are set to QBAD.

•

Use of AC 120/230 V digital input/output modules with a PM-E AC 120/230 V power module: Monitoring of the load voltage in the user program

4-16



4.4.4

Rules for Configuration in RUN (CiR)

Rules for DP and PA Slaves Keep to the following rules when configuring distributed I/Os when CiR is used: •

Make sure that the DP master system has a sufficient number of branching points for tap lines or dividing points (tap lines are not permitted at transmission rates of 12 Mbps).

•

Install the ET 200M stations with the High Feature modules IM 153-2 HF or IM 153-2 HF-FO.

•

Terminate the PROFIBUS DP and PROFIBUS PA bus lines with active bus termination elements at both ends to ensure proper bus termination even while changing the configuration.

•

PROFIBUS PA bus systems should be equipped with components of the SpliTConnect product family to avoid having to disconnect cables.

•

ET 200M Stations and DP/PA Links must always be installed with an active backplane bus. When possible install all the bus modules that will be required because the bus modules cannot be installed and removed during operation.

•

In ET 200M stations, you may only insert modules directly after the last installed module or remove the last module. Always avoid gaps between modules.


4-17


4-18


5

Basic Concepts of Engineering Below, you will find an introduction to the basic mechanisms of engineering with PCS 7. The main emphasis is on PCS 7 functions that allow rational configuration:

5.1

•

Central, Plantwide Engineering

•

Creating Projects with the PCS 7 Wizard "New Project"

•

Distributed Engineering

•

Typing, Reusability, and Central Modifiability of Engineering Data

•

Import and Reuse of Plant Data

•

Free Assignment between Hardware and Software

•

Deriving the Picture Hierarchy and OS Areas from the PH

•

Generating Block Icons

•

Generating Operator Texts

•

Basic Concepts of the PCS 7 Message System

Central, Plantwide Engineering

Central Engineering with the SIMATIC Manager The SIMATIC Manager is the central starting point for all engineering tasks. Here, the PCS 7 project is managed, archived and documented. Starting from the SIMATIC Manager, you have access to all the applications of the engineering system. If there is a connection between ES, OS, BATCH, and AS, the configuration data can be transferred to all target systems from the SIMATIC Manager and then tested online.

Engineering System The engineering system is made up of coordinated applications that allow central, project-wide engineering of all components of a PCS 7 plant: •

Configuration of the hardware and field devices (HW Config, SIMATIC PDM)

•

Configuration of the communications networks (HW Config)

•

Configuration of continuous and sequential process activities (CFC, SFC, PCS 7 Library)

•

Configuration of discontinuous process activities - batch processes (SIMATIC BATCH)


5-1


•

Design of operator control and monitoring strategies (WinCC Graphics Designer, Faceplate Designer)

•

Compilation and downloading of all configuration data to all target systems automation systems (AS), operator stations (OS), and BATCH stations (BATCH) OS Engineering

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

Import/ CFC/SFC Export Assistant

Libraries

PCS 7 Engineering HW Config

WinCC Graphics Designer

SIMATIC Faceplate SIMATIC F-Tool Designer BATCH (S7 F Systems) PDM

SIMATIC Manager / Uniform Database

Automation engineering

Engineering for network/ communication/hardware

Engineering for SIMATIC PDM fail-safe for field devices systems parameterization

Totally Integrated Database The totally integrated database of the engineering system means that any data entered is available throughout the entire system.


5-2

Section "PCS 7 Applications and How They Are Used".



5.2

Creating Projects with the PCS 7 "New Project" Wizard

Introduction The "New Project" PCS 7 Wizard makes it easier to create a new PCS 7 project because all the necessary objects can be created automatically. The "New Project" PCS 7 Wizard is started in the SIMATIC Manager.

The next section must explain the advantages of using the wizard.


5-3


Multiproject or Single Project? Note We recommend that you always create a multiproject even if you only want a single PCS 7 project because the master data library is then also created and managed in the multiproject. Working with a multiproject has many advantages and subsequent extension of the project poses no problems. All the information in the following sections relates to a project in a multiproject.

Further Options of the PCS 7 "New Project" Wizard In the dialogs, you can select the following, •

which CPU you want to use

•

which other AS objects, OS objects (and if applicable, BATCH objects) you want to use

•

what your new project will be called.

•

where the project will be stored (project path).

A preview allows you to check the structure of your project in advance. You then start the finalization of the project.

Result In multiproject engineering, a multiproject is created with a subproject in the SIMATIC Manager in keeping with the preview (see figure above). The preview is adapted to the selected settings and shows you the structure that has been created by the wizard. A master data library with the following content is also created: •

In the plant hierarchy: one folder for process tag types and one for models

•

In the Component view: one S7 program with the folders for sources, blocks and charts

Subsequent Expansion Subsequent expansion of the multiproject by adding projects and objects is done in the SIMATIC Manager.


5-4

Section "How to Create a new Multiproject with the PCS 7 Wizard".



5.3

Distributed Engineering

Introduction PCS 7 provides the following options to allow more than one configuration engineer to work at the same time: •


•


If the project data is located on a central server, it can be exchanged between the engineering stations (for example, project-specific block library): •

5.3.1

Configuring in a Network


Application You use multiproject engineering when you want to work on large-scale projects with several project teams at the same time. To allow this, you divide up the automation solution technologically into several projects. The projects are created on a central engineering station below a "multiproject" and distributed to the individual computers of the configuration engineers (distributed engineering stations) for editing. After editing and returning the projects to the multiproject, data relevant to more than one project can be synchronized with system support.

Structure of the Multiproject The multiproject is a higher-level structure above the projects in the SIMATIC Manager and contains all projects, the master data library and lower-level objects (AS, OS, programs, charts etc.) of an automation solution.


5-5


Rules for Distribution in the Projects You should make the distribution so that all automation systems and operator stations to be edited by one configuration engineer are in one project. The following rules apply:

Note • A project of a multiproject must only be edited by one engineer at any one time. •

The smallest possible unit of a project is an AS or an OS.

•

Move only entire projects to the distributed engineering station.

•

Only move the objects (AS, OS) in the form of a project to a distributed engineering station that are actually needed for editing there. This means that all other objects of the multiproject are available for editing on other distributed engineering stations.

•

An OS server must include all the technological hierarchies of the automation systems assigned to it.

Overview of the Recommended Procedure To be able to work successfully with a multiproject, you should familiarize yourself with multiprojects by reading the topic "Working with Projects in the Multiproject" in the online help of STEP 7. When working with PCS 7, we recommend the following procedure.

Note Requirement: For distributed engineering (for large projects), Windows 2003 Server or Windows 2000 Server must be installed on the central engineering station to allow work over the network. The distributed engineering stations can use the Windows XP / 2003 Server / 2000 Professional operating system.

Step

Description

1

Create the multiproject with one project and the master data library on the central engineering station (with the "New Project" wizard)

2

Create further projects and the master data library of the multiproject on the central engineering station

3

Move the projects and the master data library in the multiproject to distributed engineering stations

4

Distributed editing of the projects

5

Return the distributed projects to the central engineering station

6

Run cross-project functions on the central engineering station

Creating the configuration in the section "Creating the PCS 7 Configuration" is described according to this procedure.

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Note on step 3 - Recommended time for moving out for distributed editing There is no particular point in time at which the projects should be moved to the distributed engineering stations. We recommend that you take the following steps on the central engineering station first: •

Create the multiproject with the individual projects

•

Create the AS and PC stations for OS and BATCH below the individual projects

•

Create the structure of the plant hierarchy

•

Create the master data library with the objects common to the projects

Creating the configuration in the section "Creating the PCS 7 Configuration" is described according to this procedure.

Note on step 6 - Cross-project functions The cross-project functions ensure that you can handle a multiproject almost as a single project in the SIMATIC Manager. You can archive the multiproject, for example with all projects and the master data library or save at a different location. There are also cross-project functions that should be performed in the multiproject on the central engineering station on completion of distributed editing. These include: •

The merging of cross-project subnets and connections with textual references

•

The configuration of new cross-project (S7) connections between AS and OS

•

The compilation and downloading of all the components contained in the PCS 7 plant (AS, OS, BATCH etc.) to the target systems automatically in the correct order

•

Per OS client: The downloading of the server data of all relevant OS servers The server data only needs to be downloaded once. From this point onwards, each time an OS client starts up in process mode, the server data is updated automatically.

•

The generation/updating of the block icons

Note While cross-project functions are executing, all the projects involved must exist physically in the multiproject on the central engineering station and it is not permitted to work on them at this time.


Online help of STEP 7

•

Section "How to Add Projects to the Multiproject"

•

Section "Distributing the Multiproject for Distributed Editing (Multiproject Engineering)"

•

Section "Merging Projects after Distributed Editing (Multiproject Engineering)"

•

Section "Additional PH Functions in a Multiproject"


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5.3.2


Application Branching and merging to allow editing by several configuration engineers is also possible at the chart level (S7 program). The distribution within the project is made according to technological aspects (for example unit with the relevant charts is copied to a different project). Existing cross-chart interconnections are automatically replaced by textual interconnections. On completion of editing, the parts are copied back to the original project. Charts with the same name are replaced (following a prompt for confirmation). The textual interconnections are then re-established.

Application in Multiproject Engineering Note This option of distribution (branching) can be used independent of multiproject engineering or in addition to multiproject engineering. Within the context of multiproject engineering, the master data library is the basis for separate work on charts of a project.

Overview of the Recommended Procedure Step 1

Description Copy a technological part of the project (single chart, several charts) to a different project. Result: The copy contains textual interconnections to all sources not located in the copied parts.

2 3

Edit the copied part separately (add, delete, modify blocks and charts) Copy the edited technological part back to the original project Result: The system first deletes the charts with the same names in the original project. There are now textual interconnections in all charts that expect data from the deleted charts. The system the copies the charts from the other project.

4

Re-establish all textual interconnections with the menu command Result: The interconnections are established again both in the charts edited in the other project and in the original project in which textual interconnections arose as a result of deleting charts.


5-8

Section "Configuration by Several Users (Textual Interconnections)"



5.3.3

Configuration in a Network

Application If several engineers need to work at their engineering stations in a network on one project located on a central server at the same time, this is possible for defined parts of the project (such as AS, OS).

Application in Multiproject Engineering Note Working in a network on project data located on a central server should only be used in multiproject engineering for the data exchange between the engineers (for example master data library with process tag types and models).

Rules for Working in a Network Caution • At any one time, only one engineer can access the data of one project. •

At any one time, only one engineer can access the data of an OS (blocks WinCC Explorer).

•

When working on tables that can contain data from different projects, make sure that these projects are not edited by other users at the same time.

•

Only one commissioning engineer can work on the plant hierarchy of a project at any one time. This also applies to the properties of the hierarchy folder.

•

No configuration work must be done in the following situations (applies within a project): -

During compilation and downloading of S7 programs

-

During compilation and downloading of PCS 7 objects (OS, AS, BATCH)

-

During reorganization of the project

-

During import or export with the Import/Export Assistant


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5.4

Typing, Reusability, and Central Modifiability of Engineering Data

Principle During plant engineering, plant parts, functions or program parts result that differ from each other only in a few aspects. To work efficiently, you can create basic elements (units, program sections etc.) that can be reused and simply need the current parameter settings to be supplied.

Basic Elements That Can Be Reused Basic Elements

Description

Block type

A block type is part of a program that can be inserted in a CFC chart. When it is inserted, a block instance is generated. Block types are located in the PCS 7 Library. This contains, for example, blocks for controlling a motor or valve. You can also create your own block types or adapt blocks from the PCS 7 Library to the needs of your plant.

SFC type

An SFC type is a sequential control system that can be configured in SFC and inserted into a CFC chart. When it is inserted, an executable SFC instance is generated.

Process tag type

A process tag type is a CFC chart (this can also contain SFC types) configured for basic control of a process engineering plant for a specific control system function. With the aid of the Import-Export Assistant (IEA), process tags can be generated from them.

Model

A model can contain larger parts, for example a unit. It consists of hierarchy folders with CFC/SFC charts, pictures, reports, and additional documents. With the aid of the Import-Export Assistant (IEA), replicas can be generated from them.

Type-Instance Concept - Central Modifiability Note The advantage of the type-instance concept is that they can be modified centrally. This means that changes can be made later to the centrally located types block types, SFC types, process tag types and models and the changes then adopted in all instances and replicas. Refer to the online help systems of CFC, SFC, and IEA to find out which type changes can be accepted by the instances and replicas.

Project-specific Catalog Profile Based on the supplied hardware catalog (in HW Config: PCS 7_V6.1), you can create a project-specific catalog profile. Using a catalog profile adapted to your requirements, the hardware configuration can be performed efficiently (see also section "Defining a Project-Specific Catalog Profile").

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5.4.1

Using Block Types, Faceplates, and Block Icons

Block Type Block types are pre-programmed program parts for processing repeated functions that can be inserted in CFC charts. When they are inserted, a block instance is created from the block type, and parameters can then be set for the instance and it can be interconnected. The block type determines the characteristics for all instances of this type. Block types can be adapted to project requirements (for example adapting operator texts; showing/hiding parameters). To ensure that only one version of a block type is used throughout a project, all block types should be stored centrally in the master data library and all adaptations should be made prior to instantiation. Caution By storing block types in the master data library, you make sure that only one version of a block type (with one type name) is used throughout the project. Different block types in different programs can lead to conflicts if the programs are to be controlled and monitored on one OS. The reason for this is that variables of the same block type (same type name) must also have the same structure.

Possible Block Types The following can be stored in the master data library: •

Block types from the control system library PCS 7 Library

•

Block types from libraries of suppliers

•

User-created block types from CFC charts

Central Modifiability If the interface description and/or the system attributes of a block type are modified and this is imported into the CFC data management, an existing block type of the same name can be replaced by this new version (updated). All block instances of this type are also modified so that they match the new block type. The ability to make central type modifications relates to FBs and FCs. Before the central modification is made, a warning is displayed pointing out the effects and with information on the old and new block type such as the name, date of the last interface modification etc. Central type modification can, in some circumstances, have undesired effects on the block instances; in other words, interconnections and parameter settings can be lost. In this case, you must make any adaptations necessary to the block instances yourself. A log is kept of the changes made during a central type modification and displayed automatically following the update. You can also display this log later with the menu command Options > Logs: Block Types.... If adaptations of the block instances are necessary, the log can be used as support to reduce both effort and the risk of errors. Process Control System PCS 7 - Engineering System A5E00346923-02

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Faceplates and Block Icons If a block instance is to be controlled and operated by the operator during process mode, a faceplate is required. The faceplate contains the graphic representation of all elements of the technological block intended for operator control and monitoring. The faceplate is displayed in its own window on the OS and can be opened using a block icon (typically located in the ODS overview picture). For each technological block type of the PCS 7 Library there is already a corresponding faceplate. Block icons are generated automatically following a menu command. You can also create or adapt your own block icons.

Further information

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•

Manual Process Control System PCS 7 Library

•

Manual Process Control System PCS 7; Programming Instructions Blocks

•

Section "Adapting Blocks to Project Requirements"

•

Online help in CFC



5.4.2

Using Process Tag Types

Process Tag Type A process tag type is a CFC chart (this can also contain SFC types) configured for basic control for a special control system function, for example level control, that occurs several times in a PCS 7 plant. Using the Import/Export Assistant a number of process tags can be created from one process tag type in one action by means of an import file and then adapted and interconnected to suit the specific automation task. The process tag type is stored centrally in the master data library. All adaptations should be made before the process tags are derived from it.

Sources for Process Tag Types The following can be stored in the master data library: •

Standardized process tag types from the control system library PCS 7 Library, for example for motors, valves, PID controllers etc.

•

User-created process tag types from CFC charts

Generating Process Tags During import with the Import/Export Assistant, process tags are generated from the process tag types. Each line in an import file creates a process tag in the destination project. The process tags retain the assignment to the process tag type.

Central Modifiability When a process tag type is modified, the process tags existing in the project are automatically synchronized. If actions are taken that cause inconsistencies between the process tag type and process tags (for example when some process tags of the project were not available at the time of the automatic synchronization), synchronization can also be started explicitly by a menu command.

Note Modifications that you make in the chart of the process tag type are not taken into account when the process tags are synchronized. This case, you must first delete the relevant charts and then repeat the import for the modified process tag type with the Import/Export Assistant. The easiest way to achieve this is to activate the "Delete" option in the import file. For process tag type that is already been created or a process tag derived from it, the names of the blocks must not be modified again. Import/export would otherwise be impossible.


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The assistant can resolve the following inconsistencies between the process tag type and the process tags. •

Parameters/flagged signal I/Os and messages that do not exist in the process tag type are removed from the process tags, in other words, the relevant attributes are reset.

•

Parameters/flagged signal I/Os and messages that have been redefined in the process tag type are added to the process tags, in other words, the relevant attributes are set.

•

Categories changed in the process tag type are corrected in the process tags.

•

Inconsistencies between the process tag type and the process tag that cannot be synchronized automatically are entered in the log.

During this procedure, all the projects in the multiproject should be available.

Example: Level control process tag as a basis for creating a process tag type In the following example, the process tag is a CFC chart (with additional attributes) for signal acquisition, signal preprocessing, automation, operator control and monitoring of the control system function level control. It has the following features: •

A level sensor is fitted to a tank. This converts the level from 0 through 1500 l to a current of 4 – 20 mA.

•

The signal cable is connected to a channel of an analog input module. The signal has a name contained in the signal list of your plant. This raw signal can be accessed by the automation blocks using the signal name.

•

A driver block for analog value input (CH_AI) converts the raw signal to a preprocessed signal (0 through 1500 l) um.

•

A controller block (CTRL_PID) calculates a manipulated variable from 0 through 100% from the setpoint and process value (supplied by the level sensor).

•

A driver block for analog value output (CH_AO) converts the signal to the raw signal and passes to an analog output module.

•

A control valve is connected to the analog output module over a 4 – 20 mA current lead. At 4 mA, the valve is closed, at 20 mA it is fully open, at values between it is in an intermediate position.

•

The controller block has a faceplate on the OS as well as archive tags for setpoint and process value and messages for violating the high and low level limits.

Based on a process tag defined in this way, it is possible (on completion of the test) to create a process tag type with Import/Export Assistant.


5-14

Section "Creating Process Tags from Process Tag Types (Multiproject)"



5.4.3

Application of SFC Types

SFC Type SFC types allow sequential control systems to be defined as reusable templates. An SFC type is a sequential control system that can be configured in the SFC editor and inserted into a CFC chart. When it is inserted, an executable SFC instance is generated. SFC instances are displayed as blocks with an interface in the CFC chart (analogous to block instances). To run an SFC instance, both the SFC type and the SFC instance must be downloaded to the automation system. To ensure that only one version of an SFC type is used throughout the project, all SFC types should be stored centrally in the master data library and all adaptations should be made prior to instantiation. Control strategies can also be defined SFC types and these can be used in the sequencers. A control strategy can be set by the operator or by a higher-level control (for example SIMATIC BATCH).

Note In the plant view, SFC types cannot be assigned to a hierarchy folder since they themselves are not relevant for execution.

Possible SFC Types The following can be stored in the library/master data library: •

User-created SFC types

Central Modifiability Changes to the topology (step/transition sequence, changed jump target) or step/transition configurations are made to the SFC type and become effective automatically in the SFC instances following compilation and download of the AS. SFC Visualization is updated only after compiling and downloading the OS.


Section "How to Create an SFC Type"


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5.4.4

Using Models

Model Models allow more complex functions than the process tag types (even as complex as units) to be defined as reusable templates. A model consists of hierarchy folders with CFC/SFC charts, pictures, reports, and additional documents from which any number of replicas can be generated using the Import/Export Assistant and then modified to match the specific, required automation task.

Note Models can only be created in a multiproject.

The modes are stored centrally in the master data library. All adaptations should be made before the replicas are generated.

Generating Replicas The blocks for import/export of parameter descriptions, interconnection descriptions and messages are prepared in the charts of a model. After linking the model prepared in this way to an import file, the model is imported with the Import/Export Assistant. The generated replicas are assigned the parameters, interconnections, and messages of the model. Each line in an import file creates a replica in the destination project. The replicas retain their assignment to the model.

Central Modifiability If you modify models that already have replicas, a message is displayed since the import data no longer matches the model data. With the "Create/Modify Models wizard", you can check the consistency of the model with the assigned import file and the replicas in terms of modified IEA flags.

Note In an existing model or in replicas of a model, the names of the blocks must not be modified. Import/export would otherwise be impossible.

Further information

5-16

•

Section "How to Create a Model"

•

Online help on IEA



5.4.5

Using the Master Data Library/Libraries

Master Data Library When you create a multiproject, the master data library is created automatically with the standard folders "Process tag types" and "Models". The master data library is used for storage of the master data of the project for all projects of a multiproject. When you move projects from the multiproject to distributed engineering stations for editing, you must also transfer the master data library so that all configuration engineers have an identical database available. The master data library contains all objects used in the projects and that may need adaptation for a specific project. These include block types, SFC types, process tag types, models, OS pictures, OS reports etc. The master data library ensures that a defined version of types can be reused. The master data library can include the following: •

Objects from the control system library PCS 7 Library

•

S7 Standard Library objects

•

Objects from libraries of suppliers

•

User-created objects

Libraries To provide a better overview, libraries that are no longer used should be hidden (made invisible) using the menu command.


Section "How to Create a Master Data Library".


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5.4.6

Using Project-Specific Catalog Profiles

Project-specific Catalog Profile In the same way as process tag types, models etc. that you store in the master data library for a specific project, you can also create a project-specific catalog profile for the hardware configuration so that all the engineers working in the project use the same hardware components. When you move projects from the multiproject to the distributed engineering stations for editing, the project-specific catalog profile must also be transferred.

hardware Catalog "PCS 7_V6.1" The basis for every project-specific catalog profile is the hardware catalog "PCS 7_V6.1" in HW Config with the latest versions of the modules and components released for PCS 7.

Note For more information on the module versions released for PCS 7, refer to the document PCS 7 - Released Modules (menu command: Start > Simatic > Documentation > English).

You create a new catalog profile in HW Config and then drag the required components from the hardware catalog "PCS 7_V6.1" to the new catalog profile. You can assign any name to the new catalog profile.


5-18

Section "Defining a Project-Specific Catalog Profile".



5.5

Import and Reuse of Plant Data

Import/Export Interface All the essential applications of the PCS 7 engineering system have import/export interfaces. The use of these import/export interfaces has the following advantages: •

Data from the plant planning can be synchronized with the data of the control system engineering. This allows control system engineering and class engineering to be edited at the same time independent of each other.

•

Data from the engineering system can be exported as a template, reproduced in an external program (for example Excel), and then imported back into the engineering system. This allows the configuration of repeated or similar plant information to the optimized.

Import/Export of Plant Data What?

Import/Export

Where?

Further Information

Process tag lists or charts

Plant data such as process tag lists or charts from the higher-level CAD/CAE world can be imported into the engineering system and, for example, used for the largely automatic generation of process tags.

Import/Export Assistant (IEA)

How to Exchange Data with Excel/Access

Parameters optimized with PCS 7 can then be exported back to the CAD/CAE world. Hardware configurations

Hardware configurations can be exported from HW Config HW Config and further edited based on existing plant information and then imported back into HW Config.


The symbolic names of the inputs and outputs are also exported and imported. Plant pictures

Existing plant pictures can be imported in the Graphics Designer to create OS pictures (for example as background pictures). This applies to pictures that do not contain dynamic picture elements.

Graphics Designer

Configuration Manual Process Control System PCS 7; Operator Station

Data Formats for Importing/Exporting Plant Data Refer to the section "Which Data and Data Formats can be Imported?"


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Further Import/Export Functions What?

Import/Export

Where?

Further Information

Process tag types Using the Import/Export Assistant, large Import/Export (process tags) numbers of process tags can be Assistant generated/updated based on a process tag type (IEA) and an externally adaptable import file with process tag information.

Creating Process Tags from Process Tag Types (Multiproject)

Models (replicas)

With the Import/Export Assistant, large numbers Import/Export of replicas of the model can be Assistant generated/updated based on a model and an (IEA) externally adaptable import file with parameters and interconnection information.

Generating Replicas from Models

I/Os and messages

Operator-relevant texts generated in PCS 7 can, SIMATIC for example, be translated into other languages Manager for plant operators outside PCS 7. The operatorrelevant texts are exported to a text file, translated in an ASCII editor or Excel and then imported back into PCS 7.

How to Import/Export I/Os and Messages

Formats: *.txt or *.csv When you change languages, you can select all languages that were specified when you imported into the selected project. (Language change for "Title and Comments" -> only for the selected object; language change for "Display Texts" -> for the entire project). Importing/Exportin In the process object view, you can export all SIMATIC g Contents of editable cells for parameters, signals, and Manager Entire Tables messages. These can then be edited externally (for example, to change parameter values and interconnections) and then be imported again.


Format: *.csv This, for example, allows existing plant sections or copied units to be used externally without the Import/Export Assistant and to be given modified parameter values and interconnections. Import/export of picture objects

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Information from OS picture objects (for example type of object or interconnection information) can be exported to a csv file during OS configuration.

WinCC Explorer: Graphic Object Update This information can then be edited externally in Wizard Excel (for example modifying the tag interconnections) and then imported back into WinCC.




5.6

Free Assignment between Hardware and Software

Separating Hardware and Software Configuration The connection between a hardware and software configuration can be based on the symbolic names of the signals. The hardware configuration engineer configures the hardware structures in HW Config and assigns symbolic names to the inputs/outputs of the modules and field devices specified by the plant planning. The software configuration engineer creates the charts for the process tags and interconnects the inputs and outputs from and to the process textually, again with symbolic names. During compilation, the mapping between hardware and software is based on the identical symbolic names. The individual configuration engineers do not need to worry about system-internal addresses (absolute addresses such as Q 4.0, I 1.1). This effectively separates hardware and software configuration. The software can be created before the hardware is defined, and vice versa. The CFC/SFC charts only need to be assigned to the correct automation systems immediately prior to compilation and download.

Symbol Table PCS 7 can translate the symbolic names into the required absolute addresses. This is only possible, however, when the symbolic names are assigned to the absolute addresses. This assignment is made in PCS 7 during the hardware configuration (or when importing a hardware configuration).

Example You can, for example assign the symbolic name MOTOR_751_ON to the address Q4.0 in the symbol table and use MOTOR_751_ON as an address in a program statement.

Recommendation for PCS 7 Work with symbolic names in PCS 7 projects. A symbolic name allows you to use a meaningful name instead of absolute addresses. With the combination of short symbolic names and detailed comments, you can meet requirements both of effective programming and good program documentation. If you use symbolic names, it is also easier to recognize the extent to which elements of the program match the components of the PCS 7 plant.


Section "How to Assign Symbols to Input and Output Addresses".


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5.7

Deriving the Picture Hierarchy and OS Areas from the PH

Base picture hierarchy on the plant hierarchy The OS picture hierarchy for the plant operator on the PCS 7 OS can be derived completely from the configured data of the plant hierarchy. You insert pictures in the plant hierarchy (PH) according to the structure of your PCS 7 plant that will allow the plant operator to visualize the process. You can insert one picture per OS per hierarchy folder in the PH. By inserting pictures in the plant hierarchy, you create a picture hierarchy. After compiling the OS, you will find the same hierarchy in the Picture Tree Manager that can be further edited. Recommendation: Plan the picture hierarchy during the creation of the PH.

Requirement: Note The "Compile OS" function only enters the structure of the plant hierarchy in the Picture Tree Manager if you activated the option "Base picture hierarchy on the plant hierarchy" in the general settings for the PH in the SIMATIC Manager. You then deactivate this option again after you have made changes to the picture hierarchy in the Picture Tree Manager that you do not want to be overwritten when you compile the OS again.

Deriving OS Areas from the PH OS areas can be defined according to the plant structure you created in the plant hierarchy (PH). In large plants, certain areas of the plant can then, for example, be assigned to specific plant operators. The plant operators then only see and control the areas for which they have user permissions in process mode. The only messages displayed are those relevant to this area. Generally, a unit in the PH corresponds to an OSM area. In the general settings for the PH, you can specify which hierarchy level of the PH will be taken as an OS area level. You define an area identifier for each hierarchy folder of this level. The standard setting for the area identifier corresponds to the name of the hierarchy folder in the PH. If you assign an area identifier to a hierarchy folder, all the underlying hierarchy folders and objects are also assigned the area identifier. When you compile the OS, the OS areas are transferred to the Picture Tree Manager for further editing. The display of the hierarchy levels in the Picture Tree Manager always begins at the hierarchy level that was defined as the OS area. Recommendation: Keep in mind the required OS areas when structuring the PH and specify the area identifiers.

Further information

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•


•

Online help Help on PH, IEA and PO Process Control System PCS 7 - Engineering System A5E00346923-02


5.8

Generating Block Icons and Operator Texts

5.8.1

Generating Block Icons

Generating Block Icons Block icons are used for operator control and monitoring of plants or units in process mode. The block icons are required for the block instances from the CFC charts that can be controlled and monitored. For each process picture on the PCS 7 OS, you can specify individually whether block icons should be generated and stored in this process picture. You make this setting in the plant view or process object view prior to compiling: •

For each process picture, activate the "Base block icons on the plant hierarchy" option.

•

The block icons are inserted automatically in the process pictures according to the plant hierarchy and linked with the corresponding process tags if you select one of the objects multiproject, project, or hierarchy folder and then execute the "Create/Update Block Icons" function.


5.8.2


Generating Operator Texts

Generating Units of Measure and Operator Texts To visualize the process in process mode, you use the faceplates that display, for example measured values, operating limits, unit of measure, and operator texts of the block to the plant operator. These texts are already included in the block types you use for a CFC chart. The unit of measure and operator texts of block types from the supplied libraries (for example PCS 7 Library V6.1) exist in only one language (English). The units of measure and operator texts are displayed in process mode only in the language stored in the block types regardless of the language selected for display. Changes to units of measure or operator texts (for example translation to a different language) must be made in the CFC chart in the object properties of the block type or block instance.



•

Section "How to Import/Export I/Os and Messages"


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5.9

The PCS 7 Message System

5.9.1

Basic Concept of the Message System

Message System of PCS 7 The PCS 7 message system forms the plant operator of events occurring in the process and in the control system. The events are displayed to the plant operator in process mode individually in message lists and in a group display on the PCS 7 OS (OS client). Interventions made by the plant operator are entered in another list.

Message Classes Messages can be divided into the following classes: Message Classes

Description

Process control message

These are caused by faults or errors occurring in control system components (AS, OS etc.) and detected and signaled by SIMATIC PCS 7. These errors range from the failure of a component to the wire break message of a connected I/O module. Process control messages are generated by the driver blocks in PCS 7 and do not need to be configured.

Process messages

Operator input messages

These signal process events of the automated process such as limit value violations of measured values and operating messages. •

Process messages are predefined in the blocks and do not need to be configured. When necessary, however, message texts and a message priority can be changed in the object properties of the CFC block or centrally in the process object list or by importing and exporting.

•

Operating messages represent a subgroup of process messages. They indicate process values that can be used to evaluate a technological component, for example, an operating hours counter.

These are generated when process values are manipulated, for example as occurs when a controller changes to a different mode. If you use the faceplates provided by the PCS 7 Library, operator input messages are generated automatically. If faceplates are configured according to the manual PCS 7 Programming Instructions Blocks, PCS 7-compliant operator messages are also possible for your own blocks.

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Origin of a Message Depending on the configuration, messages can originate at various locations within PCS 7. The origin of the message influences the time stamp of the message. The following diagram shows an example with the ET 200M distributed I/O station. Single-user system (OS)

1. Origin of the message in the operator station

Plant Bus Industrial Ethernet SIMATIC S7 400

2. Origin of the message in the automation system

PROFIBUS DP

3. Origin of the message in IM 153-2 (ET200M)

ET 200M

Explanation of the Figure Events occurring on the AS (2) or in the ET 200 M (3) are sent as single messages via the plant bus to the OS. The message is transferred with the relevant time stamp. Messages are displayed in the message lists of the OS in chronological order along with the time at they were generated. The following table shows the locations where a message occurs and the time stamp it receives. Where they originate

Where the message is configured

Where the time stamp is added

Messages

Operator station (OS)

In the "Alarm Logging" editor of the WinCC Explorer

On the operator station

Control system messages of the OS, attachment of non-S7 systems

Automation system (AS)

In the block types in the project library or in the block instances within the CFC charts In the block instances of the "IM_DRV" driver block in the CFC charts

In the automation system

Process and process control messages of the SIMATIC stations

In the ET 200M by the IM 153-2 (with activated 10 ms time stamps)

Selected events for initial value acquisition when a plant fails (10 ms accuracy)

Distributed I/O (ET 200M)

"Loop-in-alarm" Function Process and control system messages from technological blocks that are visualized on the OS include the "loop-in-alarm" function. This function allows direct selection of the faceplate for this process tag from within the message list. Process Control System PCS 7 - Engineering System A5E00346923-02

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5.9.2

Configuring Messages

Configuring for an Operator Station (OS) For the origin operator station, insert new messages with the corresponding message text in "Alarm Logging" (WinCC Explorer). You also specify the event (binary value, bit within an integer etc.) that will trigger the message.

Configuring for Automation System (AS) and Distributed I/O For origin automation system (AS) and distributed I/O, configure the messages when creating the CFC charts or in the process object view. If a block with message capability is used in CFC, certain message texts along with their message class and message type are preset. The AS sends these messages when the corresponding event occurs. You can adapt the message texts and their attributes to your particular situation: •

Messages of a block type: First copy the required block to the project library and make the required changes there

•

Messages of a single block instance: In the process object view or directly in the block instance in the CFC chart

Recommendation: Create a master data library when you begin configuration. Make changes to messages in a block type at the start of configuration. If CFC charts have already been created in the project, repeat the block type import. The operator texts of all instances are then adapted (exception: instances that have already be modified manually).

Further information Configuring messages is described in detail in step-by-step instructions in the Configuration Manual Process Control System PCS 7; Operator Station. The following section provides you with a brief overview of the features provided by PCS 7 for configuration of a user-friendly message system.

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5.9.3

Important Features of Message Configuration The following table is an overview of the most important features of message configuration.

Feature

Description

Possible Configurations

Message text

When you use a block with message capabilities in the CFC, for example the "Dose [FB63]" block, there are certain default message texts along with their message class and message type.

•

Language for display devices

•

Modification of the message texts for block type and block instance

You can adapt these message texts and attributes to your particular situation.

Associated Value

You can add current information, for example from the process, by • inserting associated values at certain positions in the message text. The message block evaluates the associated value and inserts the corresponding process value at the selected location in the message text. To do this, you insert a field in the message text with the following information: @[]@

Inclusion of associated values in the message texts for block type and block instance

You will find the possible associated values for the individual block instances in the online help on blocks of the PCS 7 Library Expanded event text

Based on a standard message, for example "too high", the plant operator cannot immediately recognize what exactly is "too high".

•

You should therefore add further information to the event text, for example "reactor level". The block comment is used for this purpose. With the keyword ($$BlockComment$$) preceding the event text, the block comment is included in the event text of the message.

Adding block comments to event texts for a block type and block instance

In the blocks of the PCS 7 Library, the event texts are already prepared in this way; in other words, you only need to edit the block comments individually for each block instance. Message Number

Each message configured in the ES is automatically assigned a unique message number in Alarm Logging during compilation of the PCS 7 OS.

No configuration necessary

Within these message numbers, an area of 8 bits is reserved to create a unique reference to the relevant AS. This allows one OS to monitor several automation systems and to attribute the messages to the correct AS. Message When you create a project with the PCS 7 wizard, the message • Number number range is specified (can be changed later). You can choose Assignment between the following methods: •

Assign message numbers that are unique within a CPU (necessary for assigning message priorities)

•

Assign message numbers unique within a project

Specifying the message number concept

With the option "Assign CPU-wide unique message numbers", programs can be copied 1:1 without changing the message numbers.


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Feature

Description

Possible Configurations

Message Priority

As default, the latest message is shown first in the message lists. You can modify this setting.

•

Specifying message priority for messages for block type and block instance

•

Concept of driver blocks

Each message can be assigned priority (0 is the lowest, 16 the highest). By assigning a priority, you to ensure a that the message that meets the following criteria is always displayed in the overview area of the message line: •

Not yet acknowledged

•

Highest priority

In process mode, the plant operator can also sort message lists in ascending or descending order according to priority. Note: It is only possible to specify message priorities when you have specified the message number range as "unique CPU-wide". Error location in message text

In the event of an error/malfunction, the driver blocks of the distributed I/O send a message with the following information on the location of the error to the OS: •

Number of the DP master system to which the module is attached

•

Rack in which the module is installed or station number

•

Slot number of the module in the rack

•

Message text from the text library MOD_D1_TXT or MOD_D2_TXT

The assignment of a slot and channel number specifies the channel of the module that lead to the message being triggered. Configuring message texts Enter the message texts directly in the IM_DRV block placed in the CFC. The default for the message texts (origin) for diagnostic events of HART and PA field devices is "Field device". The default should, however, be adapted to the requirements of the project by the user.

Further information

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•


•

Section "Message Configuration in SFC"



5.9.4

Acknowledgment Concept and Acknowledgment-triggered Reporting (ATR)

Acknowledgment Concept PCS 7 uses a central acknowledgment concept. If a message is acknowledged on an OS, the signaling block on the AS is informed of the acknowledgment. From here, it is passed on to all relevant operator stations as an acknowledged message.

Acknowledgment-triggered Reporting (ATR) If signals that trigger messages change the state in quick succession, a flurry of messages can be triggered. This can mean that the state of a plant is no longer adequately monitored. By configuring the "acknowledgment-triggered reporting (ATR)" function, it is possible to suppress the repeated signaling of "fluttering" states until an acknowledgment is received from the plant operator. As long as an unacknowledged message is pending on the OS, sending this message is a result of signal changes is suppressed on the AS. With ATR, you can achieve the following: •

The plant operator can "keep on top of" pending messages and

•

The communication load is reduced.

Configuring Acknowledgment-triggered Reporting (ATR) You can activate acknowledgment-triggered reporting (ATR) for a specific AS in the object properties of the CPU.

Note Configure the same message method for all automation systems of a multiproject (standard message procedure or acknowledgment-triggered reporting). Do not mix both methods within a multiproject. Otherwise, the plant operator cannot recognize the message procedure with which the message was generated. This could lead to false conclusions being drawn.


Section "How to Activate Acknowledgment-Triggered Reporting (ATR)"


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5.9.5

Time Stamp with 10 ms Accuracy

10 ms Time Stamps Reading in events with high timing accuracy is often necessary during initial value acquisition following failure of a unit with the flurry of messages this causes: From the large number of messages, it must be possible to regulars the message that led to failure of the unit (initial value). 10 ms time stamps allow extremely accurate time stamping of an incoming event: If two sensors of two stations on different PROFIBUS-DP chains connected to different automation systems are activated at the same time, the time stamps of these signal changes must not differ by more than a maximum of 10 ms. This assumes time-of-day synchronization of all the devices connected to the plant bus.

Further information

5.9.6

•

Section "How to Configure the Hardware for 10 ms Time Stamps"

•

Function Manual Process Control System PCS 7 10 ms Time Stamps

Acoustic/Optical Signaling

Acoustic Signaling Device Function In addition to the visual display of messages and alarms, acoustic or optical signaling may be necessary for certain messages. PCS 7 provides the "acoustic signaling device" function with the following options •

You can connect a signal module with an ISA or PCI interface in the OS. Up to three external signaling devices, for example three horns or three different lamps can be activated for different message classes. Connecting a signal module allows an additional watchdog function.

•

You can use a standard sound card that is installed in the OS. The acoustic signal is produced by a *.wav file that continues to be played until an acknowledgment is received. If there are several alarms of the same time, all *.wav files are played at the same time. The sound card allows sign of life monitoring to be implemented.

It is possible to mix signal modules and sound cards.

Further Information

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•

For more detailed information on the function and installation of signal modules, refer to the manual Process Control System PCS 7; WinCC Basic Process Control

•

For more detailed information on configuring the acoustic signaling device, refer to the Configuration Manual Process Control System PCS 7 Operator Station


6


6.1

Configuration of the Engineering System

6.1.1

Central Starting Point - The SIMATIC Manager The SIMATIC Manager is the central starting point for all engineering tasks. Here, the PCS 7 project is managed, archived and documented. Starting from the SIMATIC Manager, you have access to all the applications of the engineering system. If there is a connection between ES, OS, BATCH, and AS, the configuration data can be transferred from the SIMATIC Manager to the target systems. Testing in online mode is done on the ES (see section "Testing" and refer to the Configuration Manual Process Control System PCS 7 Operator Station).

The Various Views The SIMATIC Manager provides the three following views that allow optimum editing depending on the task in hand. Note One major feature of these views is that the objects they contain exist only once. View

Purpose

Component View

In the component view, you organize the projects of the multiproject, create hardware components and start the hardware configuration of the automation systems, bus components, process I/O, and PC stations.

Plant View

In the plant view, you can structure and display a project according to technological aspects; in other words, you structure automation and operator control and monitoring functions hierarchically. The structures for the PCS 7 OS in process mode are derived from this plant hierarchy (for example OS areas, pitch hierarchy).

Process Object View The process object view provides a universal view of the process tags. It shows the plant hierarchy combined with a table view of all the aspects of the process tag/process object (for example parameters, signals, messages, etc.). In the process object view, all the data of the basic control throughout a project can be displayed in a process control-oriented view. Project-wide means that the data of all projects in a multiproject is acquired.

Changing from One View to Another To change the view, select the View menu in the SIMATIC Manager. Process Control System PCS 7 - Engineering System A5E00346923-02

6-1


Structure of a PCS 7 Project Similar to the directory structure of the Windows Explorer with its folders and files, the PCS 7 multiproject is organized in projects, folders, and objects. Folders can contain objects that in turn can contain further folders and objects. The multiproject is at the top of the object hierarchy and represents all the data and programs of an automation solution. Here, you can see example of a multiproject with the most important folders in the component view and plant view:

Multiproject First project of the multiproject (open) SIMATIC 400 station CPU S7 program Source files of the S7 program Blocks (FBs, FCs, OBs, DBs) Charts (CFC charts, SFC charts, SFC types) CP interface to the plant bus SIMATIC PC station for ES, OS or BATCH Other projects of the multiproject (closed)

Master Data Library of the Multiproject S7 program Source files of the S7 program Blocks (FBs, FCs, OBs, DBs) Charts (CFC charts, SFC charts, SFC types)

Multiproject First project of the multiproject (open) Process cell First unit Technological function with CFC/SFC charts (closed.)

Master Data Library of the Multiproject Process tag types Models

Object-Oriented Working The various object types are linked directly to the application required to edit them in the SIMATIC Manager, in other words, when you open the object the corresponding application is also started.

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6.1.2

The Component View

Multiproject Engineering In the component view, you work with all the functions such as archiving, dearchiving, copying, deleting, pasting etc the projects of the multiproject. In the component view: •

You split up the multiproject technologically for distributed editing

•

You merge the projects back into the multiproject following editing

•

You run the cross-project functions after the projects have been synchronized

Hardware Configuration Working in the component view, you configure the hardware of the automation systems, the bus components, and the process I/O. In the component view, you create the following objects below the projects: •

SIMATIC S7-400 stations (AS)

•

SIMATIC PC station for the engineering station (ES), operator stations (OS) and BATCH stations (BATCH)

When you double-click on "Hardware" with a station selected, you change to the HW Config application where you can add and assign parameters for further hardware components (for example CP, ET 200M) or other software applications (server or client) in the stations. This step in configuration is known as hardware configuration.

Note Once you have completed hardware configuration, you then work mainly in the plant view and in the process object view.

AS Configuration The objects in the component view are identified as components according to their importance (for example S7 program, station, OS, PLC/AS (CPU), chart folder, ...). In the component view, you organize the block types and SFC types by copying the from the master data library to the chart folder's of the AS in which they are used. Only then are they are available in the catalog for CFC/SFC configuration.

OS Configuration Starting the component view, you begin configuration of the operator station for process mode. Selecting the "Open Object" context-sensitive menu command with the OS selected, starts the WinCC-Explorer (see Configuration Manual Process Control System PCS 7; Operator Station).


6-3


Other Available Functions Component View

Selection of Important Functions •

Creating a New Multiproject with the PCS 7 Wizard

•

Expanding the Multiproject by Adding Further Projects

•

Inserting the SIMATIC Stations

•

Inserting and Configuring the Operator Stations

•

Inserting and Configuring the BATCH Stations

•

Inserting and Configuring the Engineering Station

•

Distributing the Multiproject for Distributed Editing (Multiproject Engineering)

•

Merging Projects after Distributed Editing (Multiproject Engineering)

•

Running cross-project functions

•

Compiling - downloading

Offline or Online? You can switch over the component view between: Component view > offline

This view of the project structure visualizes the project data on the engineering station. This is the default view when you create a new project. In the offline view, the complete data on the engineering station is displayed for the S7 program (offline).

Component view > online

This view of the project structure visualizes the project data on the target system (CPU). In the online view, the data on the target system are displayed for the S7 program (online). You use this view for access to the target system.

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6.1.3

The Plant View

Plant Hierarchy In the plant view, you structure the project according to technological aspects. The automation, operator control and monitoring functions are arranged hierarchically (plant, unit, functions, ...). You name the hierarchy folders according to their technological significance. You arrange the following in the hierarchy folder: •

CFC and SFC charts for the AS

•

Pictures and reports for the OS

•

Additional documents such as descriptions of units, process tag sheets, planning documents etc. (from Word, Excel, ...)

The resulting project structure is the plant hierarchy.

Further Aspects •

The technological objects (plants (process cells), units, functions (phases), ...) can be handled as a single entity (for example copied).

•

The technological objects can be manipulated without any concrete hardware assignment.

•

You can derive the OS areas and the pitch hierarchy for the PCS 7 OS from the plant hierarchy.

•

The plant hierarchy is the basis for plant-oriented identification of process objects. The hierarchy path forms the plant designation (higher level designation HID) with which you can specify the folders that contribute to the naming scheme.

•

You insert and position the process pictures in the plant view. The block icons of the blocks used in the process picture can be generated automatically from the plant hierarchy.

Master Data Library The master data library contains the master project data you store in it such as block types, SFC types, process tag types, models, OS pictures, OS reports, additional documents etc. for use in the individual projects of the multiproject.


6-5


Other Available Functions Plant View

Selection of Important Functions Plant Hierarchy •

Settings and Properties of the PH

•

Inserting Further Hierarchy Folders

•

Inserting Objects in the Hierarchy Folder

•

Rules for Copying and Moving within the PH

•

Checking the Consistency of the PH

•

Additional PH Functions in a Multiproject

•

Specifying the AS/Os Assignment

Master Data Library: •

Creating the Master Data Library

•

Copying Library Objects to the Master Data Library

•

Working with Process Tag Types

•

Working with Models

AS-OS Assignment For each hierarchy folder, an assignment to an OS and to an AS must be made in the plant hierarchy. This AS-OS assignment has the following consequences in the component view:

6.1.4

•

All CFC and SFC charts inserted in the plant view are stored in the chart folder of the assigned AS.

•

All pictures and reports inserted in the plant hierarchy are stored in the folder of the assigned OS.

The Process Object View You use the process object view when you require details of process tags and CFC charts and want to edit their attributes and aspects. Working with the process object view is ideal when you want to assign to say parameters, comments or interconnections for large volumes of objects.

Advantages Compared with the plant view, the advantage of the process object is that all modifiable attributes of an object can be edited. All editable aspects are consistent and presented in a practical form for the user. Jumps to CFC, SFC, HW Config, WinCC Explorer allow editing of aspects that cannot be edited directly in the process object view (such as module parameter assignments, picture contents). The context-sensitive menu of the process object view provides functions such as "Undo" and "Redo" with which you can undo or restore changes.

6-6



Structure On the left-hand side, the process object view displays the plant hierarchy (tree structure). On the right-hand side, you see a table of the underlying objects along with their attributes (contents window). The tree structure displays the same objects as in the plant view. In the tree structure, the process object view also shows the CFCs, SFCs, pictures, reports and additional documents. Process Object View

Selection of Important Functions: •

Section "Editing Mass Data in the Process Object View"

Aspects of the Process Objects In the contents window, you see the attributes of the objects organized according to the following aspects. Tab

Purpose

General

Here, you see all the underlying process objects (process tags, CFCs, SFCs, reports, or additional documents) for the plant section currently selected in the tree structure along with general information on the objects.

Parameters

Here, you see all the flagged I/Os of the process tags and CFCs displayed in the "General" tab that were selected explicitly for editing in the process object view (S7_edit = para).

Signals

Here, you see all the flagged I/Os of the process tags and CFCs displayed in the "General" tab that were selected explicitly for editing in the process object view (S7_edit = signal).

Messages

Here, you see the corresponding messages for all the process tags, CFCs and SFCs displayed in the "General" tab.

Picture Objects

Here, you see all the picture links that exist in WinCC for the process tags and CFCs displayed in the "General" tab.

Measured Value Archives

Here, you see all the archive links that exist in WinCC for the process tags and CFCs displayed in the "General" tab.


6-7


Other Technological Objects In the process object view, you can not only edit the attributes of objects but also create the following technological objects: Object

Purpose

Hierarchy Folder

Expansion of the plant hierarchy by adding objects such as plant, unit, function etc. within a project.

CFC/SFC

Creation of empty CFCs and SFCs that can then be further edited with the appropriate editors.

Additional Document

Creation of empty or import of existing additional documents, for example Excel or Word if the relevant application is installed.

Picture

Creation of empty pictures that can then be further edited with the Graphics Designer.

Report

Creation of empty reports that can then be further edited with the page layout editor.

Process Tag (from Library)

Insertion of process tags from the catalog of process tags types in the master data library. You can drag the process tag type to a hierarchy folder in the process object view or in the plant view. This creates a process tag in this hierarchy folder.

Offline or Online? You can switch over the process object view between: Process object view > offline This view visualizes the project data on the engineering station. This is the default view when you create a new project. In the offline view, the entire data is displayed on the engineering station. Process object view > online In test mode (online), additional columns are displayed in the "General", "Parameters" and "Signals" tabs, with which you can test and commission the process tags and CFC charts online on the CPU (target system).

Further information

6-8

•

Online help Help on PH, IEA and PO

•

Section "Editing Mass Data in the Process Object View"



6.1.5

Relationships between the Views Since the component view and the plant view/process object view represent different aspects of the same objects, certain functions affect these objects in both views: •

Deleting objects deletes them in all three views.

•

Newly created objects in the plant hierarchy/process object view are also created in the AS/OS assigned to the hierarchy folder in the component view.

•

Creating new objects in the component view has no effect on the plant hierarchy/process object view. Tip: If the plant hierarchy exists, you should only edit objects in this view or in the process object view. The component view is then only used to create and edit the automation systems, operator stations, and BATCH stations.

6.1.6

Cross-View Functions and How to Use Them

Working with Units (Plant View) The functions that you can use throughout a plant and whose cross-device relationships (PH, OS, AS) are managed by the ES include, for example, the following: •

Copying an entire unit, containing the charts for the AS and pictures for the OS.

•

Deleting a unit along with all the objects belonging to the unit.

•

Moving a unit to other devices (AS and OS).

Copying a SIMATIC Station (CPU) in the Project (Component View) When you copy a SIMATIC station, the hardware properties of the station are copied 1:1. All the interconnections to shared addresses, to run-time groups and the interconnections between charts are retained in the relevant program folder. The plant hierarchy (PH) is retained. All the charts involved in the copy function now exist twice in the PH (original and copy with a different name).

Copying a SIMATIC Station (CPU) from Project to Project (Component View) If you copy a SIMATIC station from one project to another, the hardware properties of this station are copied 1:1. lf the interconnections to shared addresses, to runtime groups and the interconnections between charts are retained in the relevant program folder. The station is assigned a new name. Connections between stations copied across project boundaries are retained and are consistent if the relevant subnets between the stations are also copied. The plant hierarchy associated with the copied station is set up in the destination project. If the station in the source project has relationships with the PH, these are also recreated in the destination project (setup of a PH or use of an existing PH with the same name in the destination project).

Copying an S7 Program (Component View) In the SIMATIC Manager, you can copy an entire S7 program within a project or to another project. All the interconnections to shared addresses, to run-time groups and the interconnections between charts are retained when the program folder is copied. Process Control System PCS 7 - Engineering System A5E00346923-02

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6.2

PCS 7 Applications and How They Are Used PCS 7 includes the following applications with which you can configure the plant:

Application

Purpose

HW Config

Configuring the Hardware Hardware configuration displays the hardware structure of a station or a PC station. With HW Config, you specify the racks and their slot assignments according to the actual structure of the station; you configure and assign parameters to the modules, and configure the distributed I/Os.

NetPro

Configuration of networks and connections Using NetPro, you can configure, make parameter assignments, and document the network configuration for your plant extremely simply and clearly. With NetPro you can do the following:

SCL

•

Create a graphic view of your network

•

Specify the properties and parameters for each subnet

•

Specify the node properties for each networked module

•

Configure connections (also cross-project connections)

•

Document the network configuration

•

Download the network configuration and hardware configuration to the target system

Programming blocks SCL (Structured Control Language) is high-level programming language for programmable controllers. It includes not only high-level language elements but also typical elements of a PLC such as inputs, outputs, timers, the memory, block calls etc. as language elements. In other words, SCL supplements and expands the STEP 7 programming software with its programming languages LAD, FBD and STL.

CFC

Configuring Continuous Processes CFC (Continuous Function Chart) is a graphic editor that can be used in conjunction with the STEP 7 software package. It is used to create the entire software structure of the CPU from ready-made blocks. When working with the editor, you place blocks on function charts, assign parameters to them, and interconnect them.

SFC

Configuring Sequential Control Systems SFC (Sequential Function Chart) is a tool for creating a sequential control system. With this application, you can create and commission technological sequential control systems.

Graphics Designer

Editing of process pictures In the Graphics Designer, you ended the process pictures that are displayed for the operator on the operator station and that are used for controlling the process. When you are creating process pictures, PCS 7 provides you with a function that allows you to insert all the block icons (clear, graphic representations of a process tag) automatically in the process picture. You can also insert other graphic objects and define the dynamic attributes of the objects. A simple example: You can visualize the current state of a valve so that the operator sees immediately whether the valve is open or closed.

6-10



Application Tag Logging

Purpose Archiving process values The "Tag Logging" editor is an important tool for archiving measured values. In Tag Logging, you can create various different archives and assign the process values you want to save to these archives. This allows you to define archiving strategies tailored to the needs of your plant.

Alarm Logging

Archiving messages and alarms Alarm Logging is used for the following functions in the processing of messages and alarms:

Report Designer

•

Receiving messages from processes

•

Preparing and displaying messages in process mode

•

Acknowledgments by the operator

•

Archiving

Design of the layout for printouts of process values or messages. The Report Designer provides functions for creating and outputting reports. You can adapt the supplied standard layouts individually. The Report Designer provides the required editors.

@PCS 7

Connection to the works management level In a production process, new data of relevance to the works and enterprise management levels is constantly being produced. You can access this data using the @PCS 7 software package. This package allows you to use the data from the higher control levels and create your own statistical information and evaluations.

SIMATIC BATCH

Automating batch processes With the SIMATIC BATCH software package, you can configure process cells with recipe-oriented control strategies with exacting requirements. This allows complex tasks with changing control sequences to be handled simply and flexibly.

SIMATC PDM

SIMATIC PDM is a software package for configuration, parameter assignment, commissioning, and maintenance of devices (for example transducers) and for configuring networks. SIMATIC PDM allows simple monitoring of process values, alarms, and status information of the device.

Faceplate Designer

Creation of faceplates Using the Faceplate Designer, you create PCS 7-compliant templates for faceplates.

S7 H Systems

This supports you when configuring an S7-400H/S7-400FH. CFC charts created by the user have the functions necessary for error detection added to them automatically.

S7 F Systems

This supports you when configuring an S7-400F/S7-400FH. CFC charts (F charts with F blocks) created by the user already include the functions required for error detection and the reaction to errors.


Tool for fast engineering of mass data (for example importing process tag types and models).

PCS 7 Library

The PCS 7 libraries include blocks and functions for use in PCS 7 plants.

Hardware Catalog

The hardware catalog "PCS7_V6.1" contains all approved devices and modules (in each case, the latest version).

DOCPRO

Using DOCPRO, you can create and manage plant documentation.

SFC visualization

SFC Visualization of the operating system allows sequential control systems configured with the SFC tool to be represented and operated in the same way as on the engineering system. This does not involve any extra configuration effort.


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6-12


7

Configuring PCS 7

7.1

Overview of the Steps in Configuration

Overview The basic activities described below are arranged in a practical order that you can follow to achieve a rational workflow during configuration. Depending on the requirements of your project, some of the steps in configuration are mandatory and others are optional. From the table below, you can see which configuration steps are necessary and which are options.

Overview of the Configuration Steps Configuration Tasks

must

can

Setting up the PC stations (see manual Process Control System PCS 7; PCConfiguration and Authorization)

X

Creating the PCS 7 project (multiproject)

X

Creating the SIMATIC 400 stations (AS)

X

Creating the SIMATIC PC stations for

X

X

Operator stations and engineering station

BATCH stations when using SIMATIC BATCH

•

Operator Stations (OS)

•

BATCH stations (BATCH)

•

Engineering station (ES)

Creating the Plant Hierarchy

X

Creating the master data library

X


Configuring the hardware (AS, I/O)

X For distributed editing by several configuration engineers X

Creating network connections

X

Creating the SIMATIC Connections

X

Configuring AS Functions

X

•

Creating CFC charts

X

•

Programming SIMATIC Connections for ASAS Communication

•

Programming the Interface to the I/O (driver blocks)


X X

7-1

Configuring PCS 7

Configuration Tasks •

must

Creating process tags from process tag types

can X When processing mass data in a multiproject

•

Creating Sequential Control Systems (SFC)

•

Creating Models

X X When processing mass data in a multiproject X

Configuring OS Functions Described in the Configuration Manual Process Control System PCS 7; Operator Stations Configuring BATCH Functions

X

Described in the Configuration Manual Process Control System PCS 7; SIMATIC BATCH

When using SIMATIC BATCH X

Configuring the interface to the management level (@PCS 7 and SIAMTIC IT)

When interfacing PCS 7 to the management level

Described in the manual Process Control System PCS 7; @PCS 7 Merging Projects after Distributed Editing (Multiproject Engineering)

X For distributed editing by several configuration engineers

Using cross-project functions (multiproject engineering)

X For distributed editing by several configuration engineers

Compiling and downloading to the target systems

X

Procedure Described Creating the configuration as described in the following sections is structured according to this procedure. To be able to work through all the topics, we assume that the PCS 7 project was created during multiproject engineering; in other words, the PCS 7 project is divided into several projects, these projects are distributed for editing and merged back into the multiproject to allow cross-project functions to be implemented.

Note With the procedure described here, you have full system support. You can, of course, follow a different procedure, however you then lose some or all the support provided by PCS 7.

7-2


Configuring PCS 7

7.2

Setting up the PC Stations To allow all automation systems and PC stations (OS, BATCH) of a PCS 7 project to be configured, downloaded, and tested from a central engineering station (ES), the following settings must be made on all PC stations. •

Specification of the communication cards for the communication via the teminal bus

•

Set the access points and the operating mode for the communication cards

These setting also have to be made on the central engineering station.



7.3

Creating the PCS 7 Project

7.3.1

Overview of the Defaults and Individual Steps This overview shows you the individual steps for creating and setting up a PCS 7 project: What?

Where?

Setting the Defaults for the PCS 7 Project

SIMATIC Manager

Creating a New Multiproject with the PCS 7 Wizard

PCS 7 Wizard (in the SIMATIC Manager)

Expanding the Multiproject by Adding Further Projects

SIMATIC Manager

Expanding a Project of the Multiproject by Adding Further Components

SIMATIC Manager


7-3

Configuring PCS 7

7.3.2

How to Set the Defaults

How to make the most important settings: 1. Open the SIMATIC Manager with Start > SIMATIC > SIMATIC Manager. 2. In the SIMATIC Manager, select the menu command Options > Settings... Result: The "Settings" dialog opens. 3. Set the location for storing projects and libraries in the "General" tab. This setting is advisable so that projects/libraries can be backed up before backups are imported (images). 4. In the "Language", set the language and the mnemonics you want to work with. 5. In the "Wizard" tab, check whether the "PCS 7" option is set. This setting is necessary to be able to start the PCS 7 "New Project" Wizard afterwards. 6. Leave the default setting in the "Message Numbers" tab (always assign unique message numbers CPU-wide) or select "Always prompt for settings". 7. In the "Archive" tab, you can select the archiving program you want to use (for example PKZIP) and the paths for archiving/dearchiving. 8. Confirm the dialog box with "OK".

Note Some settings, for example changing language, require the program to be restarted.

You make all other settings when you first create the PCS 7 project with the PCS 7 "New Project" wizard. You can change these settings later in the "Settings" dialog box.


7-4

Online help for the "Settings" dialog box


Configuring PCS 7

7.3.3

How to Create a new Multiproject with the PCS 7 Wizard

PCS 7 "New Project" Wizard With the PCS 7-"New Project" wizard, you create a new PCS 7 project as a multiproject. This includes the following: •

One project

•

The master data library

You are guided through the individual configuration steps of the PCS 7 wizard. While working through the wizard, you specify the CPU, select the number of hierarchy levels of the plant hierarchy and the AS objects to be created (CFC/SFC charts) and OS/BATCH objects. Technological names such as plant, unit and function are specified and you can adapt these later to your own situation. The wizard also makes it easier to create a new single project since once again all the necessary objects can be created in the dialogs.

Procedure To create a multiproject with the wizard, follow the steps outlined below: 1. In the SIMATIC Manager, select the menu command File > "New Project" Wizard. 2. Select the option "Multiproject with project and master data library" and confirm with "Next". You can check the structure of the multiproject using the "Preview" button. 3. Select the required CPU and confirm with "Next". 4. In the next two dialogs, specify the configuration you require (CFC/SFC chart; PCS 7 OS) and confirm with "Next". 5. Enter the name of the multiproject in "Directory Name". 6. Start to create the multiproject with the "Finish" button. 7. In the "Message Number Assignment Selection" dialog box, set the message concept to "Always assign unique message numbers project-wide". 8. Confirm the dialog box with "OK". Result: The multiproject is created and contains one project as shown in the preview. The relevant objects are created in the component view and in the plant view. A master data library with the following content is also created: •

In the Component view: one S7 program with the folders for sources, blocks and charts


7-5

Configuring PCS 7

•

In the plant hierarchy: one folder for process tag types and one for models

Note If you want to create a single project with the PCS 7 Wizard, activate the "Single Project" option. The remaining steps are the same for both types and is explained below based on the example of a multiproject. You also use this option if you want to create a further project for your multiproject and want support from the wizard. After creating the project, assign it to the multiproject (File > Multiproject > Insert into Multiproject).

Opening the Multiproject When you create a multiproject with the PCS 7 Wizard, it is opened automatically in the SIMATIC Manager. When you open the multiproject later, make sure that you always open it with the menu command File > Open > "Multiproject" tab > "" > OK.

7-6


Configuring PCS 7

7.3.4

How to Add Projects to the Multiproject To create a new (empty) project in your multiproject, follow the steps outlined below: 1. Select the required multiproject in the SIMATIC Manager 2. Select the menu command File > Multiproject > Generate in Multiproject. 3. Enter a name and specify where it will be stored. 4. Confirm the dialog box with OK. Result: A new empty project is created in the multiproject and can be configured (HW Config, plant hierarchy etc.).

Support of the Wizard If you want to use the PCS 7 Wizard, create a "Single Project" with the Wizard. After creating the project, assign it to the multiproject with File > Multiproject > Insert into Multiproject.

Further information When working in multiproject engineering, read the information in the section "Configuring in a Multiproject" on the rules for distributing the automation systems, operator stations and BATCH stations in the individual projects of the multiproject.

7.3.5

How to Insert an Existing Project in a Multiproject If you want to continue using existing projects (single projects unchanged or modified), you can integrate these in your multiproject. If the project already belongs to another multiproject, a message is displayed. If you want to include such a project in the multiproject, it is removed from the other multiproject.

Procedure To include a project in the multiproject, follow the steps outlined below: 1. Open an existing multiproject. 2. Select File > Multiproject > Insert into Multiproject in the SIMATIC Manager. 3. Select the project you want to insert. 4. Confirm the dialog box with OK.

Note If these projects originate from an earlier PCS 7 version, keep to the procedure described in the manuals Process Control System PCS 7; SW Update ....


7-7

Configuring PCS 7

7.3.6

How to Remove a Project from the Multiproject

Procedure If you want to remove an unnecessary project from the multiproject, follow the steps outlined below: 1. Select the project you want to take out of the multiproject. 2. Select File > Multiproject > Remove From Multiproject in the SIMATIC Manager. Result: The project is no longer part of the multiproject. It is, however, not deleted; only the assignment to the multiproject is canceled. If you want to delete the project, you can do this with the menu command File > Delete > User Projects.

7.3.7

How to Expand a Project by Adding Further Components The PCS 7 "New Project" Wizard is used to create the basic configuration that you can then expand by adding further objects.

Procedure The procedure described here does not depend on the selected view. The objects you can select to be included depend on the currently selected object and the selected view. 1. Select the folder/object in the SIMATIC Manager. 2. Select the "Insert" menu. Result: All the objects that can be inserted below the folder are available in the "Insert" menu. The available selection depends on whether you selected the object in the process object view, plant view or in the component view. 3. Select the object you require in the menu and specify the object name.


7-8

Online help on the SIMATIC Manager


Configuring PCS 7

7.3.8

How to Store Shared Declarations In the Component view, you can create a project-specific "shared declarations" folder. You can then use this to store shared declarations that can be used by various applications. The "shared declarations" folder contains the following two subfolders: •

Enumerations Using the enumerations, you can define textual representatives for the parameter values of the block or chart I/Os with data types BOOL, BYTE, INT, DINT, WORD, and DWORD. A suitable text is assigned to each value of an enumeration and this is displayed at the I/O. Several values can be assigned to each enumeration.

•

Units The unit of measure (for example mbar, l/h, kg, ...) is a text with a maximum of 16 characters. It can be entered along with the description of the parameters of block or chart I/Os and is, for example, used in process pictures when visualizing the values of block I/Os. As default, all the units of measure included in the CFC basic set are available.

Procedure 1. Select the project in the component view of the SIMATIC Manager. 2. Select the Insert > Shared declarations > Shared declarations menu command. Result: The "shared declarations" folder with the "Enumerations" and "Units" subfolder is created. 3. If you want to declare an enumeration, select the "Enumerations" folder and then the Insert > Shared declarations > Enumeration menu command followed by the Insert > Shared declarations > Value menu command. 4. If you want to declare a unit, select the "Units" folder and then the Insert > Shared declarations > Unit menu command.




7-9

Configuring PCS 7

7.4

Configuration of the AS and PC Stations You create the following objects in the projects of the multiproject in the SIMATIC Manager: •

A "SIMATIC 400 station" for each automation system

•

A "SIMATIC PC station" for each operator station (OS server and OS client)

•

A "SIMATIC PC station" for each BATCH station (BATCH server and BATCH client)

•

A "SIMATIC PC station" for the engineering station

You configure the hardware of the automation systems and the PC stations for ES, OS, and BATCH in the HW Config application.

Note If you require distributed editing of the projects of the multiproject, read the information in the section "Configuring in a Multiproject" on the distribution of automation systems, operator stations and BATCH stations to the individual projects of the multiproject.

7.4.1

How to Insert the SIMATIC 400 Stations in the Projects of the Multiproject Once you have created the multiproject with the PCS 7 Wizard, as default, there is already one automation system inserted. Insert any further automation systems you require manually.

Procedure 1. Select the project into which you want to insert a SIMATIC station in the component view of the SIMATIC Manager. 2. Select the menu command Insert > Station > SIMATIC 400 Station Result: A new station is inserted ("SIMATIC 400 station(1)"; you can adapt the name to your requirements). 3. Follow the same procedure if you want to install further SIMATIC stations.

Further information

7-10

•


•

Section "How to Create a SIMATIC Station"


Configuring PCS 7

7.4.2

How to Start Configuring SIMATIC 400 Stations This section describes how to start the basic configuration of the automation systems. We assume the following for a multiproject •

that the automation systems will be created in the individual projects and that the communications processors for network attachment will be configured on the central engineering station. This is described below.

•

that the full hardware configuration with attached I/O will be completed on the distributed engineering stations after distributing projects for editing. The full hardware configuration is described in the section "Configuring the Hardware".

Procedure To start the basic configuration of the automation systems, follow the steps outlined below: 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 2. In the SIMATIC 400 > Rack-400 hardware catalog, select the required rack and insert it by dragging with the mouse. Make sure that the arrangement selected here matches the arrangement of the physical hardware. 3. In the SIMATIC 400 > PS-400 hardware catalog, select the required power supply and insert it by dragging with the mouse. 4. In the SIMATIC 400 > CPU-400 hardware catalog, select the required CPU and insert it by dragging with the mouse. 5. Confirm the open dialog box "Properties - PROFIBUS Interface DP" with "OK". 6. Continue in the same way to add any other components you require. 7. Select the menu command Station > Save and Compile in HW Config.


Section "Configuring the Hardware"


7-11

Configuring PCS 7

7.4.3

How to Insert CPs in the SIMATIC Stations and Assign Them to Networks The communications processors (CP) inserted in the SIMATIC 400 stations must be configured for network attachment in HW Config and assigned to the communications network. In multiproject engineering, it is advisable to perform this configuration work on the central engineering station for all projects. This ensures, for example, that node addresses are unique on the bus.

Procedure 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object in the detailed view. Result: Hardware configuration of the automation systems opens. 2. If the hardware catalog is not visible, select the menu command View > Catalog. 3. In the hardware catalog SIMATIC 400 > CP-400, select the CP you require for the network being used (CP 443-1 or CP 443-5Ext) and insert it by dragging with the mouse. Result: Once you have inserted the CP, the "Properties – Interface" dialog box opens. 4. Set the required address on the bus for the CP you have selected. 5. Select the subnet in the "Subnet" group: -

If you have not yet set up a subnet, click on the "New" button and define new network.

-

If you have already set up a subnet, select the required network in the "Subnet" group.

6. Exit the properties dialog by confirming your entries with "OK" 7. Select the menu command Station > Save and Compile.


7-12

Section "Configuring the Hardware"


Configuring PCS 7

7.4.4

Inserting and Configuring the Operator Stations Each OS server, redundant OS server, and OS client of a PCS 7 OS is managed as a SIMATIC PC station in the SIMATIC Manager. It always contains the following objects: •

A WinCC application (multiple workstation project, redundant project, time project)

•

A communications processor (this is not inserted by the wizard)

•

An OS

If you created the multiproject with the PCS 7 wizard, you will already have inserted a PCS 7 OS if you selected the appropriate option. You must insert any further operator stations you require manually. The same applies for inserting and assigning parameters to the communications processors (CP).

Procedure 1. Select the project into which you want to insert the operator station in the component view of the SIMATIC Manager. 2. Select the menu command Insert > Station > SIMATIC PC Station. Result: A new SIMATIC PC station is inserted in the selected project. 3. Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the required name. 4. Select the SIMATIC PC station in the component view and open HW Config by double-clicking on the "Configuration" object in the detailed view. Result: The hardware configuration of the SIMATIC PC station opens. 5. If the hardware catalog is not visible, select the menu command View > Catalog. The hardware catalog opens. 6. Under SIMATIC PC Station > HMI ... in the hardware catalog, select the required WinCC application and drag it into the configuration table: -

WinCC application (for example for OS server or single station)

-

WinCC application (stby) (for redundant OS server)

-

WinCC application client (for OS client)

-

WinCC application CAS (for central archive server)

7. In the hardware catalog SIMATIC PC Station > CP Industrial Ethernet, select the communications processor installed in the SIMATIC PC station and drag it with the mouse to the PC station. If you are using a standard network adapter, select the processor IE General. Result: The "Properties - Ethernet Interface" dialog box opens.


7-13

Configuring PCS 7

8. Set the required address on the bus for the CP. -

If the network adapter is connected to the terminal bus activate the "IP protocol is being used" option.

-

If the network adapter is connected to the plant bus activate the "Set MAC address / Use ISO protocol" option. If a maintenance station is being operated activate the "IP protocol is being used".

-

For a network adapter connected on the plant bus via BCE, set the name in the "General" tab and in the "Keep Alive for Sending Connections" area of the "Options" tab set "Interval" to "30".

9. Select the subnet in the "Subnet" group: -


-


10. Exit the properties dialog by confirming your entries with "OK" 11. Select the menu command Station > Save and Compile. 12. Follow the same procedure if you want to install further operator stations.

Specifying the Target and Standby Operator Stations Once all the required operator stations have been created in the SIMATIC Manager, and the network connections have been configured for all target and standby operator stations, the computer path of the target OS or standby OS must be assigned to each operator station. If you only have a single OS, you only need to specify the target OS. If you have a redundant OS, you must specify both the target OS (master) and the standby OS. You make this setting in the object properties of the OS in the component view. Select the "OS" object below the SIMATIC PC station and select the menu command Edit > Object Properties (path to target/standby OS computer).

Further information

7-14

•


•



Configuring PCS 7

7.4.5

Inserting and Configuring the BATCH Stations The BATCH server and each BATCH client of a BATCH station are managed and SIMATIC PC stations in the SIMATIC Manager. This always contains the following object: •

A BATCH application (standard, standby, client)

If you created the multiproject with the PCS 7 wizard, you will already have inserted a BATCH station if you selected the appropriate option. You must insert any further BATCH stations you require manually.

!

Warning Configuring applications (WinCC, SIMATIC BATCH, ...) on separate "SIMATIC PC station" objects and then merging them to create one PC station by assigning the same computer name to the "SIMATIC PC station" objects is not permitted!

Requirement The SIMATIC BATCH optional package is installed and licensed on the engineering station.

Procedure 1. Select the project into which you want to insert the BATCH station in the component view of the SIMATIC Manager. 2. Select the menu command Insert > Station > SIMATIC PC Station. Result: A new SIMATIC PC station is inserted in the selected project. 3. Set the computer name of the SIMATIC PC station: -

Select the SIMATIC PC station.

-

Select the menu command Edit > Object Properties.

-

Enter the computer name in the last field.

4. Select the SIMATIC PC station in the component view and open HW Config by double-clicking on the "Configuration" object in the detailed view. Result: The hardware configuration of the SIMATIC PC station opens. 5. If the hardware catalog is not visible, select the menu command View > Catalog. 6. Under SIMATIC PC Station > HMI ... in the hardware catalog, select the required BATCH application and drag it into the configuration table: -

BATCH application for BATCH server

-

BATCH application client for BATCH client

-

BATCH application (stby) for redundant BATCH server

7. In the hardware catalog SIMATIC PC Station > CP Industrial Ethernet, select the communications processor installed in the SIMATIC PC station and drag it with the mouse to the PC station. If you are using a standard network adapter, select the processor IE General. Result: The "Properties - Ethernet Interface" dialog box opens. Process Control System PCS 7 - Engineering System A5E00346923-02

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Configuring PCS 7


Enable the option "IP protocol is being used".



-


10. Exit the properties dialog by confirming your entries with "OK" 11. Select the menu command Station > Save and Compile. 12. Follow the same procedure if you want to install further BATCH stations.

Further information

7.4.6

•


•


Inserting and Configuring the Engineering Station The engineering station is configured in the SIMATIC Manager by inserting a SIMATIC PC station, configuring the hardware in HW Config and configuring the communication connections in NetPro. The communication connections set up for the PC station can then be checked with the diagnostic functions of the Station Configuration Editor.

Procedure 1. Select the project into which you want to insert the engineering station in the component view of the SIMATIC Manager. 2. Select the menu command Insert > Station > SIMATIC PC Station. Result: A new SIMATIC PC station is inserted in the selected project. 3. Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the required name. 4. Select the SIMATIC PC station in the component view and open HW Config by double-clicking on the "Configuration" object in the detailed view. Result: The hardware configuration of the SIMATIC PC station opens. 5. If the hardware catalog is not visible, select the menu command View > Catalog. 6. Under SIMATIC PC Station > HMI ... in the hardware catalog, select the WinCC application and drag it into the configuration table. 7. In the hardware catalog SIMATIC PC Station > CP Industrial Ethernet, select the communications processor installed in the SIMATIC PC station and drag it with the mouse to the PC station. If you are using a standard network adapter, select the processor IE General. Result: The "Properties - Ethernet Interface" dialog box opens.

7-16


Configuring PCS 7


If the network adapter is connected to the terminal bus activate the "IP protocol is being used" option.

-

If the network adapter is connected to the plant bus activate the "Set MAC address / Use ISO protocol" option. If a maintenance station is being operated activate the "IP protocol is being used".

-

For a network adapter connected on the plant bus via BCE, set the name in the "General" tab and in the "Keep Alive for Sending Connections" area of the "Options" tab set "Interval" to "30".



-


10. Exit the properties dialog by confirming your entries with "OK" 11. Select the menu command Station > Save and Compile.



•

Section "Setting up PC Stations"


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Configuring PCS 7

7.4.7

How to Configure and Download the PC Stations As of PCS 7 V6.1 SP1, the project-specific network settings for the communication adapters (Ethernet) of the engineering station are downloaded direct to the PC station (remote).

Requirements •

-

Operating system

-

Specific software for the PC station (for example, PCS 7 Engineering, OS Server)

•

All PC stations to be downloaded are connected to the engineering station via at least one network.

•

The operating system network is set up.

•

The network addresses of the PC stations are set.

•

The protocol for the communication is set to TCP/IP.

•

The following is settings have been made on each PC station:

•

7-18

The following is installed on each PC station:

-

The communication adapter for communication between the PC station and the terminal bus has been selected.

-

The network addresses for the plant bus are set.

-

The access point of the PC station has been set to: "S7ONLINE: = PC internal (local)".

The PCS 7 project has been created.


Configuring PCS 7

Downloading the Configuration and Network Settings Note Perform the following steps for the engineering station before continuing the configuration and download for additional PC stations.

1. Open the PCS 7 project in the SIMATIC Manager. 2. Select the target computer in the Component view. 3. Select the menu command CPU > Configure Network. The “Configure” dialog opens. The selected PC station in the project appears in the "Target Computer" field.

Note If the selected PC station is not shown, this indicates a network problem or an error in the project configuration.

4. Click the "Configure" button. The “Configure: ” dialog opens. 5. Click on the "OK" button in the "Configure: Target computer". 6. Click on the "OK" in the "Information" dialog. Result: The configuration data are transferred to the PC station. To activate the network connections, you now only have to download the network settings to this PC station. The conclusion of the "Configure" task is displayed in the status bar of the dialog. 7. Click on the "Close" button. 8. Select the menu command PLC > Download for the computer selected in step 2. The "Download CPU in the current project". 9. If the dialog warns you that the configuration data will be overwritten, make the decision as follows: -

Click on "YES" for a first-time installation.

-

If the PC station is in process mode, you can only click the "YES" button during an allowed interruption of the communication.

The "Target Module" dialog opens. 10. Click on "OK" in the "Stop Target Module" dialog. The "Download" dialog opens. 11. Click on the "Finish" button to confirm. The download procedure is carried out. Result: The PC station is read for operation once the configuration is loaded. 12. Repeat steps 2 to 11 for all PC stations.


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Configuring PCS 7

Switching the Protocol on the Bus (Industrial Ethernet) Caution The TCP/IP and ISO protocols cannot be disabled since they are both needed for the configured operation!

If the protocol of a bus in a plant needs to be switched (from TCP to ISO, for example), you need to briefly set a mixed protocol (TCP and ISO) on the engineering station. The configuration data can then be downloaded to the AS and the HMI systems.


7-20

Documentation SIMATIC Net; Commissioning PC Stations - Instructions and Quick Start


Configuring PCS 7

7.5

Creating the Plant Hierarchy (PH)

Plant Hierarchy (PH) In the plant view, you structure the project according to technological aspects. The automation, operator control and monitoring functions are arranged hierarchically (plant, unit, functions, ...). You name the hierarchy folders according to their technological significance. You arrange the following in the hierarchy folder: •

CFC and SFC charts for the AS

•

Pictures and reports for the OS

•

Additional documents such as descriptions of units, process tag sheets etc. (Word, Excel, ...)

The resulting project structure is the plant hierarchy.

Described below We assume the following for a multiproject

7.5.1

•

that the plant hierarchy is created on the central engineering station and, if necessary, is filled with additional documents. This is described below.

•

that the CFC/SFC charts or OS pictures/OS reports created on the distributed engineering stations are assigned to the hierarchy folders.

Structure of the PH

PH Created with the PCS 7 "New Project" Wizard With the "New Project" PCS 7 wizard, you create a PCS 7 multiproject (with project and master data library) including the corresponding plant hierarchy (PH). The following hierarchy objects are created in the plant view or in the process object view: •

Multiproject (in the example: s7_Pro4_MP)

•

Project (in the example: s7_Pro4_Prj)

•

Plant (in the example: Plant(1))

•

A unit (in the example: Unit(1))

•

A technological function (in the example: Function(1))


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Configuring PCS 7

•

Master data library (in the example: s7_Pro4_Lib) with the folders for models and process tag types. -

In the component view, and S7 program with the folders for Source files Blocks Charts

-

In the plant view, the folders for Process tag types Models

Selecting the Plant Hierarchy If the plant hierarchy is not visible, select the menu command View > Plant View.

Preview The following sections describe the following:

7-22

•

Which settings you need to make for the plant hierarchy.

•

How to expand the units and technological functions to the plant hierarchy according to the technological aspects of your plant.

•

Which rules apply when creating the plant hierarchy.


Configuring PCS 7

7.5.2

Settings and Properties of the PH If you create a multiproject with the PCS 7 assistant, certain defaults or parameter settings are made in the dialogs (for example the number of hierarchy levels, assignment to AS etc.). You can change the settings later or adapt them for hierarchy folders to be added later.

Definition of the Higher Level (Plant) Designation (HID) The higher-level or plant designation (HID) is used to identify parts of the plant uniquely according to functional aspects. The HID is structured hierarchically according to the plant configuration. When making the settings for the plant hierarchy, you can specify which hierarchy levels are included automatically in the HID and how many characters each part of the name will have. As a result, the HID can be made up of the names of the various hierarchy folders, for example "[NameHierarchyfolderLevel1]\[NameHierarchyfolderLevel2]" For each hierarchy folder at each hierarchy level, you can also specify whether its name is included in the HID or whether it should be removed from the HID. Hierarchy folders that are included in the HID, are said to be hierarchy folders included in the designation.

Note To ensure consistent naming throughout the entire project, make sure that you select a suitable naming scheme for the hierarchy folders in the plant view during configuration. The number of characters in the names of the hierarchy folders must not exceed the number of characters specified for the HID.

Overview of the Settings for the Plant Hierarchy Setting

Description

Number of hierarchy levels:

You can select the maximum number of possible hierarchy levels in the project. A maximum of eight levels of hierarchy folders is possible. At each level, you can insert as many hierarchy folders as required.

Basing the Picture Hierarchy on the Plant Hierarchy

With this option, the OS picture hierarchy is derived completely from the configured data of the plant hierarchy. When you later compiled the OS, this picture hierarchy is transferred to the Picture Tree Manager.

Derive diagnostics screens from the plant hierarchy

With this option, the diagnostics screens are generated in the plant hierarchy for the maintenance station. You can only select this option when the option "Derive picture hierarchy from the plant hierarchy" is set.

Level Settings Max. number of characters

Specifies the maximum number of characters permitted for the name of a hierarchy folder at this level (1 to 24)


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Configuring PCS 7

Setting

Description

Included in HID

You can select the levels whose hierarchy folder names (if selected for inclusion) will be included in the HID. You can use folders that are not selected for inclusion in the designation to create further "drawers" (for example for additional documents, such as plant descriptions, process tag sheets,...). If a level is included in the naming scheme of the HID, this means that the names are entered in the origin of the message (OS) and in the tags on the OS (measuring point). Note: When assigning names, remember that when you compile the OS, the tag name must not be longer than 128 characters. This name is made up of the name of the folder in the hierarchy path, the chart name, the block name, the separator and the I/O name.

With separator

With this option, a separator can be included in the HID after the name of hierarchy folders of this level. Separators are used in the textual representation of the hierarchy path to separate the names of the hierarchy folders. The "\" character is used as the separator.

OS area

With this, you can decide which hierarchy level should count as the OS area. The default is the 1st level. The definition of an OS area is necessary for area-specific messages in process mode.

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Configuring PCS 7

7.5.3

How to Make the Settings for the PH

Procedure 1. Open the plant hierarchy in the SIMATIC Manager with the menu command View > Plant View. 2. Select a hierarchy folder and select the menu command "Options > Plant Hierarchy > Customize...". Result: If you have selected several projects in a multiproject, you will first see a dialog box with a list of the selected projects. You can make the setting shown in the following dialog box only after selecting a project. Note The settings have the function of a template and are passed on to all other projects that were included in the selection. Projects that were not selected retain their settings. If you select the multiproject explicitly, all the projects it contains will adopt the settings you made in the template project. 3. Confirm your selection with "OK". Result: The "Plant Hierarchy – Settings" dialog box appears

4. Make the following settings for the plant hierarchy for the project. (Refer to the section "Settings and Properties of the Plant Hierarchy"). 5. Confirm your settings in the dialog box with "OK".


Configuration Manual Process Control System PCS 7; Operator Station.


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Configuring PCS 7

7.5.4

Rules for Naming in the PH

Extending the Basic Structure With the PCS 7 wizard, you could create a maximum of 5 hierarchy levels without further nesting of hierarchy folders. You can further extend this basic structure during configuration by adding further hierarchy folders and/or technological objects. When doing this, remember the following rules for naming folders/objects in the plant hierarchy.

Rules for Naming Folders/Objects •

The following special characters must not be used in the name of a hierarchy folder [ . ] [ % ] [ / ] [ \ ] [ " ].

Note The characters [ ‘ ] [ . ] [ % ] [ \ ] [ * ] [ ? ] [ : ] [ blank ] within a name are converted to the substitute character $ when you compile the OS. The ES separator [ \ ] is converted to the [ / ] character. If, for example, you assign the name "TICA:1" for a CFC chart (this becomes "TICA$1" on the OS) and the name "TICA*1" for another CFC chart, (also becomes "TICA$1"), you will receive an error message when you transfer the second chart because the chart name already exists.

•

The maximum length of a tag name is 128 characters. Remember, however, that many of the editing windows on the OS cannot display 128 characters in their entirety. You should therefore restrict the length of the HID.

•

Remember that the length of the texts transferred depends on the maximum text length of a target block in the operator station (Tag Logging, for example event 50 characters; origin 32 characters). When compiling the OS, texts up to a maximum length of 255 characters are transferred. Remedy: Increase the maximum character length of the user text field or select a shorter HID.

7-26

•

Structure the plant hierarchy so that for each SIMATIC 400 station there is a hierarchy folder as the highest hierarchy node below the project.

•

The message texts of the transfer messages are made up of the hierarchy path, chart name, and the block name (if you decided to include the names in the HID).


Configuring PCS 7

7.5.5

How to Insert Further Hierarchy Folders With the wizard, you can create a maximum of 8 hierarchy levels without further nesting of hierarchy folders. You can further extend this structure created by the wizard by adding further hierarchy folders and/or technological objects.

Hierarchy Folder The hierarchy folder is used to structure the plant in a hierarchy. It can contain further hierarchy folders and objects such as CFC charts, SFC charts, process pictures, reports or additional documents (Excel, Word, ...). The higher-level designation (HID) of an object results from the names of the hierarchy folders (path) and the object name (if you decided to use these are formed the HID).

Procedure 1. Open the plant hierarchy in the SIMATIC Manager with the menu command View > Plant View. 2. Select a hierarchy folder below which you want to insert a further hierarchy folder. 3. Select the menu command Insert > Technological Object > Hierarchy Folder. 4. Enter the technological name of the hierarchy folder.

Assigning Technological Names After you insert a hierarchy folder, this is displayed in the right hand window. It is prepared so that you can assign a new name. The name field with the name assigned by the system is selected and the cursor is located after the last character of the folder name. You can now enter the required technological name at the keyboard (delete and edit).


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Configuring PCS 7

7.5.6

How to Insert Objects in the Hierarchy Folder The technological objects CFC charts, SFC charts, OS pictures, and OS reports can be inserted in the plant hierarchy both in the plant view and in the process object view. The methods for inserting objects are practically identical. Below, we describe how to insert the objects in the plant view.

Procedure 1. Open the plant hierarchy in the SIMATIC Manager with the menu command View > Plant View. 2. Select the hierarchy folder below which you want to insert the object. 3. Select the menu command Insert > Technological Object > "".

Additional Documents in the Project In addition to the objects (CFC/SFC charts, pictures/reports) required for automation and for operating and monitoring of the plant, you can also insert additional documents in a hierarchy folder (unit descriptions, process tag sheets, planning documents etc). Follow the steps outlined below: 1. Select the hierarchy folder below which you want to insert the additional document. 2. Select the menu command Insert > Technological Object > Additional Document. Result: The "Insert Additional Document" dialog box opens. All available applications are displayed.

Note You can also create a new additional document here by selecting the type in the "Registered Applications" box, entering the name and confirming with "OK". Result: The additional document is created in the PH. You can then open it and edit it by double-clicking on it.

3. Click the "Import" button. 4. Select the additional document you require. 5. Confirm your selection with "OK".

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Configuring PCS 7

7.5.7

Rules for Copying and Moving within the PH

Rules for Copying/Moving/Deleting Hierarchy Folders •

If you copy or delete hierarchy folders, all the objects they contain are copied or deleted as well. By copying, you can copy, for example, an entire unit at once. You then only need to modify the copied unit (for example link to process signals).

•

If the target hierarchy folder to which you want to copy or move has no assignment to an AS (chart folder) and/or to the OS, this is created automatically by the system (refer also to the segment "How to Specify the AS/OS Assignment"). This means that within a project the same assignment is made for the copied hierarchy folder as the source folder had. If there are multilevel hierarchy branches with different assignments, the different assignments are retained.

•

When more than one project is involved, every AS and OS in the destination environment is identified. If an assignment cannot be made unequivocally, (no or only one AS or OS), a list of the possible alternatives is displayed for selection. Once again, if hierarchy branches have different assignments, they are also different in the destination as specified in the source hierarchy branch.

•

If the destination hierarchy folder to which you want to copy / move already has an assignment to an AS and/or to an OS, this assignment is passed on to all copied objects.

•

You can copy, move and delete a hierarchy folder containing objects with different assignments. A warning is displayed asking you whether you really want to copy or move the folder. If you answer "Yes", all the objects are copied to the AS (or OS) assigned to the destination hierarchy folder. If you answer "No", nothing happens.

•

If the hierarchy folders you want to copy/move are models or replicas of models, remember the special rules that apply to them (refer to the section "How to Work with Models in the SIMATIC Manager").


Section "Relationships between the Views"

•

Section "Cross-View Functions and How to Use Them"


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Configuring PCS 7

7.5.8

How to Specify the AS-OS Assignment For the hierarchy folders, an assignment of an OS to an AS must be made in the plant hierarchy. The AS-OS assignment produces the following results in the component view: •

All CFC and SFC charts inserted in the plant hierarchy are stored in the chart folder of the assigned AS.

•

All pictures and reports inserted in the plant hierarchy are stored in the folder of the assigned OS.

Procedure 1. Select the hierarchy folder for which you want to make the AS-OS assignment in the plant view. 2. Select the menu command Edit > Object Properties and change to the "AS-OS Assignment" tab. 3. From the "Assigned CPU" drop-down list box, select the S7 program you want to assign to the selected hierarchy folder. 4. If the lower-level objects have a different assignment and you want to have the same assignment for all lower-level objects, check the "Pass on selected assignment to the lower-level objects" check box. Note The "Pass on selected assignment to lower-level objects" option is only active when the lower-level objects have a different or no assignment. 5. From the "Assigned OS" drop-down list box, select the operator station you want to assign to the selected hierarchy folder. 6. If the lower-level objects have a different assignment and you want to have the same assignment for all lower-level objects, check the "Pass on selected assignment to the lower-level objects" check box. Note If the "area-oriented" compilation mode is activated, the OS assignment can only be changed for PH folders of the OS area level. 7. Click the "OK" button to save your settings. Result: The AS-OS assignment is made and passed on to the lower-level objects or not depending on the setting you selected. Note If you have distributed the projects so that there is only one OS or one AS in a project, you do not need to make an AS-OS assignment.

Further information

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•

Online help on the PH, IEA and PO

•

Online help for the "PLC-OS Assignment" tab Process Control System PCS 7 - Engineering System A5E00346923-02

Configuring PCS 7

7.5.9

How to assign objects to the PH You can also assign objects from the component view, for example a CFC chart or SFC chart, to the plant hierarchy later. This is always the case when, for example, charts are inserted directly in the component view and you then create a plant hierarchy later. If you always create the charts and pictures in the plant view or the process object view, these assignments are made automatically.

Requirement The hierarchy folder must have the same PLC or OS assignment as the assigned object. If the destination hierarchy folder has a different PLC/OS assignment, the assigned object is also moved to this PLC/OS in the component view.

Procedure 1. Select the required object in the component view. 2. Holding down the Shift key (move), drag the object to the required hierarchy folder of the PH. If you have created pictures/reports directly in the OS and want to make these objects known in the plant hierarchy later, follow the steps outlined below: 1. Select the OS in the component view of your project. 2. Select the menu command Options > Import WinCC Objects. 3. Select the required object in the component view. 4. Holding down the Shift key, drag the object from the component view to the required hierarchy folder of the PH.

Assignment after Copying / Moving When you copy / move a hierarchy folder to a hierarchy folder that is assigned to a different AS or OS, the copied/moved hierarchy folder also receives the assignment of the destination folder. When you copy / move objects (such as CFC charts, OS pictures/reports) to a hierarchy folder assigned to a different PLC/OS, these objects are also copied / moved to the other PLC or OS. When copying/moving hierarchy folders with CFC charts and OS pictures, the references of the dynamic objects from these OS pictures to CFC blocks are updated in the target hierarchy folder.

Caution The process variables referenced in the C scripts in WinCC must be defined in the "#define section".


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Configuring PCS 7

Interconnections after Copying / Moving When you copy / move CFC charts, the interconnections to shared addresses are automatically copied or deleted. You make the setting either in CFC (menu command Options > Customize > Copy/Move...) or in the SIMATIC Manager (menu command Options > Charts > Settings for Copying/Moving...). The default is "include interconnections".

Canceling the PH Assignment If you want to use charts, pictures, reports in a project without PH or want to delete the PH in the current project without losing the charts, pictures or reports, you can cancel the assignment to the PH with the menu command Plant Hierarchy > Cancel Assignment.... The function is available in the component view and in the plant view.

Interconnections between Charts and Pictures When you copy/move hierarchy folders containing interconnected pictures and charts, the picture interconnections are always updated. Explicit updating is not necessary. When you compile the OS, all changes that affect ES variables are updated.

7.5.10

How to Check the Consistency of the PH With the menu command Options > Plant Hierarchy > Consistency Check, you can check whether the configured data is consistent with the settings made in the project or multiproject.

Consistency tests

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•

The names, number of objects and uniqueness of hierarchy folders, CFC charts, SFC charts, pictures, reports and settings for the OS area are automatically checked.

•

The results are displayed in the individual tab dialogs.

•

Information about the test results in the tabs is available by pressing the "Help" button.


Configuring PCS 7

Additional tests for a selected multiproject Note If a multiproject is selected, the following checks are also made: •

Check for unique names of S7 programs. Check whether the names of CFC charts and SFC charts are unique in the entire multiproject.

•

Check that only one object for each type (S7 program, OS) is available in the master data library.

•

Check for differing PH / settings

•

If project or hierarchy folder is selected, the checks relate solely to the project.

Procedure 1. Select the multiproject or a project in the plant hierarchy. 2. Select the Options > Plant Hierarchy > Check Consistency menu command. Result: the "Check Consistency - Log" dialog box opens displaying errors. 3. Eliminate the errors and run the consistency check again.

Test Log On completion of the check, a message is displayed or if an error occurred, the error log is output. You can also display the log later without running the check again with the menu command Options > Plant Hierarchy > Display Log. A log is displayed when the last consistency check has shown that the configured data are consistent with the settings that have been made.

Note Violations of the naming scheme can occur, for example, when you change settings at a later date or copy/move folders to different levels. The system tolerates these violations to avoid unnecessary error messages while you are working.

Further information For further information on the log, refer to the online help.


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Configuring PCS 7

7.5.11

Additional PH Functions in a Multiproject

PH Functions Specific to Multiprojects The functions of the plant hierarchy are adapted to the needs of multiproject engineering. Support begins with the creation of the multiproject by the PCS 7 wizard. The following functions are important for multiprojects: •

•

•

•

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Creating a Multiproject In the SIMATIC Manager, the PCS 7 wizard automatically creates a multiproject. -

The project is created with the content selected in the PCS 7 wizard (PH, AS, OS).

-

Two hierarchy folders are created in the master data library in the PH that serve as storage for models and process tag types.

Cross-Project Consistency Checks -

The consistency check allows multiple assignment of names to process tags to be recognized early. This prevents such errors aborting the data transfer to the OS when using the "Compile OS" function.

-

It is also possible to check that the S7 program names are unique throughout all projects of the multiproject. This is essential for the Import/Export Assistant and the diagnostic functions of the maintenance station.

-

Within the master data library, a check is made to ensure that only one S7 program and only one operator station exists.

Passing on PH Settings to Other Projects of a Multiproject You connect the settings in the PH for the projects of a multiproject with the menu command Options > Plant Hierarchy > Settings...: -

Settings for a single project If you select a single project in a multiproject, you can only make the PH settings for this project.

-

Same settings for several/all projects If you select several projects in a multiproject or the multiproject itself, and then open the settings dialog, you first see an extra dialog box in which you can select a project (template) in which you can make the settings for the PH in the next dialog. The settings of this template are passed on to all projects included in the selection.

Searching for Block Icons in all Projects of a Multiproject With the Create/Update Block Icons menu command, all the pictures in the entire multiproject are included whose block icons are based on the PH. In a multiproject, the path in the PH is the key for searching in other projects. PH structures with the same name are searched for in all projects of the multiproject. The CFC charts found are included in the editing.


Configuring PCS 7

•

Synchronizing Hierarchy Folders in the Multiproject When working in a multiproject, in some situations it is necessary to create redundant folders in parts of the of the plant hierarchy in all or individual projects of a multiproject. Two situations where this is the case: -

In SIMATIC BATCH, the folder identified as "Process cell" is required in the first hierarchy level in all projects.

-

By using the same names in the plant hierarchy in the individual projects of the multiproject, AS and OS parts that belong together are detected when the functions "Create/Update Block Icons" and "Create/Update Diagnostic Screens" execute.

A function that synchronizes the plant hierarchy in the multiproject allows you to save multiple configuration. This also protects the project from (accidental) changes that would result in differing names. You can start the synchronization function (with the process object view or plant view selected) using the menu command Options > Plant Hierarchy > Update in multiproject.


7.5.12


S88 Type Definition of the Hierarchy Folders

Introduction In the PH, it is possible to assign attributes to the hierarchy folder in compliance with the S88.01 standard. This "S88 Type Definition" is required, for example, for BATCH process cells and applications at the business management level (MES). Using the object properties, you can change the object type of the highest hierarchy folder from "neutral" to "Process Cell".

Procedure 1. Select the object whose settings you want to change in the PH. 2. Select the menu command Edit > Object Properties and then the "S88 Type Definition" tab. 3. Change the object type from to process cell and confirm with "OK" When you create further folders, the folders in the two levels directly below are assigned the attributes for "Unit" and "Equipment module" according to their hierarchical level.


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Configuring PCS 7

Structure of the Plant Hierarchy The following schematic shows the 3 hierarchy folders of the S88 type definition.

Technological Significance of the PH Hierarchy Folder

Level

Symbol

Process cell

2

Within a project, only one process cell can currently be created.

Unit

3

Several units can be defined in one process cell.

Equipment module

4

Several equipment modules such as a dosing or bottling machine can be defined in a unit.

(Phase)

Meaning

Neutral Folders The three-level hierarchy can be extended by adding neutral folders to improve the structuring of the project, for example to divide units into groups. The neutral folders can be created at any level. The total number of possible levels (S88 hierarchy levels, levels with neutral folders) is limited to eight. Neutral folders can, for example, be inserted above the "Unit" level. This level can then be used, for example, as the area level. A further level could, for example, be inserted below the "Equipment Module" level. This level can then serve as a control module level.

Successor for the "Unit" Object Type With the "Unit" object type, a different unit from the same or another project can be selected as the "successor" to the unit. If this successor is in a different project, it is inserted in the current project as a hierarchy folder with a link. This is set in the "S88 Type Definition" tab with the "Successor / Predecessor" button. A successor is the unit that handles the operations to be performed in a production process after this leaves another unit (the predecessor).


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Configuring PCS 7

7.6


7.6.1

Introduction - Master Data Library

Overview It is helpful during configuration, if all objects (blocks, charts, source files, process tag types, models, SFC types etc.) used in the project are grouped in their own library. This means, for example, that you can be sure that only one version of a particular block type is used throughout the entire project. Different versions in different programs can lead to conflicts if the programs are to be controlled and monitored on one OS. Reason: Block types of the same name in different programs, must have the same variable structures, since there is only one variable structure for a block type on the OS.

Master Data Library When you create a multiproject with the PCS 7 Wizard, a master data library is created automatically. The master data library is used for storage of the master data of the project for all projects of a multiproject. When you move projects from the multiproject to distributed engineering stations for editing, you must also transfer the master data library so that all configuration engineers have an identical database available. The master data library contains all objects used in the projects and that may need adaptation for a specific project. These include block types, SFC types, process tag types, models, OS pictures, OS reports etc. The master data library ensures that a defined version of types can be reused. The master data library is archived automatically along with the multiproject. The master data library can include the following: •

Objects from the control system library PCS 7 Library

•

Objects from libraries of suppliers

•

User-created objects


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Configuring PCS 7

Maintaining the Master Data Library The planning at this point should be very careful. Block types you create yourself or adapt to the needs of the project should be tested thoroughly before you include them in the master data library. Changes at a later point in time (after generating block instances) are supported by the system, but involve more effort, for example due to central modification or recompilation of the OS. One of the advantages of master data libraries is that they are automatically archived along with the multiproject.

Note Remember to update your master data library in which you use blocks from the PCS 7 library after a change of version of the PCS 7 library. To synchronize block types, you can use the function "Update Block Types", refer to the section "How to Update Block Types".

Note The supplied libraries are always copied during PCS 7 installation. If you have edited supplied libraries, the libraries you have changed will be overwritten by the originals if you install again.

Overview of the Steps in Creating a Master Data Library What?

Where?


SIMATIC Manager

Copying Objects to the Master Data Library

SIMATIC Manager

Adapting Blocks to the Project Requirements SIMATIC Manager (component view)

7-38

Creating Process Tag Types

SIMATIC Manager (plant view)

Creating Models

SIMATIC Manager (plant view)

Testing the Library Objects

CFC or SFC Editor

Documenting the Library Objects

In the relevant editors

Hiding Libraries

SIMATIC Manager


Configuring PCS 7

7.6.2

Objects of the Master Data Library

Structure of the Master Data Library In the component view, the master data library contains an S7 program with one folder each for blocks, source files and charts as well as the object symbol (symbol table). In the plant hierarchy (plant view or process object view), the master data library contains one folder each for process tag types and models. These two hierarchy folders each have an AS assignment to the S7 program and identifiers that identify them as hierarchy folders of a master data library. The pictures and reports that are intended as templates, are copied to a hierarchy folder of the master data library after they have been tested in the project. At the same time, an OS is created in the master data library that you can see in the component view. Note: This OS is not part of the automation solution.

Component View You copy all the block types (technological blocks, driver blocks, communication blocks etc.) required in the multiproject to the block folder of the master data library in the component view. This may be a collection from PCS 7 libraries, libraries of suppliers, or blocks you have written yourself. The blocks from the PCS 7 libraries are suitable for most situations encountered during configuration and can usually be used unchanged. If blocks need to be adapted for special requirements, make the adaptations early; in other words, before the blocks are used in the projects. SFC types are stored in the chart folder of the master data library. Note: SFC types can also be part of process tag types or models.

Hierarchy Folders of the Master Data Library A multiproject consists of one or more projects and a master data library with the hierarchy folders for "process tag types" and "models". These hierarchy folders each have an AS assignment to the S7 program of the library and identifiers that identify them as hierarchy folders of a master data library and an OS assignment. They are identified by their own icons: •

Models A model consists of hierarchy folders with CFC/SFC charts, pictures, reports, and additional documents from which any number of replicas can be created using the IEA.

•

Process tag types CFC chart configured in a library for basic control of a process engineering system for a special control system function, for example level control. Copies can be made from this process tag type that can be adapted to the specific automation task and then used in the system. The copy of a process tag type is a process tag.


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Configuring PCS 7

The hierarchy folders of the library are handled differently from the hierarchy folders of the project. This means: •

When it is copied or moved, the hierarchy folder loses its identifier if the target is not a master data library, or the same hierarchy folder already exists in the target. If a hierarchy folder loses its identifier, its symbol changes to that of a normal hierarchy folder.

•

You cannot insert any new hierarchy folders with this identifier explicitly in the master data library. They are, however, created automatically in the master data library when you create models or process tag types and the corresponding folder no longer exists.

•

Hierarchy folders that lose their identifier do not regain it when they are returned to the master data library.


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Configuring PCS 7

7.6.3

How to Create a Master Data Library

Specifying the Master Data Library If you have created your multiproject with the PCS 7 Wizard, it already contains a master data library. If you do not yet have a master data library in your multiproject, you can •

create a new library in the SIMATIC Manager and define this as the master data library or

•

define an existing library as the master data library.

Note Only one library can be defined in the multiproject as the master data library. The master data library can only contain one S7 program.

Procedure To create a new library as the master data library in your multiproject, follow the steps outlined below: Requirement: No library must be defined in the multiproject as a master data library. If necessary, you may need to cancel the definition of an existing master data library (see Step 2). 1. In the SIMATIC Manager, select the menu command File > New > Libraries and enter a library name (ideally the multiproject name) and, where necessary, the path to the storage location. Result: The library is created and opened. 2. Select the library in the multiproject in the component view and Select the menu command File > Multiproject > Define as Master Data Library. Result: The library is defined as master data library. 3. Select the library and then the menu command Insert > Program > S7 Program. Result: An S7 program along with a block and source file folder is created. 4. Add a chart folder below the S7 program with Insert > S7 Software > Chart Folder. Result: Your multiproject has a new master data library. The models or process tag types folders do not need to be created explicitly in the plant hierarchy. These are created automatically when you create models process tag types. Note The SIMATIC Manager permits names longer than 8 characters. The name of the library directory is, however, restricted to 8 characters. Library names must therefore differ from each other in the first 8 characters. The names are not casesensitive. Remember that the name of the file is always the same as the original name of the library when created because changes to names are not synchronized at the file level in the SIMATIC Manager.


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Configuring PCS 7

7.6.4

Working with Libraries This section explains the most important functions when handling libraries. You should know these functions, for example, when you want to include objects from libraries in the master data library.

Library Functions In the SIMATIC Manager, you can use the following functions with libraries: •

Open a library with the menu command File > Open > "Libraries" tab .

•

You can copy a library by saving it under a different name with the menu command File > Save As.

•

You can delete a library with the menu command File > Delete > Libraries.

•

You can delete parts of libraries such as charts, blocks, source files with the menu command Edit > Delete.

•

You can hide unused libraries and show them again: With the menu command File > Manage > Libraries and then by selecting the library and the "Hide" button to hide them. The library can be made visible again with the "Display" button.

Note Since the master data library contains all the objects to be used in the project, you should hide all the libraries except for the master data library.

Creating a new Library To create a new library, follow the steps below: 1. Select the menu command File > New in the SIMATIC Manager 2. Change to the "Libraries" tab and enter the name and, if necessary, the location for the library. 3. Confirm with "OK". Result: A new library is created in the multiproject.

Note The SIMATIC Manager permits names longer than 8 characters. The name of the library directory is, however, restricted to 8 characters. Library names must therefore differ from each other in the first 8 characters. The names are not casesensitive. Remember that the name of the file is always the same as the original name of the library when created because changes to names are not synchronized at the file level in the SIMATIC Manager.

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Configuring PCS 7

7.6.5

How to Copy Objects from other Libraries to the Master Data Library The following section describes how to enter objects from the supplied PCS 7 library (PCS 7 Library) or from libraries from other suppliers in the master data library.

Procedure If you want to copy part of a library, for example software, blocks, pictures etc, follow the steps outlined below: 1. In the SIMATIC Manager, select the menu command File -> Open and change to the "Libraries" tab. 2. Select the required library and confirm with "OK". Result: The library is opened. 3. Select the part of the library you want to copy in the open library (source). Select the menu command Edit > Copy (for example process tag types, blocks). 4. Select the folder in the master data library (destination) in which you want to store the copied part of the library. 5. Select the menu command Edit > Paste. Result: The copied library is stored in the master data library.

Notes on Copying •

If you want to copy the supplied process tag types from the PCS 7 Library to your master data library, select the required process tag type in the "Templates" folder, copy it and then paste it into the "Charts" folder of your master data library.

•

If you copy blocks from different libraries, it is possible that blocks could have different names (and functions) but the same block numbers. In this case, a dialog opens in which you can rename the block or synchronize the attributes.

•

Renaming (rewiring) works only when copying to offline.

•

The symbolic name is copied when you copy the blocks from a library. If you do not copy from a library, but from an S7 program, the symbolic name is lost and must be entered later in the symbol table.

Notes on Multiple Instance Blocks •

If blocks contain code that calls further blocks (multiple instance blocks), the suitable version of these called blocks must also be copied. Missing FBs called by other blocks can be identified later by the engineering system but missing FCs cannot (neither during compilation nor downloading).

Note Remember that the CPU changes to STOP if FCs are missing. •

Remember that the block numbers of the blocks it calls are entered in the code of the multiple instance block. If you change these numbers and the numbers in the code, it is possible to rewire in the SIMATIC Manager (Options > Rewire...). Exception: with protected blocks.


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Configuring PCS 7

7.6.6

How to Update Block Types

Updating Block Types After including a new version of a block type in the master data library or after adapting a block type in the master data library, you can use the "Update block types" function to list all components in which an older version of the modified block type is used. You can also select the components in which the modified block type should be updated throughout the entire multiproject.

Procedure 1. Select one or more blocks in the block folder of the master data library. 2. Select the menu command Options > Charts > Update Block Types. Result: the "Update Block Types" dialog box opens. 3. Select the S7 programs to be checked for differences compared with the block types selected in the master data library. 4. Complete the dialog with "Next". Result: All selected S7 programs are checked and a further dialog opens in which you can select the block types. Here, you can also see information on the consequences. 5. Specify the block types to be updated for the specific programs: All the block types to be updated are selected. Where necessary, you can deselect those you do not want updating. If there are no block types to be updated (none displayed), close the dialog. 6. Complete the dialog with "Next". Result: The block types are updated in the selected S7 programs and a log is displayed.


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Context-sensitive online help for the two dialogs above


Configuring PCS 7

7.6.7

Adjusting the Blocks

7.6.7.1

Adapting Blocks to Project Requirements The blocks from the PCS 7 libraries are suitable for most situations encountered during configuration and can usually be used unchanged. If you need to adapt blocks for a concrete project and for special requirements, make the adaptation before you use the blocks in the projects and store them in the master data library. What?

Where?

How to Modify Attributes of the Block I/Os Locking Message Attributes Against Changes in Block Instances Translating Message Texts Setting the Language for Display Devices Exporting/Importing Operator and Display Texts

LAD/CSF/STL Editor PCS 7 message configuration SIMATIC Manager SIMATIC Manager SIMATIC Manager

Note Blocks must only be adapted to project requirements in the library. In the following sections, it is assumed that this is the master data library.

7.6.7.2

How to Modify Attributes of the Block I/Os

Attributes of Block I/Os The block I/Os of the block types have attributes that you can adapt to the project requirements.

Procedure 1. Select the block to be modified in the block folder of the master data library. 2. Select the menu command Edit> Open Object. Result: The LAD/STL/FBD editor is started (you receive a message if the block is protected). If you select an object in the tree structure of the interface, its content is displayed. 3. In the right-hand pane, select the required I/O and select the menu command Edit > Object Properties. Result: The properties dialog opens. 4. Select the "Attributes" tab Result: The attributes are displayed in table form. 5. Here, you can modify or enter the attributes and their values. By clicking in the "Attribute" column, you open a drop-down list box displaying the possible attributes for this I/O. You can modify attributes without any great difficulty, since there is a syntax check when you enter attributes and you will be informed of errors or missing information. Note You will find information on using attributes and a description of the attributes in the online help on the LAD/STL/FBD editor.


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Configuring PCS 7

Note the following special situations: •

You should configure the texts for the attributes "S7_string_0", "S7_string_1", "S7_unit" and "S7_shortcut" in the language that will be used by the operator on the OS. If you require these texts in additional languages on the OS, you must translate them in the text lexicon of WinCC.

•

With the "S7_enum" attribute, you can assign an enumeration to a block parameter. On the ES, an enumeration data type with the name selected by the user is created. In the block parameters with which the enumeration is to be used, a parameter of the data type BOOL, BYTE, INT, DINT, WORD, or DWORD is created. This parameter is given the "S7_enum" system attribute. The value is the name of the enumeration defined on the ES. The name of the enumeration can be translated into different languages.

•

If you modify attributes that involve the faceplates or the block structure on the OS (for example S7_m_c), errors may occur when you interconnect the faceplates or when you compile the OS.

•

The attributes are divided into attributes with "type character" (property relates to the block type) and "instance character" (property relates to a single instance), a distinction that is not immediately apparent.

•

7-46

-

Changes to attributes with type character (for example S7_link) also apply to all existing block instances.

-

If the attributes have the character of an instance (for example S7_visible), a modification does not affect existing block instances and simply becomes the default. Exception: With the attributes "S7_string_0", "S7_string_1", "S7_unit" and "S7_shortcut", CFC adopts the modification if the user has not changed the value in the block instance.

Reading back parameters from the CPU. In the read back dialog, you can set the parameters to be read back: -

all (S7_read_back = true; default)

-

those that can be operator controlled and monitored (S7_m_c := 'true')

-

marked parameters (S7_read_back := 'true')

-

none, in other words, the block is completely exempted from the read back (S7_read_back = false)


Configuring PCS 7

7.6.7.3

How to Lock Message Attributes Against Changes in Block Instances

Message Texts and Message Attributes Messages are important for the operator when controlling the process. With the aid of messages, you can monitor and evaluate the process. Message texts and message classes are preset in the block types in the PCS 7 libraries. Messages include, for example, "Process value too high", "External error", "Overfeed". These messages are sent by the automation system when the corresponding event occurs. You can adapt these message texts and attributes to your particular situation. You can make these adaptations either to the block type or to the block instances. If you want to avoid message attributes being modified in the block instances, you can lock the instances.

Procedure 1. Select the block to be modified in the block folder of the master data library. 2. Select the Special Object Properties > Message... context menu command. Result: Message configuration is opened. This displays all the messages configured for this block. 3. By putting a check mark in the entered in the column before it.

column, you can interlock the text you

4. Confirm your settings with "OK".

Note If block instances already exist, the modification can be passed on to the instances by repeating the block import.

Further information For more detailed information on adapting operator and message texts, refer to the Configuration Manual Process Control System PCS 7; Operator Station.


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Configuring PCS 7

7.6.7.4

How to Compile Message Texts

Multiple Language Message Texts You can enter message texts in more than one language. The PCS 7 library blocks already have message texts in three languages (German, English, French). If you require a language that is not currently available for the message texts of blocks, you can set the language and translate the texts.

Procedure - (based on the example of a block type) 1. In the SIMATIC Manager, select the menu command Options > Language for Display Devices. 2. From the list of "Available Languages", select the language to be displayed on the OS. Click on " Æ " to transfer the selected language to the list of "Installed Languages in Project". 3. Select the language and click on the "As Standard" button. 4. Open the dialog for message configuration (select the block, right-click and select the context-sensitive menu command Special Object Properties > Message) and translate the texts. 5. Confirm the entry of the translated texts with "OK".


7.6.7.5


How to Set the Language for Display Devices The language for display devices is relevant for transferring messages from the ES to the OS (Compile OS). If you have not selected the required language, the message texts are transferred to the wrong text library and do not appear in process mode.

Procedure 1. In the SIMATIC Manager, select the Options > Language for Display Devices... menu command. 2. Set the language for the PCS 7 blocks, for example "English (USA)". 3. Select the language you want to define as default in the "Installed Language in Project" box and click the "Standard" button. 4. Complete the dialog with "OK". For your project, you can select several languages from the list of available languages and define one of them as standard.

Further information

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•


•

Online help on the dialog


Configuring PCS 7

7.6.7.6

How to Create your own Blocks for the Master Data Library You can create PCS 7-compliant AS blocks or faceplates yourself and store them in the master data library. You will find information on creating your own blocks in the manual Process Control System PCS 7; Programming Instructions Blocks. This also describes how to store your own blocks in a library and how they can be installed on the target computer with setup for inclusion in the master data library.

7.6.7.7

Using Faceplates and Block Icons for OS Pictures

Faceplates and Block Icons If a block instance is to be controlled and operated by the operator during process mode, a faceplate is required. The faceplate contains the graphic representation of all elements of the technological block intended for operator control and monitoring. The faceplate is displayed in its own window on the OS and can be opened using a block icon (typically located in the ODS overview picture). For each technological block type of the PCS 7 Library there is already a corresponding faceplate. Block icons are generated automatically following a menu command. You can also create or adapt your own block icons. Per block type, several block icons can be created in a process picture to visualize certain variants of a type. Note In CFC, you can assign the block icons to specific instances in the object properties of the blocks.

Faceplates for Block Types of the PCS 7 Library The display and operator input options of the faceplates for the block types of the PCS 7 library are described in the Manual Process Control System PCS 7 Library.

Creating Your Own Faceplates You will find step-by-step instructions on creating your own faceplates in the manual Process Control System PCS 7; Programming Instructions Blocks.

Creating your own Block Icons For information on generating and adapting block icons, refer to the Configuration Manual Process Control System PCS 7; Operator Station.




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Configuring PCS 7

7.6.7.8


Application With the option of exporting entire contents of entire tables from the process object view, you can, for example, assign modified parameter values and interconnections to a copied unit externally. You can then import the modified data again. This method can be used as an an alternative to the Import/Export Assistant.

Import/Export of Parameters, Signals, and Messages To visualize the process in process mode, you use the faceplates that display, for example measured values, operating limits, unit of measure, and operator texts of the blocks to the plant operator. In the process object view, you can do the following with the information of parameters, signals and messages: •

export them to a file,

•

edit them with standard applications (MS Excel, MS Access),

•

and read them in again (import).

ll the editable fields for parameters, signals, and messages in the process object view are imported/exported. The charts in the selected and all lower-level hierarchy folders are taken into account (according to the selection in the process object view). After export, you receive a message indicating the file (CSV file) and path in which the data was stored. Here, all the contents of the cells are in double quotes and separated from each other by semicolons so that they can be edited with MS Excel or MS Access.

Note With the measure described above for importing and exporting, you edit the instances; in other words the option of central modification is lost.

Languages PCS 7 allows you to store all the operator and display texts in any language. The only requirement is that the language is already installed in your project: You can display the available languages in the SIMATIC Manager with the menu command Options > Language for Display Devices. The number of languages available is decided when you install Windows (system property).

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Configuring PCS 7

Structure of the Export and Import File for I/Os The export file or import file for I/Os consists of the following 19 columns: Columns Column Titles

Meaning

1-4

Hierarchy; Chart; Block; I/O;

Identification of the I/O

5 - 15

Block comment; I/O comment; Value; Unit; Attributes that are exported/imported Interconnection; Signal; Identifier; Text 0; Text 1; Watched; Enumeration

16 - 19

Data type; I/O; Block type; I/O type.

Information on the I/O

Rules for the Export and Import File for I/Os •

The CSV file for importing I/Os must include at least the first four columns for identification of the I/O. The remaining columns are optional and can be used in any order.

•

The columns with information on the I/O are ignored when importing.

•

Empty text fields (cells) are ignored when importing. This means that you can create or modify texts by importing, but they cannot be deleted.

•

If several I/Os are listed for a block, in other words, several rows exist for the block, the block comment will exist the same number of times. If you modify the comment, only the block comment of the last row is taken into account during import.

Structure of the Export and Import File for Messages The export file or import file for message texts consists of the following 20 columns: Columns Column Titles

Meaning

1-5

Hierarchy; Chart; Block; I/O; Subnumber;

Identification of the I/O

6 - 19

Block comment; Class; Priority; Origin; OS Attributes that are exported/imported area; Event; Batch ID; Operator input; Free text 1; Free text 2; Free text 3; Free text 4; Free text 5; Info text;

20

Block type

Information on the I/O

Rules for the Export and Import File for Messages •

The CSV file for importing message texts must include at least the first five columns for identification of the I/O. The remaining columns are optional and can be used in any order.

•

Empty text fields (cells) are ignored when importing. This means that you can create or modify texts by importing, but they cannot be deleted.


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Configuring PCS 7

How to Export I/Os 1. Select the menu command Options > Process Objects > Export I/Os.... Result: An export file (CSV file) is generated containing all the attributes and information on the I/O of the object (project, hierarchy folder, or CFC chart) selected in the tree structure. The information from the process object view ("Parameters" and "Signals" ignoring filters) including titles is written.

How to Export Messages 1. Select the menu command Options > Process Objects > Export Messages.... Result: An export file (CSV file) is generated containing all the message texts (and information on the block) of the object (project, hierarchy folder, or CFC chart) selected in the tree structure.

Further Editing Note When editing exported texts, make sure that you do not overwrite any management information (language IDs or path information). With the ASCII editor, you edit only lines that begin with "T-ID=".

Caution Always open the files from within the tool (for example start Excel > File > Open) and not by double-clicking on the file. If you edit with a spreadsheet editing tool never edit the first column or the first row and do not delete any semicolons.

How to Make a Backup Export Prior to Importing Before you import, a dialog box is displayed in which you can check the import file (name and content). Here, you can also set the "Execute backup export" option. With the "Execute backup export" option, you can export precisely the I/Os and messages listed in the import file you have selected but that still contain the current data (attributes) of the project.

How to Import I/Os 1. Select the menu command Options > Process Objects > Import I/Os.... 2. Select the required import file (CSV file). Result: The attributes and information of the I/O of the selected import file are imported into the selected project; in other words, the I/Os of the named process tags (hierarchy, chart, block, I/O) are assigned.

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Configuring PCS 7

How to Import Messages 1. Select the menu command Options > Process Objects > Import Messages.... 2. Select the required import file (CSV file). Result: The message texts of the selected import file are imported into the selected project; in other words, the blocks of the named process tags (hierarchy, chart, block, I/O) are assigned.

Further information

7.6.8

•


•

Online help on the individual dialog boxes

Working with Process Tag Types Process tag types are installed automatically in the process tag types folder in the master data library as soon as a new process tag type is generated from a CFC chart. The process tag types are managed in the master data library. The following functions are available:

Overview of the Functions Below you will find an overview of the major functions available for working with process tags/process tags types. These functions are available in the SIMATIC Manager using the menu command Options > Process Tags (when a chart or a process tag type is selected). Functions

Purpose

Create/Change Process Tag Type

•

Synchronize

Create process tag types from CFC charts as follows: -

By selecting I/Os of blocks and charts that will be given descriptions for parameters and signals.

-

By selecting blocks with messages that you want to assign message texts to.

•

By modifying an existing process tag type

•

Check existing process tags for discrepancies compared with the process tag type and synchronize any differences.

When a process tag type is modified, the process tags existing in the project are automatically synchronized. If actions were taken that caused inconsistencies between the process tag type and process tags (for example when some process tags of the project were not available at the time of the automatic synchronization), synchronization can also be started explicitly.

Assign/create import file

To generate process tags, an import file must be assigned to the relevant process tag type. With the "assign import file to a process tag type" assistant, you can do the following: •

Assign an existing import file

•

Open and check an import file that has already been assigned

•

Create and assign a new import file


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Configuring PCS 7

Functions

Purpose

Import

Import of the data of the process tag types The process tag type is copied from the master data library to the specified target projects as a process tag. The data is then imported. The same number of process tags are generated as there are entries in the import file. As a result of the import, a process tag of this process tag type is created in the target project for every row of the import file according to the specified hierarchy path.

Export

Export of the data of the process tags for a process tag type The following options are available: •

Select a process tag to export this alone.

•

You can select a parent hierarchy folder or the project node to select and export all underlying process tags.

As the result, a row is created in the relevant export file for each process tag of a process tag type found.

Further information

7-54

•

Section "How to Create a Process Tag Type from a CFC Chart"

•

Section "How to Modify a Process Tag Type"

•

Section "How to Synchronize Process Tags with the Process Tag Type"

•

Section "What Happens during Import?"

•

Section "What Happens during Export?"

•



Configuring PCS 7

7.6.9

Working with Models Models are created from the hierarchy folders in the master data library that contain the required CFC charts. The new models are stored and managed in the master data library. The following functions are available:

Overview of the Functions Below you will find an overview of the major functions available for working with models and replicas. These functions are available in the SIMATIC Manager with the menu command Options > Models. Functions

Purpose

Creating/Modifying Models

You can create models with the Import/Export Assistant as follows: •

By selecting I/Os of blocks and charts that will be given descriptions for parameters and signals and that will then be imported.

•

By selecting blocks with messages that you assign message texts to and then import.

•

By assigning the model data to an import file.

You obtain a model in which the selected I/Os and messages are each assigned to a column of an import file. If you modify an existing model, so that the column structure or the column titles change, the assignment to the structure of the current IEA file is no longer correct. In this case, you must select a suitable IEA file or adapt the file. If replicas of the modified model exist, you can also make the modifications in the replicas. Import

Import of the data of the models The model is copied from the master data library to the specified target projects as a replica. The data is then imported. The same number of replicas are generated as there are entries in the import file. As a result of the import, a replica of this model is created in the destination project for each row of the import file according to the information in the hierarchy path.

Export

Export of the data of the replicas for a model The following options are available: •

Select a model to export this alone.

•

You can select a parent hierarchy folder or the project node to select and export all underlying replicas.

As the result, a row is created in the relevant export file for each replica of a model found.



•

Section "What Happens during Import?"

•

Section "What Happens during Export?"

•



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Configuring PCS 7

7.6.10

How to Test Library Objects Objects you stored in the master data library were created with the corresponding tools (for example CFC Editor). These tools provide functions for compiling, downloading, and testing. Unsuccessful completion of the test, the objects are then stored in the master data library. Process tags and models are then declared as a process tag type or model following the test and stored automatically in the master data library.

Requirement Since the test always takes place on the AS, it must be possible to reach the AS from the engineering station. If the modes contain pictures, the pictures are tested on the OS.


7.6.11

In the online help of the relevant tools (for example CFC Editor)

How to Document Library Objects Objects you stored in the master data library were created with the corresponding tools (for example CFC Editor or LAD/STL/FBD editor). These tools have their own print functions with which you can document these objects (printouts).


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Online help of the relevant tools (for example CFC Editor)


Configuring PCS 7

7.7


Further Reading If you now want to edit the multiproject (including the master data library) prepared as described above on distributed stations with several editors at the same time, remember the following. If you do not want to distribute the multiproject for editing, you can skip the following sections and continue at the section "Configuring the Hardware".

Introduction It is possible to edit the projects of the multiproject on distributed stations allowing several editors to work on smaller handier projects at the same time. The distributed editing of projects and the merging on a central engineering station server for cross-project functions is the most efficient method compared with other procedures. Despite distributing the projects on several engineering stations, is possible to read other projects at any time. This can, for example, be used to copy functions and to access libraries.

Note You should always work with a multiproject even if it only contains one project. In this case, you do not need to distribute it for editing.

Requirements If you want to distribute projects on different computers within a network, the following requirements must always be met: •

The projects are located in folders that are shared for read and write access. This means the following: -

The shares for drives on which the multiproject or the projects are located must be created before setting up the multiproject.

-

The share names must be unique within the network.

-

The shares and share names of the resources (folders) involved in the multiproject must not be changed. Reason: When a project is inserted into the multiproject, PCS 7 generates a reference to the location of this project. The reference depends on the share and share names of the resources involved.

-

A project can only be found using the share name under which it was included in the multiproject.

-

Entire drives must not be shared. Folders must only be shared in 1 hierarchy level.


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Configuring PCS 7

•

PCS 7 must be installed on the computers on which the folders with the projects are located since PCS 7 provides the necessary database server functions for access to the projects.

•

If you include projects for which you have configured messages in a multiproject, make sure that the message number ranges of the CPUs do not overlap if you are using project-oriented assignment of message numbers. If you use CPU-oriented message member assignment, such overlapping does not occur.

If you want to use cross-project functions in such a constellation, you must also make sure that the following conditions are met: •

All the computers on which the projects and the multiproject are located can be reached over the network during the entire editing time.

•

While class-project functions are executing, no editing must take place.

We recommend that you merge all the projects onto one programming device/PC and run the cross-project functions locally.

Recommendations •

One engineer manages the multiproject centrally. This engineer creates the structures for the projects. This person also distributes the projects for distributed editing and returns them again to the multiproject (including synchronization of the cross-project data and execution of cross-project functions). The following activities should be performed on the central engineering station: -

Moving, copying, and deleting the projects of the multiproject

-

Moving projects out of the multiproject for distributed editing

-

Merging of the projects into the multiproject following distributed editing

•

It is not possible to make a general recommendation about how many stations a project should have. The projects on a distributed engineering station should each have only one 1 AS or 1 OS.

•

Only move the PCS 7 objects to a distributed engineering station that are actually necessary for editing. This means that all other objects of the multiproject are available for editing on other distributed engineering stations.

•

Keep in mind the number of available editors when distributing the projects.

Note If there is only one OS in the project, this must always be recompiled on the central engineering station. This ensures the correct structure of the cross-project connections to the automation systems.


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Section "Conditions for Further Editing in the Multiproject".


Configuring PCS 7

7.7.1

Conditions for Further Editing in the Multiproject

Please note the following conditions •

To work in the network, Windows 2003 Server or Windows 2000 Server must be installed on the central engineering station. The distributed engineering stations can use the Windows XP / 2003 Server / 2000 Professional operating system.

•

The storage location of projects within the network is specified in UNC notation: in other words \\computername\sharename\storagepath and not with drive letters (for example d:\Projects\Storagepath...).

•

The folder with the project must already be shared with other editors on the relevant PC. The share name must be unique.

•

The storage paths must not be modified later (after storing projects)!

•

All the projects and the S7 programs must have unique names within the multiproject.

•

After distributed editing of projects containing an OS, each OS must be recompiled on the central engineering station. To speed up compilation, unmodified objects can be deactivated in the "Compile and Download Objects" dialog box (menu command in the SIMATIC Manager: PLC > Compile and Download Objects).

•

A mixture of the previous project-oriented and the new CPU-oriented message number concept is not possible.


Section Requirements for Compiling and Downloading"

•

Online help on STEP 7


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Configuring PCS 7

7.7.2

Overview of the Steps

Prior to Distribution There is no particular point in time at which the projects should be moved to the distributed engineering stations. The columns "Must/Can" in the following table indicate which steps must be performed and which can be performed prior to distribution. The description of the steps in configuration assumes that this procedure is used. Activity

Refer to the section

must

can

X

Create the multiproject Creating the PCS 7 Project with (all) projects Configuring the AS and PC stations (structure) Creating the Plant Hierarchy

X X X

Creating the master data library

X

Create the basic Configuring the Hardware configuration for all the Creating network connections projects of the Creating the SIMATIC Connections multiproject

X X

Distribution -> Distributed Editing -> Merging The following list of steps also reflects the recommended order in which the activities should be performed. Activity


Where?

Move projects to How to Move Projects to Distributed Engineering Central Engineering station: distributed engineering Stations SIMATIC Manager stations for distributed editing Edit projects on distributed stations

How to Continue Editing Projects on Distributed Stations

Merge projects on the How to Move Project Edited on Distributed central engineering Stations to the Central Engineering Station station

Distributed engineering station Central Engineering station: SIMATIC Manager

Prior to Distribution or after Merging Must/Can indicates whether the activity must or can be performed after distributing. Activity


must

Configure crossproject functions

How to Merge Subnets from Different Projects into a Multiproject

X

Compile/download configuration data

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Cross-Project Connections in a Multiproject

X

Compiling and downloading

X

can


Configuring PCS 7

7.7.3

How to Store the Projects of the Multiproject

Requirement •

The multiproject is located on a central engineering station to which all other engineering stations have access.

•

The multiproject contains the libraries (in particular the master data library with the models and process tag types).

Storage of the Projects Projects to be inserted in the multiproject •

can be created on the central engineering station and then moved for editing: Refer to the section "How to Move Projects to Distributed Engineering Stations"

•

can be created on the distributed engineering stations (including hardware configuration) and inserted in the multiproject later Refer to the section "How to Move Project Edited on Distributed Stations to the Central Engineering Station"

Procedure 1. Specify the storage location for your projects. Create the required folder structure with the Windows Explorer. Refer to the sections "Distributing the Multiproject for Distributed Editing (Multiproject Engineering)" and "Conditions for Further Editing in the Multiproject". 2. In the SIMATIC Manager, select the menu command Options > Customize and set the storage location of the projects, multiprojects, and libraries. The DOS naming convention must be adhered to.




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Configuring PCS 7

7.7.4

How to Move Projects to Distributed Engineering Stations

Requirements •

The project is physically located on the central engineering station and is included in the multiproject.

•

The distributed engineering station is obtainable over the network.

Procedure 1. Select the project in the multiproject that you want to move to the distributed engineering station in the component view of the SIMATIC Manager. 2. Select the menu command File > Save As ... Make the following settings: -

Enable the "Insert in multiproject" option.

-

Select "Current multiproject" in the drop-down list box.

-

Enable the "Replace current project" option.

-

Enter the required storage location on the distributed engineering station (in UNC notation).

3. Confirm the dialog box with OK. Result: An identical copy of the project of the central engineering station is created on the distributed engineering station. The copy is inserted automatically in the multiproject and replaces the original project. The existing original project is removed from the multiproject, but remains on the central engineering station. It can remain there as a backup or can be deleted.

Note Before the copied project can be copied back to its old location (same folder name), this backup must be deleted.

Note In the same way, you can also save the project on a data medium and pass this on for distributed editing or archive the project with the "Archive" function and pass on the archive on a data medium.

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Configuring PCS 7

Note You can also move a project to a distributed engineering station as follows: 1. Select the menu command File > Multiproject > Remove for editing... Result: The "Select directory" dialog opens. 2. Select a directory and confirm the dialog with "OK". 3. Result: The project is marked as "removed for editing" and grayed out. When a project has been moved, in contrast to the procedure described above, you cannot use the "Archive", "Save As", and "Compile OS" functions.


Section "How to Move Project Edited on Distributed Stations to the Central Engineering Station"


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Configuring PCS 7

7.7.5

How to Continue Editing Projects on Distributed Stations

Requirement All the PCS 7 software components required for editing are installed on the distributed engineering station.

Distributed Editing of the Project •

All functions that are not cross-project functions are possible without restrictions.

•

No special actions are required for:

•

-

pure editing work,

-

compilation of an AS or

-

downloading an AS over a preselected module (not with the option "PC internal (local)")

Special actions are required for: -

downloading an AS directly via the interface module of the distributed engineering station

-

OS in process mode (OS simulation)

Procedure for downloading an AS from a distributed engineering station If you want to download an AS (for example for testing), follow the steps below in the project: 1. Insert a local SIMATIC PC station with a suitable CP module. 2. Configure S7 connections (configured connection) from this OS to the AS. If you want to test an OS on an engineering station in process mode (contextsensitive menu Start OS Simulation), the two steps above are necessary regardless of the setting of the PG/PC interface and the following step is also necessary: 3. Adapt the computer name in the WinCC Explorer. Note Before the project can be copied back to the central engineering station, the modifications made in this section must be reversed.


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Section "How to Move Projects Edited on Distributed Stations to the Central Engineering Station"


Configuring PCS 7

7.8

Configuring the Hardware Configuring the hardware involves the following topics:

7.8.1

•

Defining a Project-specific Catalog Profile

•

Exporting/Importing the Hardware Configuration

•

Configuring the SIMATIC 400 Station (CPU, CPs, Central I/O)

•

Setting Time-of-day Synchronization

•

Configuring the Distributed I/O (Standard)

•

Configuring the Distributed I/O for Configuration Changes RUN

•

10 ms Time Stamps

•

Acknowledgment-triggered Reporting (ATR)

•

Downloading the Configuration to the CPU

Overview of Hardware Configuration

Introduction You map the structure of your plant at the automation level (AS, OS, BATCH) in the SIMATIC Manager and in HW Config. You create your SIMATIC 400 station (when necessary distributed in various projects) and configure the required I/O and communication hardware. Depending on your plans structure, you can configure various project types on the PCS 7 OS. This means that you can configure plants with one or more OS servers or clients. Generally, you work with a multiple workstation project; in other words you will create several OS servers and OS clients. You also have the opportunity of creating redundancy at each level (for example redundant OS, use of H stations, etc).

Overview of the Individual Steps in Hardware Configuration This overview shows you the recommended order of individual configuration steps and tells you the program section in which the configuration work is done: Tool

Purpose

Commissioning Wizard

Configuring the PC station

SIMATIC Manager

Insert all the SIMATIC 400 stations in the project. You insert the engineering station, the operator stations, and the BATCH stations in the project as PC stations.

HW Config

Insert hardware components in the SIMATIC 400 stations. You insert hardware components and a WinCC application that belong to the particular PCS 7 OS or BATCH station.


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Further Reading In multiproject engineering, the SIMATIC 400 stations and the PC stations for the engineering station, operator stations, and BATCH stations may already have been created in your project. The following section describes how you continue by adding the hardware components to the SIMATIC 400 stations. If this is not the case, work through the following sections first before you continue here: •

Inserting and Configuring the Operator Stations

•

Inserting and Configuring the BATCH Stations

•

Inserting and Configuring the Engineering Station


7.8.2

You are also find information on hardware configuration of the OS stations in the Configuration Manual Process Control System PCS 7; Operator Station.

Defining a Project-specific Catalog Profile

Why Does it Make Sense to Use a Project-Specific Catalog Profile? In the much the same way as you group the programs, blocks etc. in the master data library for a specific project, you can also create a project-specific catalog profile so that everyone involved in configuration uses the same hardware. You can make this available centrally (access over network) or can distribute it along with the other data.

How to Set up a Project-Specific Catalog Profile 1. Select the menu command options > Edit Catalog Profiles in HW Config. Result: Two catalog profiles are opened: The "Standard" profile and an "empty" profile that does not yet contain any components. 2. Drag the folders and modules you require from the standard profile window to the "empty" profile window. You can also adapt the structure to your needs with the menu command Insert > Folder. 3. Save the new catalog profile with the menu command Profile > Save As. Result: The new catalog profile is created. This then appears in the "Profile" list box of the "Hardware Catalog" window where it can be selected. Note DP slaves installed later (using GSD files) are only contained in the "Standard" profile ("Additional Field Devices" folder) and are not automatically included in user-created profiles!

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Configuring PCS 7

How to Export a Project-Specific Catalog Profile To make a catalog profile available at another workstation, follow the steps outlined below: 1. Select the menu command options > Edit Catalog Profiles in HW Config. 2. Select the menu command Profile > Export. 3. Select the catalog profile you want to export and set the destination path for the export. Result: The catalog profile is copied to the selected destination (.DAT). You can also save the file on a data medium and transport it to the destination in this way.

How to Import a Project-Specific Catalog Profile 1. On the workstation on which you want to use the catalog profile, select the menu command Options > Edit Catalog Profiles in HW Config. 2. Select the menu command Profile > Import. 3. Set the path to the source and select the catalog profile you want to import. Result: The catalog profile is imported and appears in the "Profile" list box of the hardware catalog. Note You can delete catalog profiles that you do not require with the menu command Profile > Delete. Existing catalog profiles with the same name: If a catalog profile of the same name already exists, a screen prompt is displayed.


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7.8.3

Exporting/Importing the Hardware Configuration

Introduction You can work on station configurations not only within the entire project (for example saving or opening), but also independent of the project by exporting it to a text file (ASCII file, CFG file), editing it, and then importing it again. The symbolic names of the inputs and outputs can also be exported and imported.

Applications •

Data import from hardware planning tools

•

Station configuration using electronic media (for example E-mail)

•

An export file can be printed out with word processing systems or can be edited for documentation purposes.


Online help on HW Config

•

Section "Import/Export of the Hardware Configuration"

7.8.4

Configuring the SIMATIC Station (CPU, CPs, Central I/Os)

7.8.4.1

Creating the Concept for Address Assignment Before you can start with the configuration of the hardware, first create a concept for assigning addresses. The networks are independent of each other and have their own range of numbers for addresses. When assigning addresses a distinction must be made between •

Node addresses

•

Input/output addresses (I/O addresses).

Node Addresses Node addresses are addresses of programmable modules (PROFIBUS, Industrial Ethernet addresses). They are required to address the various nodes of a subnet, for example to download a user program over the plant bus (Industrial Ethernet) to the CPU. You will find more information on assigning a node addresses on a subnet in the section on networking stations.

Input/output addresses (I/O addresses) Input/output addresses (I/O addresses) are required to read inputs or to set outputs in the user program. Principle: The input and output addresses are assigned by PCS 7 when you place modules in the SIMATIC 400 station in HW Config. Each module therefore has its base address (address of the first channel); the addresses of the other channels are relative to this base address. To make handling simpler, the addresses can be assigned symbolic names (symbol table).

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Configuring PCS 7

Possible Plant Configuration Below, you can see an overview of a possible plant configuration with node addresses and I/Os inserted. ES / OS

AS 4xx-2

2

MPI

Industrial Ethernet 1

PROFIBUS DP (1) ET 200M

ET 200S

CP 443-5 ext. CP 443-1 CPU 416-2 ET 200S

ET 200iS

0

ET 200M

1

PROFIBUS DP (2)

1) Industrial Ethernet: Max. 100 Mbps; max. 1024 nodes (BCE: max. 100 Mbps; max. 8 nodes) 2) MPI: MPI is required in PCS 7 only for test and diagnostic purposes DP master system: Max. 12 Mbps; max. 126 nodes; profile: PROFIBUS DP

Note For the 10 ms time stamp, PROFIBUS DP must be connected to the SIMATIC 400 station via a CP 443-5 Extended or via the internal DP interface.


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Configuring PCS 7

7.8.4.2

Overview of the Steps in Configuration The following table provides you with an overview of the various configuration steps and the corresponding tools.

What?

Where?

Creating a SIMATIC 400 Station

SIMATIC Manager

Inserting Modules in a SIMATIC 400 Station

HW Config

Inserting a Communications Processor (CP)

HW Config

Setting the CPU Properties

HW Config

Setting the Process Image

HW Config

Configuring Fault-tolerant Systems (H Systems)

HW Config

See Manual Process Control System PCS 7; Fault-tolerant Process Control Systems. Configuring Fail-safe Systems (F Systems)

HW Config

See Manual S7- 400F/S7-400FH Programmable Controllers, Fail-safe Systems. Setting Time-of-Day Synchronization

HW Config

Configuring the Distributed I/O for Standard

HW Config

Configuring the Distributed I/O for Configuration Changes in Run (CiR)

HW Config

Assigning Symbols for Input and Output Addresses

HW Config (Symbol Table)

Configuring PA Devices

PDM

Configuring the Diagnostic Repeater

SIMATIC Manager + HW Config

Configuring Intelligent Field Devices

PDM

Configuring HART Devices

PDM

Configuring Y-Links and Y-Adapters

HW Config

Importing/Exporting the Hardware Configuration

HW Config

Configuring 10 ms Time Stamps

HW Config

Activating Acknowledgment-triggered Reporting

HW Config


HW Config

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Configuring PCS 7

Recommended Order of the Activities To configure and assign parameters for the setup, it is advisable to follow the order shown below: Order of the Activities Create a station How to Create a SIMATIC Station AStarting the Application for Configuring the Hardware Arrange the central rack Arrange modules in the rack How to Insert Modules in a SIMATIC Station Insert and configure the distributed I/O Assign the symbols Specify the properties of modules/interfaces Setting the CPU Properties Setting the Process Image Save the configuration and check consistency Download the configuration to the target system How to Download the Configuration to the CPU Upload from the target system to the PG (upload, for example for service purposes).




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7.8.4.3

How to Create a SIMATIC 400 Station In multiproject engineering, automation systems may have already been created in your project. If you need to insert further automation systems, follow the steps outlined below.

SIMATIC 400 Station If you want to create an automation system, you require a SIMATIC 400 station with a power supply, a CPU and a communications processor. You then configure the central and distributed I/O and any further modules you require. The following sections explain how to insert the individual components in the project and set their properties.

Procedure Before you can start to configure and assign parameters, you require a SIMATIC 400 station in your project that you insert at the level directly below the project, where you can then set its properties. 1. Select the project into which you want to insert the automation system in the component view of the SIMATIC Manager. 2. Select the menu command Insert > Station > SIMATIC 400 Station. Result: A new SIMATIC 400 station is inserted in the selected project. 3. Follow the same procedure if you want to install further automation systems. You can adapt the names by selecting the SIMATIC 400 station, right-clicking and selecting the Object Properties menu command.


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Section "How to Insert Modules in a SIMATIC 400 Station"


Configuring PCS 7

7.8.4.4

How to Insert Modules in a SIMATIC 400 Station

Inserting Hardware Components After you have created the SIMATIC 400 station, add the hardware components to the station from the hardware catalog.

Hardware Catalog The hardware catalog is normally displayed when you open HW Config. If this is not the case, open it in HW Config with the menu command View > Catalog. In the lower third of the catalog you can see the order number and a brief description of the currently selected component. Compare the order number with the actual physical component. This allows you to check that you have selected the correct component. Note In the hardware catalog, you can select from various profiles (Standard, PCS 7 etc.). All the profiles are based on the "Standard" profile and represent a subset of this profile. The "PCS 7_V61" profile is displayed as default when you first start the hardware configuration. In this profile, you will see the current versions of the modules and devices released for PCS 7. If you cannot find the module you require in this profile (for example an older CPU that is nevertheless released for PCS 7), select the "Standard" profile where you will find the required module. You will find a list of released modules in: Start > SIMATIC > Documentation > English > PCS 7 - Released Modules. You can create your own personal profile with the modules and devices you commonly use: see Defining a Project-Specific Catalog Profile.


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Configuring PCS 7

Procedure 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on "Hardware" (right-hand pane). Result: HW Config and the hardware catalog are opened.

2. Select SIMATIC 400 > Rack 400 in the hardware catalog and drag and insert the required rack. Make sure that the arrangement selected here matches the arrangement of the physical hardware. 3. In the SIMATIC 400 > PS-400 hardware catalog, select the required power supply and insert it by dragging with the mouse. 4. In the SIMATIC 400 > CPU-400 hardware catalog, select the required CPU and insert it by dragging with the mouse. 5. Confirm the open dialog box "Properties - PROFIBUS Interface DP" with "OK". 6. Continue in the same way to add any other components you require, for example: -

SM 400: Digital and analog signal modules (central I/O modules)

-

CP 400: communication modules: refer to the section "How to Insert a Communications Processor"

7. Select the menu command Station > Save in HW Config.

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Configuring PCS 7

Properties of the Integrated DP Interfaces The properties of the integrated DP interfaces of the CPU still need to be set. Follow the steps below: 1. Select the DP interface of the CPU. 2. Select the menu command Edit > Object Properties. 3. Click the "Properties" button of the interface in the "General" tab. 4. Now network the DP interface with a PROFIBUS network by selecting the PROFIBUS network and assigning the required address. If no PROFIBUS network has been created yet, you can create a new network with the "New" button. 5. Close the properties dialog of the DP interface in the CPU by clicking "OK" twice.

Note If you want to connect PROFIBUS DP to a CP 443-5 Ext., you do not need to set the properties. Note that the integrated DP interface does not have the same range of functions as the CP 443-5 Ext. (for example number of PROFIBUS nodes).

Inserting and Setting Further IF Interface Modules 1. Select a module slot (IF1/IF2) of the CPU. 2. Select the menu command Insert > Insert Object. 3. Select the following in the next dialogs: -

CPU

-

Firmware version

-

Interface module IF...

4. Click the "Properties" button of the interface in the "General" tab. 5. Now network the DP interface with a PROFIBUS network by selecting the PROFIBUS network and assigning the required address. If no PROFIBUS network has been created yet, you can create a new network with the "New" button. 6. Close the properties dialog of the DP interface in the CPU by clicking "OK" twice.


Section "How to Configure the Distributed I/O"

•

Section "How to Insert a Communications Processor"


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Configuring PCS 7

7.8.4.5

How to Insert a Communications Processor

CP 443-1 for Connecting AS, OS, and ES over Industrial Ethernet You require the CP 443-1 communications processor for the connection between automation systems, engineering station or OS over the plant bus (Industrial Ethernet).

Procedure 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 2. Select SIMATIC 400 > CP-400 > Industrial Ethernet ... in the hardware catalog and drag and insert the required CP. Make sure that the arrangement selected here matches the arrangement of the physical hardware. 3. Result: Once you have inserted the CP, the "Properties – Ethernet Interface CP 443-1" dialog box opens. Set the properties as follows: 4. Activate the "Set MAC address" option and assign the required MAC addresses (for example 08.00.06.01.00.12) or accept the default addresses. Make sure that the address is unique on the bus. 5. Enter the IP address and subnet mask or deactivate the "IP protocol is being used" option. 6. Click the "New" button and replace the name "Ethernet(1)" with a name that will later be more meaningful. 7. Close the properties dialog of the Ethernet interface by clicking "OK" twice.

CP 443-5 Extended for Interfacing with the Distributed I/O In addition to (or as an alternative to) the DP interfaces integrated in the CPU, you can use the CP 443-5 Extended to interface with your distributed I/O. With each further CP 443-5 Ext., you can insert further DP chains and theoretically address a further 126 DP slaves. Note Over the integrated DP interface or the CP 443-5 Ext., you use the 10 ms time stamps in conjunction with the IM 153-2 or routing (parameter assignment for the DP/PA slaves over the ES and the plant bus).

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Configuring PCS 7

Procedure 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 2. Select SIMATIC 400 > CP-400 > PROFIBUS ... in the hardware catalog and drag and insert the required CP in the SIMATIC 400 station. 3. Result: Once you have inserted the CP, the "Properties – PROFIBUS Interface CP 443-5 EXT" dialog box opens. Set the properties as follows: 4. Assign the required PROFIBUS address for the DP master ("Parameters" tab; "Address:" combo box).

Note The addresses 1 and 126 are default addresses for PROFIBUS slaves. Do not use these in the project.

5. Create a new network with the New" button and replace "PROFIBUS(1)" with a name that will later be more meaningful. 6. Change to the "Network Settings" tab and set the transmission rate "1.5 Mbps" and the "DP" profile. 7. Complete the dialog by clicking "OK" twice.


7.8.4.6


How to Assign Symbols to Input and Output Addresses

Introduction You can assign symbols to the addresses of inputs and outputs when configuring modules without needing to start the symbol table in the SIMATIC Manager (symbols editor). Refer to the section "Free Assignment between Hardware and Software"

Note The assigned symbols are not downloaded when you download to the station (menu command: PLC > Download to Module). Effect: If you upload a station configuration back to the PG (menu command: PLC > Upload to PG), no symbols are displayed.


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Configuring PCS 7

Procedure 1. Select the digital/analog module whose addresses you want to assign symbols to. 2. Select the menu command Edit > Symbols. Result: The symbol table is opened. 3. Enter the required symbols for the addresses listed. 4. Confirm your entries with "OK".

Note If you click on the "Add Symbol" button in the dialog, the name of the address is entered as a symbol.


7.8.4.7


Setting the CPU Properties The CPU properties are set automatically in the PCS 7 environment and are suitable for most applications, see "Default Parameter Values for the CPUs". The following table contains the most important settings of the CP properties for PCS 7. What?

Where?

Setting the startup mode of the CPU (see below)

HW Config (Object Properties)

Setting OB85 (I/O access error) (see below)


Setting the Process Image


Adapting the local data (see below)


Setting the Startup of the CPU The S7-400 CPU is capable of the following types of startup:

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•

Warm restart

•

Cold restart

•

Hot Restart


Configuring PCS 7

Warm restart In a warm restart, execution of the program restarts at the beginning of the program with a "basic setting" of the system data and user address areas. Nonretentive timers, counters, and memory bits are reset. All data blocks and their contents are retained. When you restart (warm restart) an S7-400 (for example by changing the mode selector from STOP to RUN or by turning the power ON) organization block OB100 is processed before cyclic program execution begins (OB1). As default, all the PCS 7 blocks that have a special startup behavior are installed in OB100. Warm restart = default setting for PCS 7 and normal applications

Cold Restart A cold restart is used only in exceptional situations when one of the following functions is required: •

During a cold restart, the process image input table is read and the user program is executed starting at the first instruction in OB1.

•

Data blocks created by SFCs in the work memory are deleted, the other data blocks have the default values from the load memory.

•

The process image and all timers, counters, and memory bits are reset regardless of whether they were set as retentive.

Hot Restart In a hot restart, program execution is resumed at the pointer to which it was interrupted (timers, counters, and memory bits are not reset).

Note When using S7-400 CPUs in the PCS 7 process control system, the hot restart is not permitted.

How to Set the Type of Startup 1. Select the CPU in HW Config. 2. Select Edit > Object Properties. Result: The "Properties - CPU ..." dialog box is displayed. 3. Change to the "Startup" tab. Recommendation: Accept the default settings. 4. Set the required startup type for "Startup after Power On". 5. Confirm the dialog box with OK.


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Setting of OB85 (I/O access error) The operating system of the CPU calls OB85 when an error occurs during updating of the process image (module does not exist or defective) if the OB call is not suppressed during configuration. If you want to activate the OB85 call for I/O access errors, we recommend that you select the option "Only for incoming and outgoing errors" so that the cycle time of the CPU is not increased due to repeated OB85 calls as can be the case with the option "At each individual access". Option "Only for incoming and outgoing errors" = default setting for PCS 7 Apart from the configured reaction "Only for incoming and outgoing errors", the address space of a module also influences how often OB85 starts: •

For a module with an address space up to a double word, OB85 starts once, for example, for a digital module with up to 32 inputs or outputs, or for an analog module with two channels.

•

For modules with a larger address space, OB85 starts as often as the number of double word commands required to access it, for example twice for a fourchannel analog module.

How to Configure the Reaction to I/O Access Errors 1. Select the CPU in HW Config. 2. Select Edit > Object Properties. Result: The "Properties - CPU ..." dialog box is displayed. 3. Change to the "Cycle/Clock Memory" tab. 4. In the "OB85 - Call Up at I/O Access Error" combo box, select the setting "Only for incoming and outgoing errors". 5. Confirm the dialog box with OK.

Adapting the Local Data The local data stack contains: •

The temporary variables of the local data of blocks

•

The start information on the organization blocks

•

Information on the transfer of parameters

•

Interim results of the logic in Ladder programs

When you first create organization blocks, you can declare temporary variables (TEMP) that are available on the while the block executes and are then overwritten again. Before the first access, the local data must be initialized. Each organization block also requires 20 bytes of local data for its startup information. The CPU has limited memory for the temporary variables (local data) of blocks currently being executed. The size of this local memory, the local data stack, depends on the particular CPU. The local data stack is equally divided among the priority classes (default). This means that each priority class has its own local data area. This ensures that high-priority classes and their OBs have space for their local data.

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Configuring PCS 7

Assigning local data to priority classes: Some priority classes require more or less memory in the local data stack than others. With suitable parameter settings for the S7-400-CPUs, it is possible to set local data areas of different sizes for the various priority classes. You can deselect priority classes that are not required. This extends the memory area of the S7-400-CPUs available for other priority classes. Deselected OBs are ignored during program execution and therefore save computing time. How to calculate the local data is described in an FAQ on the Web.

How to Adapt the Local Data The local data requirement is assigned by means of the priority classes (see also: online help for the dialog box). To adapt the local data, follow the steps outlined below: 1. Select the CPU in HW Config 2. Select Edit > Object Properties. Result: The "Properties - CPU ..." dialog box is displayed. 3. Select the "Memory" tab and adapt the local data where necessary. 4. Confirm the dialog box with OK.

Note Make sure that you also take into account the reserves configured for Configuration in RUN (CiR).

Setting the Process Image Refer to the section "Setting the Process Image"



•

Section "Default Parameter Values for the CPUs"


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Configuring PCS 7

7.8.4.8

Setting the Process Image The driver blocks for the modules in the PCS 7 library do not access the I/O directly to query the current signal states, but rather access a memory area in the system memory of the CPU and the distributed I/O: the process input image (PII) and output image (PIQ). This process image includes both the digital inputs and outputs as well as the analog inputs and outputs. The process image begins at I/O address 0 and ends at the upper limit you select in "Size of the Process Image" (see below).

Updating the Process Image The process image is updated cyclically by the operating system automatically. Processing of the Process Image Tables for CPUs Supplied after 10/98 Start of the current cyclic processing

Start of the next cyclic processing

Å Current cycle time of OB1 Æ Output of the PIQ

Update of the PII

Processing of Output of the PIQ OB1, or the cyclic interrupts

Update of the PII

Processing of OB1, or the cyclic interrupts etc. Æ

Advantages of the Process Image Compared with direct access to the input/output modules, the main advantage of accessing the process image is that the CPU has a consistent image of the process signals for the duration of one program cycle. If a signal state on an input module changes while the program is being executed, the signal state in the process image is retained until the process image is updated again in the next cycle.

Size of the Process Image For PCS 7, the size of the process image must be set equal to or greater than the number of inputs and outputs used. As default, the first analog output module has the base address 512 in the process image. Recommendation: Set the size of the process image of the inputs and outputs to a higher value. This means that you have space available for further analog modules.

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Configuring PCS 7

Procedure To set the process image size, follow the steps outlined below: 1. Open the hardware configuration. 2. Select the CPU. 3. Select Edit > Object Properties. Result: The "Properties - CPU ..." dialog box is displayed. 4. Select the "Cycle/Clock Memory" tab and set the size of the process image. 5. Confirm the dialog box with OK.

Note The default size of the process image is CPU-specific. See also Section "Default Parameter Values for the CPUs"


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Configuring PCS 7

Process Image Partitions Apart from the process image (PII and PIQ), you can also specify up to 15 process image partitions for an S7-400 CPU (CPU-specific, no. 1 up to max. no. 15). This allows you to update subareas of the process image when necessary, independently of the cyclic updating of the process image. Note • Each input/output address must be assigned to a process image partitions. • Each input/output address that you assign to a process image partition no longer belongs to the OB1 process input/output image. • Input/output addresses can only be assigned once throughout the OB 1 process image and all process image partitions. • Make sure that signals and signal processing (module and corresponding driver) are executed in the same OB. You make the assignment to the process images during hardware configuration of the I/O modules (see Figure below).

Procedure To set the process image partitions, follow the steps outlined below: 1. In the hardware configuration, select the I/O module you want to assign to a process image partition. 2. Select the menu command Edit > Object Properties > Addresses. 3. Change to the "Addresses" tab and make the required assignment to a process image partition (PIPx; x=1 through 15). 4. Confirm the dialog box with OK.

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Configuring PCS 7

System Update of Process Image Partitions If you link the updating of a process image partition to an OB, the partition is updated automatically by the operating system when this OB is called. This strategy is similar to the updating of the (total) process image that is updated cyclically or after OB1 has been executed. During operation, the assigned process image partition is then updated automatically as follows: •

The process image inputs partition before the OB is executed

•

The process image outputs partition after the OB is executed

Processing a Process Image Partition when Linked to an OB Start of the current cyclic interrupt (OB) processing

Start of the next cyclic interrupt (OB) processing

Å Current cycle time of the OB Æ Updating of the PII partition

Execution of the Output of the PIQ partition cyclic interrupt

Updating of the PII partition

Execution of the Output of the cyclic interrupt PIQ partition etc. Æ

Assignment of the Process Image Partition to the OB You can specify which process image partition is assigned to which OB when you assign parameters to the CPU and the priority of the OB (see following Figure).


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Procedure To assign the process image partitions to OBs, follow the steps outlined below: 1. Select the CPU in the hardware configuration CPU. 2. Select the menu command Edit > Object Properties. 3. Change to the "Cyclic Interrupts" tab and make the settings you require. 4. Confirm the dialog box with OK.


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Configuring PCS 7

7.8.4.9

Configuring Fault-tolerant Systems (H Systems)

SIMATIC H Station For a fault-tolerant automation system, a SIMATIC H station is inserted in the project in the SIMATIC Manager as a separate station type. Only this station type allows the configuration of two central units each with an H-CPU providing a redundant structure for the process control system.

Where is it Described? For a step-by-step description of configuring fault-tolerant process control systems, refer to the manual Process Control System PCS 7; Fault-tolerant Process Control Systems.

7.8.4.10

Configuring Fail-safe Systems (F Systems)

SIMATIC F/FH Station? For a fail-safe and fault-tolerant automation system (FH system), a SIMATIC H station is inserted in the project in SIMATIC Manager as a separate station type. For a fail-safe automation system (F system), a SIMATIC H station is inserted in the project in the SIMATIC Manager.

Where is it Described?

7.8.4.11

•

Manual Automation Systems S7-400F/S7-400FH, Fail-safe Systems.

•

For a step-by-step description of configuring fault-tolerant process control systems, refer to the manual Process Control System PCS 7; Fault-tolerant Process Control Systems.

Default Parameter Values for the CPUs When working with new projects created with PCS 7 V6.1, PCS 7 sets default values for the automation systems. The table in section "Default Parameter Values for the CPUs" shows the default parameters for typical CPUs in terms of performance of the CPUs for PCS 7 projects. These values are set as defaults in the configuration of the CPU with PCS 7 software. They suffice for typical applications but can be changed within limits as required for configuration. In the tabs of the properties dialog of the CPU (menu command Edit > Object Properties), you can adapt these parameters. Note After adapting the parameters, a download with the CPU in STOP is necessary.


Section "Default Parameter Values for the CPUs"


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Configuring PCS 7

7.8.5

Setting the Time-of-Day Sychronization

7.8.5.1

Principle of Time-of-Day Synchronization

Synchronizing the Time of Day throughout the System The evaluation of process data is only possible when all components of the process control system work with the identical time of day so that messages can be placed in the correct chronological order regardless of the time zone in which they are generated. To achieve this, an OS server, for example, must take over the function of time master so that all other operator stations and automation systems on the plant bus received their time from this master and therefore have the identical time of day. As soon as an error occurs in time-of-day synchronization, a process control message is generated. Time-of-day synchronization is performed over both buses of a plant: •

Terminal bus – the OS clients obtain the time of day from a selected server, the OS servers (in a Windows domain) obtain the time of day from the domain controller.

•

Plant bus – the CPs of the OS servers that are currently passive time masters receive the time of day over this bus. At the same time, the automation systems are also synchronized over this bus.

Time-of-day Synchronization of a PCS7 System The time-of-day master is responsible for distributing the time signal over Industrial Ethernet/Fast Ethernet to the automation systems and operator stations to be synchronized. In terms of the time-of-day synchronization of a PCS 7 system, the following situations must be distinguished: •

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The servers are in a domain. In a Windows domain, all OS servers fetch their time from the domain controller over the terminal bus. This, in turn, obtains its time from an external time transmitter connected to the COM port (for example GPSDEC, DCFRS). The OS clients fetch the time from a selected OS server (over the terminal bus). The plant bus is synchronized by the OS server that enters process mode first (active time master). If highly accurate synchronization of the plant bus is required, a SICLOCK TM with GPSDEC can be connected to the plant bus as time master. All the automation systems are then synchronized by the SICLOCK TM. The OS servers and OS clients are synchronized, as described above, by the domain controller.


Configuring PCS 7

•

The servers are not in a domain. For highly accurate synchronization, a SICLOCK TM with GPSDEC is connected to the plant bus. "Time-of-day synchronization over plant bus, master" is set on all servers in the Timesync editor. In this case, all automation systems and all OS servers are synchronized by SICLOCK TM. If the SICLOCK TM fails, one of the servers takes over the function as active time master. The OS clients receive the time of day from a selected OS server. If a less accurate time is adequate on the plant bus, an external time transmitter can be connected to one or more OS servers (GPSDEC, DCFRS). All automation systems and all OS servers are automatically synchronized by the server with the most accurate time.

Using CPU Clocks The CPUs of the AS (and OS) have an internal clock whose time and data you can set and evaluate.

Representation of Time Zones Throughout the plant, there is only one continuous uninterrupted time of day - UTC. Locally on the OS, an additional local time that differs from UTC can be calculated and used for display. The local time is calculated based on UTC adding or subtracting a time difference. The local time also takes into account standard and daylight saving time. Note As of PCS 7 V6.0, UTC is always used internally in the system. Time information displayed to the operator in process mode is in local time calculated based on UTC. This makes system configuration possible across time zone boundaries. This allows system configurations in which, for example, the automation system is in a different time zone from the operator station. When necessary, the operator can also change over between displayed in UTC or local time during operation.

Time Stamp in the Diagnostic Buffer, in Messages, and OB Startup Information The time stamps are generated with UTC.

Setting Time-of-Day Synchronization - Where is it Described? For time-of-day synchronization to function throughout a system, settings must be made on the participating components. Components Involved

Procedure, see:

AS: CPU, CP 443-1, CP 443-5 Extended

Next section "How to Set Time-of-Day Synchronization on the AS"

OS

Manual Process Control System PCS 7; Operator Station

Manual Process Control System PCS 7; 10 ms Time Stamps


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Configuring PCS 7

7.8.5.2

How to Set Time-of-Day Synchronization on the AS

Settings CPU 1. Open the hardware configuration of the required station. 2. Select the CPU and select the menu command Edit> Object Properties. 3. Change to the "Diagnostics/Clock" tab. 4. In the "Clock" group, select the type of synchronization "As slave" for the synchronization on the PLC and (On MPI > None). 5. Confirm your entry with "OK".

Setting CP 443-1 (Industrial Ethernet) 1. Open the hardware configuration of the required station. 2. Select the CP 443-1 and select the menu command Edit> Object Properties. 3. In the "Time-of-Day Synchronization" tab, select the "Activate SIMATIC timeof-day synchronization" option: 4. Confirm your setting with "OK".

Setting CP 443-5 Extended (PROFIBUS DP) 1. Open the hardware configuration of the required station. 2. Select the CP 443-5 Extended and select the menu command Edit> Object Properties. 3. Activate the "DP master" in the "Operating Mode" tab. 4. Select the "Options" tab and activated the option "From station to LAN" in the "Time-of-day synchronization" group. By activating this option, the time-of-day frames of the time master are forwarded to the PROFIBUS network. 5. Confirm your entry with "OK".


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Manual Process Control System PCS 7; 10 ms Time Stamps


Configuring PCS 7

7.8.6

Configuring the Distributed I/Os (Standard)

7.8.6.1

How to Configure the Distributed I/O

Overview PROFIBUS DP is the most widely used fieldbus system in Europe (master/slave bus system). The technical properties of this bus allow its use in almost all areas of industrial automation. Apart from its extremely simple installation (twisted pair cable), its extremely high transmission rate (up to 12 Mbps), the flexible network structures possible (bus, star, ring) and the option of redundancy with a fiber-optic double ring are its major features.

Inserting a DP Slave – Example ET 200M In your project, you require, for example, an analog input and output module, and one digital input and one digital output module. You can insert the required components by dragging them from the hardware catalog to your project. Follow the steps outlined below: 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 2. Select PROFIBUS-DP > ET 200M > IM 153-... in the hardware catalog and drag this module to the DP master system(1). The DP master system(1) is the line to the right of the RACK window. Result: The "Properties – PROFIBUS Interface IM 153-... " dialog box opens. Note From the hardware catalog, select the IM 153 that matches the backplane bus you are using (passive or active backplane bus) and the product version marked on the actual IM 153 module you intend to use. In PCS 7, the active backplane bus is used.


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3. For the "PROFIBUS Address", select an address for the DP slave that is unique in your DP network (for example 7). You must set the selected address on the IM 153-... using DIL switches (hardware switches). Confirm the dialog box with OK.

4. Select the ET 200M and select the menu command Edit> Object Properties. 5. Change to the "Operating Parameters" tab. 6. Activate the option "Replace modules during operation" and confirm the dialog with "OK".

Note If you do not select this option and the module fails, the AS interprets the module failure as a failure of the ET 200M.

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Inserting Input and Output Modules 1. Select PROFIBUS-DP > ET 200M > IM 153-... > ... in the hardware catalog and drag and insert the required modules (lower window in hardware configuration).

2. Now make the module settings for your particular situation (diagnostic interrupt, measurement ranges etc.) in the Object Properties (select the module > Edit > Object Properties). (For all modules: Setting address and process image partition in the "Addresses" tab.) Note The channel specific setting "Reaction to CPU-STOP" (OCV, KLV, SV) of a module (for example analog output module with four channels) within the ET 200M distributed I/O station must be set identically for all channels. Note Remember that the measuring range for the analog input module must also be set on the module itself using a coding key. You can find the code letter for setting the measuring range selection module in the object properties of the module in the "Inputs" tab to the right beside "Position of Measuring Range Selection Module". If you use an ET 200M (IM 153-x), you must install at least one input/output module in the ET 200M or a CiR object to avoid consistency errors when saving and compiling the hardware configuration.


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Assigning Symbolic Names to the Channels You assign driver blocks to the channels on the modules using symbolic names listed in the symbol table. You declare the symbol names in hardware configuration. Follow the steps outlined below: 1. Select the first module in the ET 200M (slot 4), press the right mouse button and then select "Edit Symbolic Names...". 2. Enter the symbolic names in the "Symbol" column to reflect the technological significance of the value being read in. Use the process tag list of your project.

3. Follow the same procedure with the other modules and enter the symbolic names for all the other process values you require. Use the process tag list of the plant description.

Further information

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•

Manual SIMATIC; Distributed I/O Device ET 200M

•

Manual SIMATIC; Distributed I/O Device ET 200S

•

Manual SIMATIC; Distributed I/O Device ET 200iSP


Configuring PCS 7

7.8.6.2

How to Configure PA Devices

Introduction Communication with PA field devices is over a DP/PA adapter or a DP/PA Link. To configure field devices for PROFIBUS-PA (PROFIBUS for Process Automation), remember the following points:

DP/PA Link The DP/PA Link is a gateway between PROFIBUS DP and PROFIBUS PA. It consists of the IM 157 interface module and a maximum of 5 DP/PA couplers interconnected over backplane connectors. The DP/PA Link is a DP slave (in the role of a quasi "master") that opens PROFIBUS- PA for the connection of PROFIBUS- PA devices. The device must be arranged as a DP slave taken from the hardware catalog and attached to the DP master system (see also section "How to Configure the Distributed I/O"). The display of the DP/PA Link not only shows the icon for the device itself but also an icon for the "DP/PA system" - similar to that of the DP master system. The PA field devices must be attached to this icon. To attach PA devices, PROFIBUS-PA operates at a fixed transmission rate of 45.45 Kbps (no configuration necessary).

Procedure 1. Install the optional software SIMATIC PDM (PDM = Process Device Manager) to be able to configure the PA slaves from the hardware catalog later. 2. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 3. Configure a DP master system (HW Config). 4. Drag the DP/PA Link (IM 157) from the hardware catalog to the DP master system. Result: The dialog for specifying the master system opens. 5. Specify the master system (DP or PA) and confirm with "OK". Result: The properties dialog PROFIBUS Interface opens. 6. Make the settings for the PROFIBUS interface. 7. Select the DP/PA Link to be able to see DP slave structure in the lower part of the station window. 8. Slot 2 represents the "master" for the PA devices. Double-click on slot 2 to configure the PA subnet. 9. Click the "Properties" button (below "Interface") in the "General" tab and select the subnet with a transmission rate of 45.45 Kbps.


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10. Then configure the PA devices. You will find the PA devices in the hardware catalog under "PROFIBUS-PA" (Standard profile).

Note The "PROFIBUS-PA" entry is only visible when the SIMATIC PDM optional software is installed. You must configure at least one PA device in PROFIBUS PA. Otherwise errors will occur during compilation and the consistency check. From now on, the PA devices are configured with SIMATIC PDM (double-click on the device).

Further information

7.8.6.3

•


•

Manual SIMATIC; Bus Adapters DP/PA-Link and Y-Link

•

Manual PDM; The Process Device Manager

•

Section "Configuring the SIMATIC 400 Station (CPU, CPs, Central I/O)"

How to Configure the Diagnostic Repeater

Introduction The diagnostic repeater allows simple diagnostics for detecting communication errors in PROFIBUS DP chains with the DP Vx protocol.

Requirements •

The diagnostic repeater is installed and wired up.

•

The PROFIBUS address is set.

•

The diagnostic repeater is configured (configuration and parameters).

•

The DR switch behind the flap is set to ON (as supplied).

•

The power supply for the DP master is turned on.

Configuring the Hardware 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 2. Drag the diagnostic repeater from the PROFIBUS-DP > Network Components folder to the DP master system of your CPU. The "Properties - PROFIBUS Interface Diagnostic Repeater" dialog opens.

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3. Set the address and properties (bus parameters). 4. Double-click on the diagnostic repeater. The "DP Slave Properties" dialog box opens. 5. In the "Parameter Assignment" tab, select the DP alarm mode DPV0 (OB 82 is called for diagnostic events). Requirement: The mode on the DP master is set to DPV1. 6. Select the menu command Station > Save and Compile. 7. Select the menu command PLC > Download to Module to download the current configuration. This completes the hardware configuration of the diagnostic repeater. Now run the topology identification.

Topology Identification Requirement: To be able to detect the topology, a PG/PC must be connected to the relevant PROFIBUS network and a DP module must exist and be configured. If several PROFIBUS networks exist, the topology must be identified for each individual network. 1. Connect the PG/PC to the PG interface of the diagnostic repeater of the network. 2. To identify the technology, change to the SIMATIC Manager and select the project for which you require the typology identification in the component view. 3. Select the PROFIBUS master system in which the diagnostic repeater is located. 4. Select the menu command Options > Set PG/PC Interface and select the "Interface parameter assignment used" as in your configuration (for example CP 5611 (PROFIBUS)). 5. Select the menu command "Properties" and set the properties you require in the properties dialog. Make sure that the address is set to "0". 6. Acknowledge the dialog with "OK" and also the warning that is displayed. 7. Select the menu command PLC > PROFIBUS > Prepare Line Diagnostics. 8. In the "Prepare Line Diagnostics" dialog, select the "Restart" menu command. Result: The system data is acquired. 9. Close a dialog with the "Close" menu command as soon as the identification is completed. 10. Select the menu command Options > Set PG/PC Interface and reset the interface parameter assignment to "PC internal (local)". 11. Acknowledge the dialog with "OK" and also the warning that is displayed. 12. Select the required diagnostic function with the menu command PLC > Diagnostics/Settings > ...


Manual SIMATIC; Diagnostic Repeater for PROFIBUS- DP


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7.8.6.4

How to Configure Intelligent Field Devices with SIMATIC PDM

Overview SIMATIC PDM is a complete and heterogeneous tool for configuration, parameter assignment, commissioning, and diagnostics in conjunction with intelligent process devices. You can use SIMATIC PDM during all phases of a project (engineering, commissioning, and runtime). SIMATIC PDM allows a large number of process devices to be configured with one software package using a uniform user interface. You use SIMATIC PDM as an integrated tool in the SIMATIC Manager (network and plant view) and in HW Config. The integration in HW Config allows you to edit devices attached to PROFIBUS DP. All other devices are edited in the process device network and plant view of SIMATIC PDM. The display of device parameters and functions is uniform for all supported process devices and does not depend on their communications attachment, for example whether they use PROFIBUS DP/PA or the HART protocol. The following main functions have advantages particularly for testing and commissioning as follows: •

Setting

•

Changing

•

Verification

•

Management

•

Simulation

of process device data. You can also display selected values, alarms and status signals from the device on the screen and effectively implement process monitoring. Using simulation or in the manual mode of the devices, process-relevant values can be manipulated.

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User Interface of PDM The user interface supports several views: •

View within HW Config

•

Process devices network view within the SIMATIC Manager (View > Process Devices Network View)

•

Process devices plant view within the SIMATIC Manager (View > Process Devices Plant View)

•

Parameter assignment, commissioning, and runtime view (Start > SIMATIC > STEP 7 > SIMATIC PDM - LifeList)

Communication SIMATIC PDM supports several communications protocols and components for communication with the following devices: •

Devices with PROFIBUS-DP communication

•

Devices with PROFIBUS-PA communication

•

HART devices These devices can be attached in various ways. The following basic forms can be distinguished: -

HART devices over PROFIBUS-DP connected to ET 200M or ET 200iSP

-

HART devices connected to HART multiplexers or HART interface


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System Requirements •

You have created a device in HW Config that is configured with SIMATIC PDM.

•

To be able to go online with PDM, you require a PROFIBUS DP interface, for example CP 5611. The CP must be set to the PROFIBUS DP interface (in the SIMATIC Manager: menu command Options > Set PG/PC Interface).

Procedure (HW Config) 1. Double-click on the device you want to configure with SIMATIC PDM in HW Config. 2. Select "Specialist" in the dialog so that all the modification options are available. 3. Confirm with "OK". Result: SIMATIC PDM is opened.

Procedure (Process Devices Plant View) 1. In the SIMATIC Manager, select the menu command View > Process Devices Plant View. Result: The process devices plant view opens. 2. Select the required station and the "Devices" object. Result: All existing devices are displayed. 3. Select the required object and select the menu command Edit > Open Object. 4. Select "Specialist" in the dialog so that all the modification options are available. 5. Confirm with "OK". Result: SIMATIC PDM is opened.

Further information

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•

Online help on STEP 7


Configuring PCS 7

7.8.6.5

How to Configure HART Devices with SIMATIC PDM

HART Modules HART modules are analog modules to which HART transducers can be connected (HART = Highway Addressable Remote Transducer). HART modules are intended for distributed operation on the IM 153-2 (ET 200M) or IM 152 (ET 200iSP). To assign parameters for the HART transducers, start the SIMATIC PDM parameter assignment tool.

Representation of HART Transducers The transducers for HART modules are displayed like interface modules in the configuration table.

Procedure – Example ET 200M Example: The module is inserted in slot 4. The transducer for the first channel is then displayed as slot 4.1. Requirement: You have opened a station with a DP master system and an ET 200M with free slots in HW Config. 1. Insert an analog input module (6ES7 331-7TB00-0AB0) by dragging it to the ET 200M. 2. Drag two "HART Field device" modules below the analog input module. 3. Select the menu command Station > Save. Result: The configuration saved. 4. Double-click on the first field device. Result: The "Insert SIMATIC PDM Tag Object(s)" dialog opens. 5. Enter a name (plant designation) for the field device (tag) or select an object and confirm with "OK". Result: The user selection dialog opens. 6. Select "Specialist" in the dialog so that you have all the modification options available and confirm with "OK". Result: SIMATIC PDM is opened. 7. Configure your HART device.




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7.8.6.6

How to Configure Y-Links and Y-Adapters

Introduction To implement the changeover from a PROFIBUS master system to a singlechannel PROFIBUS master system, the Y-Link is preferred as the gateway.

Y-Link The Y-Link consists of two IM 157 interface modules and a Y-adapter. The Y-adapter is part of the Y-Link and is used to interface PROFIBUS-DP with the DP master in the IM 157. From the perspective of the programmable controller, the Y-Link is a DP slave, and from the perspective of the underlying DP master system, it is a DP master.

Procedure 1. Select the required SIMATIC H station in the component view and open HW Config by double-clicking on the "Hardware" object (right-hand pane). Result: Hardware configuration of the automation systems opens. 2. Drag an IM 157 from the PROFIBUS-DP > DP/PA-Link folder to the redundant DP master system of your CPU. The "Properties - PROFIBUS Interface IM 157" dialog opens. 3. Change the proposed address of the IM 157 in the DP higher-level master system and confirm with "OK". Result: After closing this dialog, a dialog opens in which the lower-level master system is displayed. 4. Select PROFIBUS-DP here and confirm with OK. Result: The Y-Link is inserted in the redundant Insert DP master system. The transmission rate of the lower-level DP master system is set to 1.5 Mbps as default. 5. If you want to change the transmission rate of the lower-level DP master system, double-click on it. Result: The dialog with the properties of the lower-level master system is displayed. 6. Select the "Properties" button Result: The "Properties PROFIBUS" dialog box is opened. 7. Enter the name of the lower-level DP master system and change to the "Network Settings" tab. 8. Select the transmission rate 45.45 Kbps to 12 Mbps and confirm with "OK". 9. Then configure the DP slaves for the lower-level DP master system.


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Manual SIMATIC; Bus Adapters DP/PA-Link and Y-Link


Configuring PCS 7

7.8.6.7

How to Use the Diagnostics of SIMATIC PDM

Configuration Support Apart from the diagnostic options provided by the maintenance station, you can also use the diagnostic options provided by SIMATIC PDM to support you when configuring. Use "SIMATIC PDM - LifeList" to check which DP devices and HART devices are obtainable in the network (causes of possible connection errors are described in the online help for SIMATIC PDM).

Note SIMATIC PDM requires device-specific information for devices with diagnostic capability. After installing SIMATIC PDM, this information is available for the devices included in the SIMATIC PDM list "Integrated devices.chm" Start > SIMATIC > Documentation > "Language" > SIMATIC PDM - Integrated Devices. You can add further devices using the "Manage device catalog" tool.



•

Online help on SIMATIC PDM

•


•



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7.8.7

Configuring the Distributed I/O for Configuration Changes in Run (CiR)

7.8.7.1

Principle of Configuration Changes in RUN

Introduction There are plants that must not be closed down during operation. This may, for example, be due to the complexity of the automated process or due to the high costs of restarting. Nevertheless, it may be necessary to extend or modify the plant. Using CiR (Configuration in RUN), it is possible to make certain changes to the configuration in RUN.

Principle A modification to the plant during operation using CiR is possible when you make provision for subsequent hardware expansion of your automation system for a specific master system in your original configuration. You define suitable CiR objects that you can later replace with real objects (slaves and/or modules) in the RUN operating state. You can then download a configuration modified in this way to the CPU while the process is running.

Validity You can make modifications to plant during operation with CiR (Configuration in RUN) in sections of plant with a distributed I/O. This is possible only with a configuration as shown in the figure (to avoid overcomplicating the picture, only one DP and one PA master system are shown) and the following hardware.

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CPU (412, 414, 416, 417 as of firmware version V3.1.0 / 414H, 417H in single operation as of firmware version V3.1.0)

•

CP 443-5 Ext (as of firmware version V5.0)

•

IM 153 (as of 6ES7153-2BA00-0XA00)

•

IM 157 (as of 6ES7157-0AA82-0XA00)


Configuring PCS 7

MPI/DP interface of a CPU 41x or DP interface of a CPU 41x or interface module IF 964 DP or external DP interface module CP 443-5 ext. PROFIBUS: DP master system

DP master

Modular DP slave ET 200M, ET 200S or ET 200iS

IM 157 + DP/PA couplers

SUBNET: DP master system

DP/PA-Link PA slave (field devices) Compact DP slave

PA slave (field devices)

Steps Involved Below, you will see the steps required for a program and configuration modification along with the corresponding plant status. Step

Meaning

CPU operating mode

Plant status

1

Configure the actual (real) configuration of your STOP plant

Offline configuration

2

Initial configuration of suitable reserves for future plant expansions

STOP

Offline configuration

3

Downloading the configuration

STOP

Commissioning

4

Conversion of the CiR objects to real objects as necessary. Plant modifications are only possible for master systems with a CiR object or for ET 200M stations with a CiR module.

RUN

Permanent operation

If necessary, repeat the CiR procedure (step 4 in the table above) several times in succession. The only thing you then need to take into account is that you have adequate numbers of slaves and I/O volume in reserve so that you can implement all your plant expansions.


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Recommendations for CiR Below, you will find several tips on making configuration modifications in RUN:

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Following each modification to the configuration, create a backup copy of your current plant configuration. Is only possible to continue editing the project without loss of CiR capability based on this backup version.

•

Whenever possible, make the configuration modifications in several steps and only make a few changes in each step. This means that you have a clear picture of the situation at all times.

•

To keep the CI are synchronization time (response of the CPU after downloading the configuration in RUN) and shortest possible, it is advisable to make modifications to only one DP master system per reconfiguration step.

•

Take the number of CiR objects into account when setting the process image (address area).

•

Remember that the number of CiR objects influences the CiR synchronization time. You should therefore only configured as many CiR objects as necessary (and as few as possible).

•

Make sure that you can also attach additional DP slaves in RUN.


Configuring PCS 7

7.8.7.2

Types of CiR Objects

Introduction to the Terminology Term

Meaning

CiR element

Generic term for CiR object and CiR module

CiR object

Placeholder for slaves to be added to the DP or PA master system later

CiR module

Placeholder for modules to be added to an ET 200M station later

CiR Elements The following CiR elements exist: Components

CiR Elements

Existing modular DP slave ET 200M

CiR module This contains the additional I/O volume and can be edited by the user. CiR object This contains the number of additional DP slaves and can be edited by the user. CiR object This contains the number of additional PA slaves and can be edited by the user.

Existing DP master system

Existing PA master system

Note When calculating the bus parameters, PCS 7 takes into account both the configured slaves and the CiR elements. As a result, when converting the CiR elements into real slaves and/or modules with the CPU in RUN, the bus parameters do not need to be changed.

CiR Objects Specify the following properties for a CiR object: •

Number of slaves that you can add with certainty (default: 15)

•

Number of input and output bytes for future use (default: 1220 each for a DP master system, 244 each for a PA master system). These relate to future user data addresses. You can configure diagnostic addresses regardless of this.

CiR Modules For the modular I/O device ET 200M (IMs of the type HF = High Feature), define additional I/O volume using a CiR module by specifying the total number of additional input and output bytes. This information relates to future user data addresses. You can configure diagnostic addresses regardless of this. The additional user data volume never needs to be used fully. The currently available user data volume must not, however, ever been exceeded. This is prevented by PCS 7.


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7.8.7.3

Overview of the Permitted Configuration Changes The following table lists all the permissible and impermissible configuration modifications (see table column Yes/No):

Configuration Modification

Supported

Adding modules to the modular DP slave ET 200M, providing you have not include it as a DPV0 slave (using a GSD file) Modifying parameters of ET 200M modules, for example selecting other alarm limits or using previously unused channels Adding DP slaves to an existing master system, however, not I slaves Adding PA slaves (field devices) to an existing PA master system Adding DP/PA adapters after an IM157 Adding PA-Links (incl. PA master systems) to an existing DP master system Assigning added modules to a process image partition Changing the process image partition assignment with existing modules or compact slaves Changing the parameter settings of existing modules in ET 200M stations, standard modules and fail-safe signal modules in standard operation) Reversing modifications: Added modules, submodules, DP slaves, and PA slaves (field devices) can be removed again Changing CPU properties Changing properties of central I/O modules Adding and removing DP master systems Changing properties of existing DP master systems, including the bus parameters, settings relating to constant bus cycle time Changing parameter settings of fail-safe signal modules in safety mode Changing the following parameters of a DP slave: bus address, assignment to the DP master, parameter assignment data, diagnostic address Removal of modules from module DP slaves (Only the module inserted last can be removed.) Removal of DP slaves from an existing DP master system (Only the slave with the highest address can be removed.) Changing the configuration of an I slave interface

Yes X

No

X X X X X X X X X X X X X X X X X X

Note If you add or remove slaves or modules, or want to make a modification to the existing process image partition assignment, this is possible for a maximum of four DP master systems.

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7.8.7.4

How to Define CiR Elements for Future Plant Expansion (CPU-STOP)

Defining CiR Elements For DP master systems, the "Activate CiR Capability" function is available. With this function, a CiR object is generated in the selected DP master system and in every underlying PA master system with CiR capability. A CiR module is inserted in each modular slave with CiR capability of the type ET 200M of the selected DP master system. You can add CiR elements either automatically or individually.

Activating CiR Capability Before the download of configuration data only in RUN is possible in your plant, you must prepare your project for CiR capability. You are supported in this by a system wizard. The wizard automatically creates a CiR object per DP chain and a CiR module the configured station with CiR capability (ET200M, DP/PA). The wizard sets the following I/O areas for future CiR activities. •

1220 bytes I and Q each per DP chain with CiR capability

•

15 slaves per DP chain with CiR capability

•

16 bytes I and Q each per CiR module

•

25 bytes I and Q each per CiR object on DP/PA chain

•

6 slaves per CiR object on the DP/PA chain.

The default values have been selected so that they are adequate for typical applications and do not need to be adapted. Check whether these default values are adequate for your application and make any necessary adaptations to individual stations or to a chain prior to the first download. Note The rule of thumb for the reserves is: As little as possible – as much as necessary, since the CiR synchronization time depends on the size of the reserves. Make sure that you do not exceed a CiR synchronization time of 1 second. •

If your changes in RUN relate only to a DP chain, the maximum CiR synchronization time is displayed when you select the CiR object.

•

If you want to make modifications to more than one chain of the same time, please add the individual times of the chains.

•

When you download the configuration data to the CPU, you will once again be informed whether the CiR synchronization time will be adhered to with the settings you have made.

•

To ensure the traceability of changes in RUN, we recommend that you only make changes in small steps and only to one DP chain each time you start CiR.

The CiR synchronization time is relevant when you activate a configuration change in RUN. A CiR action interrupts operation on the AS at a maximum for this time. The system sets an upper limit of 1 second and this is also monitored by the system. During this time, process outputs and process inputs are kept at the last valid values.


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Procedure - Adding CiR Elements to the DP Master System Automatically 1. Select the relevant DP master system. 2. Select the menu command Edit > Master System > Activate CiR Capability. Result: PCS 7 then adds the following CiR elements to the selected DP master system: -

A CiR module (assuming slots are still free) to each modular slave with CiR capability of the type ET 200M (IMs of type HF (High Feature)). This CiR module contains so many input and output bytes that a useful number of input and output bytes is available for later use.

-

A CiR object to each underlying be a master system with CiR capability. This CiR object contains as many input and output bytes as necessary so that the maximum number of input and output bytes (maximum 244 each) is occupied in the PA master system).

-

A CiR object to the DP master system. PCS 7 attempts to guarantee 15 slaves for the CiR object and to make 1220 input and 1220 output bytes available. (If the previous highest address in this master system is higher than 116, it is only possible to guarantee less slaves. If less than 1220 input and 1220 output bytes are available, the number is reduced accordingly.).

Note • The automatic addition of CiR elements is possible only when no CiR object already exists in the selected DP master system. •

The automatic addition of CiR elements is not available in DP master systems behind an IM 157.

•

If CiR capability is activated, slaves containing a CiR module and CiR objects (for example DP/PA-Link) are indicated in orange.

The defaults of the CiR objects are identical for all CPUs. After activating the CiR capability of a master system you should therefore check each CiR object to make sure that the CiR synchronization time of the master system shown in the properties window of the CiR object matches the upper limit set for the CiR synchronization time of the CPU. In some situations, you may need to reduce the number of guaranteed slaves for one or more CiR objects or increase the CiR synchronization time of the CPU using SFC 104 "CiR".

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Procedure - Adding CiR Objects to the DP or PA Master System You can define one CiR object per DP chain. 1. Select the relevant master system in the upper part of the station window. 2. Open the hardware catalog. 3. Drag the CiR object from the hardware catalog to the master system. You will then see the CiR object as a placeholder slave in the upper part of the station window. The CiR object has the following default values: -

Number of guaranteed additional DP slaves: 15

-

Maximum number of additional DP slaves: 45

-

Number of input bytes: 1220 for a DP, 25 for a PA master system

-

Number of output bytes: 1220 for a DP, 25 for a PA master system

The defaults of the CiR objects are identical for all CPUs. After activating the CiR capability of a master system you should therefore check each CiR object to make sure that the CiR synchronization time of the master system shown in the properties window of the CiR object matches the upper limit set for the CiR synchronization time of the CPU. In some situations, you may need to reduce the number of guaranteed slaves for one or more CiR objects or increase the CiR synchronization time of the CPU using SFC 104 "CiR".

Note If there are no longer enough resources available in the master system, these values are reduced accordingly. The resulting bus parameters Target Rotation Time, Target Rotation Time Typical and Watchdog are displayed in the properties window of the CiR object.

Procedure - Changing the Number of Additional Slaves and/or Number of Input and Output Bytes 1. Select the relevant CiR object 2. Select the menu command Edit > Object Properties ... Result: The properties dialog opens. 3. You can change the guaranteed number of additional slaves. The resulting bus parameters Target Rotation Time, Target Rotation Time Typical and Watchdog are displayed in the lower part of the station window. 4. You can change the number of input and output bytes. To do this, activate the "Advanced Settings" check box (default). Change the number only to lower values, increasing the values would also increase the CiR synchronization time.


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Procedure - Adding a CiR Module to a Modular ET 200M Slave Requirement: IM of the type HF (High Feature) 1. Select the relevant DP slave. 2. Open the hardware catalog. 3. Drag the CiR module from the hardware catalog to the slot immediately after the last configured module of the DP slave in the lower part of the station window. Result: The CiR module appears in the lower part of the station window as a placeholder module. The number of input and output bytes is displayed in the properties window of the CiR module. For ET200M stations, this is as follows: -

Number of input bytes = number of free slots * 16

-

Number of output bytes = number of free slots * 16

In an ET 200M station that only contains a CiR module, these values are therefore 128 (if the CiR object in the DP master system still has enough free input and output bytes).

Downloading the Configuration in STOP After defining the CiR elements, the configuration is downloaded with the CPU in STOP mode. Numerous modules can be used in an S7-400 automation system. To make sure that none of the modules used prevents future CiR activities, keep to the following procedure: When you have downloaded the configuration to the CPU in STOP mode, download the configuration again immediately afterwards this time with the CPU in RUN mode. PCS 7 and the CPU both check CiR capability during the download. With older modules or modules from other vendors, this is not possible offline.

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7.8.7.5

How to Delete CiR Elements (CPU-STOP)

Deleting CiR Elements In STOP mode, you can delete CiR objects in DP and PA master systems or CiR modules in modular slaves of the type ET 200M that you are defined earlier. (Note: the change to the configuration does not depend on the mode. Download is, however, only possible STOP). If you want to delete all CiR elements in a DP master system, you can do this simply with the "Deactivate CiR Capability" function.

Procedure - Deleting All CiR Elements of a DP Master System 1. Select the relevant DP master system. 2. Select the menu command Edit > Master System > Deactivate CiR Capability. Result: -

All CiR objects in underlying PA master systems are deleted.

-

All CiR modules in modular slaves are deleted.

-

The CiR object in the selected DP master system is deleted.

Note Deleting all CiR elements is possible only when a CiR object exists in the selected DP master system.

Procedure - Deleting a Single CiR Element If you want to delete the CiR module in a PA master system or in a modular DP slave of the type ET 200M, follow the steps outlined below: 1. Select the CiR element you want to delete. 2. Select the menu command Edit > Delete. If there is no further CiR element in the DP master system except for the CiR object, you can delete the CiR object using the same procedure.


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7.8.7.6

How to Convert CiR Elements into Real Objects (CPU-RUN)

Default Values for a New Station If you insert a new station in a chain, the following I/O areas are set as default for this station: •

80 bytes I and Q each for an ET 200M per CiR module

•

80 bytes I and Q each for a DP/PA station per CiR object in the DP/PA chain.

These default values have been selected so that their adequate for typical applications and do not need to be adapted. Before you download first-time, check whether these station-specific I/O settings are adequate for your application. You can modify these values prior to downloading for the first time without losing the CiR capability of the project. Note If you attempt an illegal operation when adding real slaves or modules to the configuration, you will only be made aware of this by an error message when you download the configuration. Following each change to the plant, you should check whether CiR capability still exists (menu command Station > Check CiR Capability).

Rules When adding components, keep to the following rules: •

Within a modular DP slave of the type ET 200M, you must only insert a CiR module in the slot immediately after the last configured module (If you add CiR elements automatically, this rule is adhered to automatically).

•

Within a master system, you must assign a higher PROFIBUS address to the added slave than the highest address used up to now.

Procedure – Adding a DP or PA Slave 1. Open the hardware catalog. 2. Drag the slave you want to add from the hardware catalog to the CiR object in the upper part of the station window. Result: The added slave appears in the upper part of the station window. The name of the slave is displayed on an orange background to indicate that this slave was created from a CiR object. Note When you add a new slave, PCS 7 updates the guaranteed and the maximum number of slaves and number of input and output bytes of the CiR object. If you add a DP slave of the type ET 200M with CiR capability, this has a CiR module from the very beginning.

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Procedure – Adding a Modular ET 200M Slave 1. Open the hardware catalog. 2. Drag the module you want to add to the CiR module in the lower part of the station window. Result: The module you have added appears in the lower part of the station window at the location previously occupied by the CiR module. The CiR module is moved by one slot. Note When you add a module to an ET 200M station, PCS 7 updates the number of input and output bytes of the corresponding CiR module. In the following figure, you can see the HW Config view after positioning a module on the CiR module.


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Procedure - Downloading Configuration in RUN You download a modified configuration in RUN in the following two steps: 1. Check that the current configuration can be downloaded (menu command Station > Check CiR Capability). 2. Download the configuration to the CPU (menu command PLC > Download to Module ...).

Note When you download the configuration to the CPU, the INTF LED lights up and then goes off again, the EXTF LED is lit permanently. You can only start to add the real stations or modules when the INTF LED has gone off again (maximum 1 sec). The EXTF LED then also goes off again.

Back up your current configuration each time you have downloaded the station configuration from HW Config (regardless of the operating state of the CPU). This is the only way that you can continue working and not lose CiR capability if an error occurs (loss of data).

7.8.7.7

How to Undo Used CiR Elements (CPU-RUN) You can reverse previous configuration changes that you are downloaded to the CPU by removing the slaves or modules you added. The following rules apply:

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•

Remove at most slaves or modules from a maximum of 4 master systems.

•

Within a DP or PA master system, when removing slaves, you must start with the slave with the highest PROFIBUS address. Then continue with the slave with the next highest PROFIBUS address.

•

Within a modular DP slave of the type ET 200M, when moving slaves, start with the slave with the highest slot number. In the HW Config view, this is the lowest module. STEP 7 provides you with the following support: The module to be removed next is entered in the lower part of the station window in the standard font, all other modules are in italics. Then continue with the module with the next highest slot number.


Configuring PCS 7

Procedure 1. Select the object you want to remove. 2. Select the menu command Edit > Delete. 3. If necessary, repeat steps 1 and 2 for each further object you want to remove. 4. Select the menu command Station > Check CiR Compatibility. 5. Download the modified configuration to the CPU.

Note • When you delete a slave, PCS 7 updates the guaranteed and the maximum number of slaves and number of input and output bytes of the CiR object. •

7.8.7.8

When you delete a module in a modular slave of the type ET 200M, PCS 7 updates the number of input and output bytes of the corresponding CiR module.

Changing the Parameter Settings for Existing Modules in ET 200M Stations (CPU-RUN)

Changing the Module Parameters in RUN With PCS 7, the module parameters can be modified during operation (without a CPU-STOP). Example: Enabling reserves channels, changing modes, measurement types etc. Depending on the capabilities of the module, the changes to module parameters can be made in RUN without affecting other modules or with restrictions without even affecting the channels of the module on which you are changing parameters. When changing parameters of modules using CiR, there is a maximum CiR synchronization time of 100 ms. When inserting module in PCS 7 projects using HW Config, please activate the module-oriented diagnostic interrupt.

Note The addresses of existing modules must not be modified with CiR.

Requirements •

A CiR object exists in the relevant DP master system.

•

The number of modules to be modified is less than 100.

For details of the ET 200M modules (signal modules and function modules) that can have parameters changed with the CPU in RUN, please refer to the information text in the hardware catalog" (information text: reconfigurable online).


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Behavior of Modules when Making New Parameter Settings With input modules, the following three reactions are possible when changing parameter settings: •

Channels that are not affected continue to return the current process value.

•

Channels that are not affected return the last valid process value prior to changing the parameter settings.

•

All channels return value "0" (on digital modules) or W#16#7FFF (on analog modules).

Output modules react as follows when parameter settings are changed: Channels that are not affected output the last valid output value prior to changing the parameter settings. For more detailed information on the reactions of specific modules, refer to the section "ET 200M Modules that Allow New Parameter Settings and their Reactions".

Behavior of the CPU when Making New Parameter Settings fter you have made changes to parameter settings in PCS 7 and have downloaded the changes to the CPU in RUN, the CPU runs the checks described in the section "Reaction of the CPU after Downloading Configuration Changes with the CPU in RUN" and starts OB80 with the event W#16#350A. It then starts OB83 with the start event W#16#3367. This explains that the input or output data of the modules affected may no longer be correct. You must no longer call SFCs that trigger the sending of data records to the affected modules (for example SFC57 "PARM_MOD"), otherwise there may be a conflict between the data records sent by the system and those sent by the user.

Note in PCS 7, the input and output values have the status "BAD" after this OB83 start

Once the CPU has completed OB83, it sends the parameter data records and each module affected receives all its data records (regardless of how many data records are affected by the change). There is then another OB83 start (start event W#16#3267 if sending was successful, or W#16#3968 if it was not successful). No other priority class is interrupted by this OB83 start.

Note In PCS 7, the input and output value is have the status "OK" following the OB83 start with the start event W#16#3267.

You can only access values in the process image that belong to the process image partition of the OB currently executing.

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If the transfer of the data records was successful, the DP master identifies the modules as available in the module status data and if unsuccessful, it marks them as unavailable. In the second situation, an I/O access an error occurs if the module is accessed (went updating the process input image or when transferring the process output image to the module or during direct access to the module that starts OB85. The input or output data of the modules behaves in the same way as if an insert/remove interrupt had occurred; in other words they may not currently being correct (because the module may not have evaluated its data records). The restriction that data record SFCs must no longer be acted for the module does not, however, apply any longer.

Note If the change to the parameter settings for a module involves, for example, deactivating the diagnostic interrupt, it is possible that the module still sends an interrupt that it had already prepared.

Possible Errors When Changing Parameter Settings The same errors can be made as when transferring data records with SFC: •

The module receives the parameter data records but cannot evaluate them.

•

Serious errors (in particular protocol errors on the DP bus) can cause the DP master to suspend the corresponding DP slave completely so that all modules of this station to count as having failed.

Changing Parameter Settings and the CPU Operating States The parameter setting change takes place following SDB evaluation in RUN. While the parameters are being changed, the INTF LED is lit. If there is a change to the HALT state, the parameter change is interrupted. It is continued if the CPU changes to STOP or to RUN. In STOP, only the OB83 calls are omitted. If there is a network failure, the parameter change is aborted. When the network returns, the parameters of all existing DP stations are reassigned.

Coordination between Master Systems It is possible that the sequence •

OB83 start (start event W#16#3367)

•

data record transfer

•

OB83 start (start event W#16#3267 or 3968)

takes place in the affected master systems at the same time.


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7.8.7.9

ET 200M Modules that Allow New Parameter Settings and their Reactions The following table contains a list of modules from the ET 200M range whose parameter settings can be changed. Please read notes 1 to 4 on the table. Key to the Table: 1. If you make channel-specific changes to parameter settings, for example deactivate diagnostics or a channel, no leaving state alarm is generated. If there was a channel-specific entering state alarm prior to changing the parameters, this remains set. This means that the LEDs on the station (IM153-2), on the DP interface module (CP 443-5 ext) and on the CPU (EXTF) remain lit. The corresponding message on the OS is not indicated as having exited the state. Remedies: Do not change parameter settings when an alarm is pending. Or remove and reinsert the module.. 2. If you change the parameter settings of a channel, the activated and unaffected channels temporarily return an analog value W#16#7FFF, which leads to the QBAD status in the channel blocks. After completing the parameter changes, the current analog value is once again indicated by the block. 3. If you need to change the setting for the measuring range module, we recommend the following procedure: Remove the module, change the parameter settings in HW Config, change the measuring range module on the module and reinsert the module. 4. It is not possible to change the parameter settings of F modules in fail-safe operation. When using F modules in stand operation, the module whose parameter settings are changed must be removed and reinserted. We recommend the following order: Remove the module, change the parameter settings with HW Config, and reinsert the module.

Module

Response of the Inputs/Outputs

Points to Note When Changing Parameter Settings

S7-300 Modules 6ES7 321–-7BH00–-0AB0 ... return last valid process value 6ES7 321–-7BH80–-0AB0 prior to parameter settings. SM 321; DI 16 DC 24 V; with hardware and diagnostic interrupt.

-

6ES7 321–-7BH01–-0AB0 SM 321; DI 16 DC 24 V; with hardware and diagnostic interrupt, clocked 6ES7 322–-8BF00–-0AB0 6ES7 322–-8BF80–-0AB0 SM 322; DO 8 DC 24 V/0.5 A; with diagnostic interrupt 6ES7 322–-5FF00–-0AB0 SM 322;DO 8 AC 120/230V/2A ISOL 6ES7 322–-5HF00–-0AB0 SM 322; DO 8 Rel. AC 230V/5A

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... output last valid output value prior to parameter settings.

-


Configuring PCS 7

Module



6ES7 331–-7NF00–-0AB0 SM 331; AI 8 16 bit 6ES7 331–-7NF10–-0AB0 SM 331; AI 8 16 bit 6ES7 331–-7PF00–-0AB0 SM 331; AI 8 RTD 6ES7 331–-7PF10–-0AB0 SM 331; AI 8 TC

... return last valid process value prior to parameter settings.

Note 1.

6ES7 331–-1KF00–-0AB0 SM 331; AI 8 13 bit

All channels return the value W#16#7FFF

Note 1.

6ES7 331–-7KB0x–-0AB0 6ES7 331–7KB8x–0AB0 SM 331; AI 2 12 bit 6ES7 331–-7KF0x–-0AB0 SM 331; AI 8 12 bit


Note 1., 2.,3.

6ES7 332–-5HD01–-0AB0 SM 332; AO 4 12 bit 6ES7332-5HF00-0AB0 SM 332; AO 8 12 bit 6ES7 332–5HB01–0AB0 6ES7 332–5HB81–0AB0 SM 332; AO 2 12 bit 6ES7 332–7ND00–0AB0 6ES7 332–7ND01–0AB0 SM 332; AO 4 16 bit


Note 1.

ET 200M Signal Modules for Process Automation (PCS 7) 6ES7 321–-7TH00–-0AB0 SM 321; DI 16 NAMUR

... return last valid process value prior to parameter settings including the status of the value.

-

6ES7 322–-8BH00–-0AB0 SM 322; DO 16 DC 24 V/0.5A


-

S7-300, Fail-safe Signal Modules (parameter settings can only be changed in standard operation) 6ES7 326–-1BK00–-0AB0 SM 326; DI 24 DC 24V; with diagnostic interrupt 6ES7 326–1RF00–0AB0 SM 326; DI 8 NAMUR with diagnostic interrupt 6ES7 336–1HE00–0AB0 SM 326; AI 6 13 bit; with diagnostic interrupt 6ES7 326–2BF00–0AB0 SM 326; DO 10 DC 24V/2A; with diagnostic interrupt


Note 4.

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Module



S7-300, ET 200, Hazardous Area I/O Modules 6ES7 321–-7RD00–-0AB0 SM 321; DI 4 NAMUR


Note 1.

6ES7 322 5RD00–-0AB0 SM 322; DO 4 15V/20mA 6ES7 322–5SD00–0AB0 SM 322; DO 4 24V/10mA


-

6ES7 331–-7SF00–-0AB0 SM 331; AI 8 TC/4 RTD


Note 2., 3.

6ES7 331–-7RD00–-0AB0 SM 331; AI 4 0/4...20mA 6ES7 331–7TB00–0AB0 SM 331; AI 2 0/4...20mA HART


-

6ES7 332–-5RD00–-0AB0 SM 332; AO 4 0/4...20mA 6ES7 332–5TB00–0AB0 SM 332; AO 2 0/4...20mA HART


Note 1.

7.8.7.10

How to Change the Parameter Settings of a Channel (CPU-RUN)

Procedure - Using an Unused Channel 1. Change the hardware configuration, check CiR compatibility with the menu command Station > Check CiR Compatibility. 2. Download the configuration to the CPU in RUN. 3. Make the rewiring change. 4. Modify the user program and download it to the CPU.

Procedure – Changing the Parameter Settings of an Unused Channel The procedure depends on whether changes to the user program and the corresponding hardware are necessary due to be changed parameters. The individual situations are described below. The user program does not need to be changed due to the parameter changes. This is the case, for example when changing an alarm limit or when deactivating the diagnostic interrupt. Change the hardware configuration, check the CiR capability with the menu command Station > Check CiR Capability and download the configuration to the CPU in RUN.

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The user program needs to be changed due to the parameter changes. This is the situation, for example, if you change the measuring range of the channel of an analog input module and you compare the corresponding analog value with a constant in your program. In this case, the constant must be adapted. 1. PCS 7: Set the values of the channel for which you want to change parameters to simulation (corresponding driver). 2. Change the hardware configuration and check CiR compatibility with the menu command Station > Check CiR Compatibility. 3. Download the configuration to the CPU in RUN. 4. Adapt the user program to the modified channel and download it to the CPU. Additionally in PCS 7: Cancel the simulation of the channel again (corresponding driver). The user program and hardware must be modified due to the parameter changes. This is, for example, the situation when you change the parameters of an input channel from "0 to 20 mA" to "0 to 10 V". 1. PCS 7: Set the values of the channel for which you want to change parameters to simulation (corresponding driver). 2. Change the relevant hardware. 3. Change the hardware configuration and check CiR compatibility with the menu command Station > Check CiR Compatibility. 4. Download the configuration to the CPU in RUN. 5. Adapt the user program to the modified channel and download it to the CPU. Additionally in PCS 7: Cancel the simulation of the channel again (corresponding driver).

Procedure – Removing a Used channel If you no longer require a channel that has been used up to now, you do not need to make changes to the hardware configuration. In this case, follow the steps below: 1. Change the user program so that the channel to be removed is no longer evaluated and download it to the CPU. 2. Change the hardware configuration and check CiR compatibility with the menu command Station > Check CiR Compatibility. 3. Download the configuration to the CPU in RUN. 4. Modify the relevant hardware (remove sensor or actuator etc.)


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7.8.8

10 ms Time Stamp

7.8.8.1

How to Configure the Hardware for 10 ms Time Stamps

Highly Accurate Acquisition of Binary Signals If you require highly accurate analysis of the process signals for a selected area, you can use 10 ms time stamps with the ET 200M. Possible applications include: •

Accurate time information when detecting a problem in a processing plant. With time stamps, it is possible to identify signals that indicate the cause of the failure of a unit.

•

Analysis of interrelationships within a plant

•

Detection and reporting the sequence of time-critical signal changes

Caution Time stamps should only be used for important selected signals relevant to the process and under no circumstances for all the binary signals that are read in. This function is useful when large numbers of signals are reported at the same time (for example when a fault occurs). Applying this to all binary signals would increase the risk of messages being lost due to buffer overflow.

Requirement Time stamps can only be used when the time-of-day is synchronized on all the devices belonging to the system. This requires a connection to a time master.

Where is it Described?

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•

You will find detailed step-by-step instructions on configuring 10 ms time stamps in the function manual Process Control System PCS 7; 10 ms Time Stamps.

•

You will find a full description and step-by-step instructions on setting time-ofday synchronization in the configuration manual Process Control System PCS 7; Operator Station.


Configuring PCS 7

7.8.9

Acknowledgment-triggered Reporting

7.8.9.1

How to Activate Acknowledgment-triggered Reporting (ATR)

Introduction If signals that trigger messages change the state in quick succession, a flurry of messages can be triggered. This can mean that the state of a plant is no longer adequately monitored. By configuring the "acknowledgment-triggered reporting (ATR)" function, it is possible to suppress the repeated signaling of "fluttering" states until an acknowledgment is received.

Procedure 1. Select the required SIMATIC 400 station in the component view and open HW Config by double-clicking on "Hardware" (right-hand pane). Result: HW Config and the hardware catalog are opened. 2. Select the CPU. 3. Select the menu command Edit > Object Properties. Result: The "Properties - ("CPU-xxx")" dialog box opens. 4. In the "Diagnostics/Clock" tab, activate the option "Acknowledgment-triggered reporting of SFB 33-35". Result: When this function is activated, SFBs 33 to 35 only report a signal change again when the previous signal change (in other words, the previous entering state message) has been acknowledged.


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7.8.10


7.8.10.1

How to Download the Configuration in CPU-STOP

Downloading the Configuration Hardware configuration of the SIMATIC stations is completed. First save and compile the hardware configuration you have created and then pass on the information to the CPU.

Note In some situations it is possible to download the hardware configuration during operation (CPU in RUN). The configuration changes you can make in RUN (CiR) are listed in the section "Overview of the Permitted Configuration Changes". Other configuration changes mean that the hardware configuration can only be downloaded when the CPU is in STOP!

Note For more detailed information about making system changes during operation in H systems, refer to the manual S7-400H Programmable Controller, Fault-Tolerant Systems

Procedure Requirement. Functioning data connection from the engineering station to the automation system. 1. Select the menu command Station > Save and Compile in HW Config. Result: Any consistency errors are reported now and you can obtain more information on them with "Details...". 2. To download the configuration, select the menu command PLC > Download to Module. Result: A dialog box opens in which you can decide whether to download in STOP or in RUN. Here, select STOP. 3. Select "Download in STOP". Result: A dialog box is displayed in which the destination modules are listed. 4. Here, you select the modules you want to download to. When you first download, you must download to all modules and then later only the modules in which you have made changes. Result: After querying the node address for the download, the configuration is downloaded to the target system. When you download, the CPU of the SIMATIC station and any communications processors are set to the "STOP" mode following a prompt. 5. On completion of the download, restart the CPU.

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6. Close hardware configuration with the menu command Station > Exit. Result: Your project is created, for example, with the following structure in the component view.

Source Files and Blocks The source texts of the user blocks and the SCL source files generated by CFC/SFC are stored in the "Sources" folder. Standard and user blocks and blocks generated by CFC/SFC, for example instances, are stored in the "Blocks" folder. "Charts" contains CFC charts, nested charts (chart in chart) and SFC charts.

7.8.10.2

How to Download Configuration Changes in CPU-RUN

Procedure Once you have made the changes, you should save and compile the configuration. Then perform the following steps: 1. Check that the current configuration can be downloaded with the menu command Station > Check CiR Capability. 2. Download the configuration to the CPU (menu command PLC > Download to Module ...). 3. Select the menu command Station > Save and Compile in HW Config. Note • If the configuration changes cannot be downloaded, close HW Config without saving. This avoids inconsistencies between the configuration in the CPU and on the ES. •

When you download the configuration to the CPU, the INTF LED lights up and then goes off again, the EXTF LED is lit permanently. You can only start to add the real stations or modules when the INTF LED has gone off again. The EXTF LED then also goes off again.


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Recommendation Back up your current configuration each time you have downloaded the station configuration from HW Config (regardless of the operating state of the CPU). This is the only way that you can continue working and not lose CiR capability if an error occurs (loss of data).


7.8.10.3

Online help on CiR

Reaction of the CPU after Downloading Configuration Changes with the CPU in RUN

Reaction of the CPU after Downloading the Configuration in RUN After downloading a modified configuration, the CPU initially checks whether the modifications are permitted. If they are, it evaluates the system data affected. This evaluation has effects on essential operating system functions such as process image updating and user program execution. These effects are explained in detail below. The time taken for the CPU to interpret the system data (known as the CiR synchronization time) depends on the number of input and output bytes in the DP master system is involved (for more detailed information, see below). The default is a maximum of 1 second. This value can be increased to 2.5 seconds. At the start of the system data evaluation, the CPU enters event W#16#4318 in the diagnostic buffer and on completion of the evaluation it enters the event W#16#4319.

Note If there is a power down during the system evaluation, all the CPU changes to STOP mode, the only practical course is to run a warm restart.

Following this, OB80 starts with event W#16#350A and enters the duration of the evaluation in its start information. This allows you, for example, to take the time into account in control algorithm is in your cyclic interrupt OBs.

Note Make sure that OB80 is always loaded on your CPU. Otherwise, the CPU changes to STOP when an OB80 start event occurs.

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Validation of the Required Configuration Change by the CPU The CPU first calculates the number of DP and PA master systems to which you are adding or removing slaves or modules, or changing the existing process image partition assignment. At a maximum of 4 affected master systems, the CPU continues the check, at more than 4, it rejects the modified configuration. in the next step, it calculates the CiR synchronization time as follows: •

If you are only changing parameter settings for existing modules, the following applies regardless of the CPU type: CiR synchronization time of the CPU = 100 ms In all other situations, the following applies: The CiR synchronization time of the CPU is the sum of the CiR synchronization times of the relevant master systems. The relevant master systems are those in which you add or remove slaves or modules, or change the existing process image partition assignment.

•

CiR synchronization time of a relevant master system = basic load of the master system + total I/O volume of the master system in bytes * time per byte. The total I/O volume of the master system is the sum of the existing real input and output bytes of the CiR elements in this master system. To calculate the basic load of a master system and the time per byte for a specific CPU type, refer to the technical specifications of your CPU.

Note • The CiR synchronization time calculated in this way is based on a worst-case scenario. This means that during CiR, the actual CiR synchronization time is always less than or equal to the calculated time. •

The CiR synchronization time of a master system is displayed in the properties window of the CiR object in HW Config.


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The following figure illustrates the relationship between the CiR synchronization time of a master system and its entire I/O volume based on the example of a CPU 417-4.

CiR synchronization in ms

1000

400 200

1K

4 K*

8 K**

Total I/O volumes in bytes

* corresponds to the maximum address area of the MPI interface, for example (2 K inputs+ 2 K outputs) ** corresponds to the maximum address area of an external DP interface module (4 K inputs+ 4 K outputs)

Based on this diagram, you can easily obtain the maximum configuration of the master system based on the maximum CiR synchronization time if you only want to make changes to one DP master system. This is explained based on an example (see below). The CPU now compares the calculated CiR synchronization time with the current upper limit for the CiR synchronization time. The default setting for this upper limit is 1 second and can be reduced or increased depending on your needs by calling SFC 104 "CiR" (max. 2.5 s). If the calculated value is less than or equal to the current upper limit, the CPU accepts the modified configuration, otherwise it rejects it. From the formula above, it is clear that the CiR synchronization time can be influenced as follows: The CiR synchronization time is reduced:

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•

the less input and output bytes you select for a master system,

•

the less guaranteed slaves you select for the master systems you intend to modify (the number of guaranteed slaves affects the number of input and output bytes directly.),

•

the less master systems you want to modify in 1 CiR action.


Configuring PCS 7

This is of particular significance for F systems. Here, the F monitoring time must include the CiR synchronization time. The highest value of all the DP master systems with a CiR object must be used (if only one DP master system is modified per CiR action) or the sum of the master systems to be modified at the same time. The following table is an example of a CPU 417-4 with six DP master systems. We assume that the maximum permitted CiR synchronization time is 550 ms. This means that modifications can be made to more than one DP master system as long as the total CiR synchronization times of these master systems does not exceed the value 550 ms. From the last column, you can see which DP master systems can be modified in one CiR action. DP Master System

Total I/O Vol. in Bytes

CiR Synchronization Time of the Master System

Distribution of Changes to DP Master Systems

1

1500

100 ms + 1500 bytes * 0.12 ms/byte = 280 ms

2

1000


3

1500


4 5 6

2500 3000 7000

100 ms + 2500 bytes * 0.12 ms/byte = 400 ms 100 ms + 3000 bytes * 0.12 ms/byte = 460 ms 100 ms + 7000 bytes * 0.12 ms/byte = 940 ms

either 1 (280 ms) or (1 and 2) (500 ms) either 2 (220 ms) or (2 and 1) (500 ms) or (2 and 3) (500 ms) either 3 (280 ms) or (3 and 2) (500 ms) 4 (400 ms) 5 (460 ms) Cannot be modified!

Example of Establishing the Configuration of a DP Master System We assume a maximum CiR synchronization time of 400 ms. The diagram shows that a maximum total configuration of 2500 I/O bytes is then possible for the DP master system (broken line). If you intend to have 250 input and 250 output bytes in the CiR object for future use, you therefore have 2000 bytes available for the initial configuration of the DP master system. Two constellations can be considered as examples: •

When using ET 200M stations with a full configuration (128 bytes for inputs, 128 bytes for outputs, some of which may be in CiR modules), you can operate 2000/(128 + 128), in other words approximately 8 ET 200M stations.

•

If you typically require 48 bytes per ET 200M station (for example 6 analog modules each with four channels of 2 bytes or a smaller configuration with a CiR module), you can operate 2000/48, in other words, approximately 42 ET 200M stations.

If such a configuration is inadequate, you can improve the situation as follows: •

Use a more powerful CPU (CPU with a lower time per byte, see Technical Specifications).

•

Select several smaller master systems rather than one large master system.

•

Select one or more master system is with a very large configuration and a CiR object with no guaranteed slaves. In such master systems, only changes to parameter settings for existing modules are possible within the framework of CiR. Select additional small master systems in which you add or remove slaves or modules, or change the existing process image partition assignment.


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Error Displays From the beginning of the validation until completion of the SDB evaluation, the INTF-LED is lit. It continues to be lit if changes are made to module parameters. On completion of the CiR action, there is a difference between the expected and actual configuration (the expected configuration has changed because you downloaded a configuration change to the CPU); as a result, the EXTF-LED is lit. If you have added slaves in the changed configuration, the BUS1F or BUS2F LED also flashes. Once you have made the actual hardware modifications, the EXTF, BUS1F and BUS2F LEDs go off.

Effects on the Operating System Functions during the CiR Synchronization Time Operating System Function

Effects

Updating the process image

Locked - The process inputs and output images are kept at their current value.

Execution of the user program

All priority classes are locked; in other words, no OBs are processed. All outputs are nevertheless kept at their current value. Existing interrupt requests are retained. Any interrupts occurring are accepted by the CPU only after completion of the SDB evaluation.

Target system

Timers continue to run. The clocks for time of day, cyclic, and delayed interrupts continue to run, the interrupts themselves are, however, locked. There are accepted only on completion of the SDB evaluation. As a result, a maximum of one interrupt can be added per cyclic interrupt OB.

PG operation

Only the STOP command is available on the PG. Data record jobs are therefore not possible.

External system status list information for example over MPI

Information functions are processed with a delay.

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7.9

Creating Network Connections Networks – known as subnets in PCS 7 – are used, on the one hand, for communication between automation systems and operator stations (plant bus, Industrial Ethernet) and, on the other hand, between automation systems and the distributed I/O (PROFIBUS DP).

Overview Creating network connections in PCS 7 involves the following topics:

7.9.1

•

How to Display Networked/Non-networked Stations

•

How to Create and Assign Parameters for a New Subnet

•

How to Create and Assign Parameters for the Network Attachment of a Station

•

How to Change the Node Address

•

How to Save the Network Configuration

•

How to Check the Consistency of the Network

•

Cross-project Networks

•

Configuring Redundant Networks

How to Display Networked/Non-networked Stations

NetPro Representation of the Project In NetPro, all configured stations and networks of a project are displayed graphically. As a result, you can immediately recognize whether and with which subnet a station is connected based on the connecting lines. You specify the network assignment of components capable of communication during hardware configuration of a station. You can change is assignment later in NetPro.

Procedure 1. Select the project for which you want to display the networking in the component view of the SIMATIC Manager. 2. Select the required network in the right-hand window. 3. Select the menu command Edit> Open Object. Result: NetPro opens and all the stations of the project are displayed graphically with their network assignment.


Online help on NetPro

•

Section "How to Create and Assign Parameters for the Network Attachment of a Station"


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7.9.2

How to Create and Assign Parameters for a New Subnet

Where and How Can Subnets Be Created ? Where?

How ?

Application

In HW Config

When inserting a communications processor (refer to Standard plants the section "How to Insert a Communications Processor".

In NetPro

Menu command Insert > Network Objects

Complex networked plants

In the SIMATIC Manager

Menu command Insert > Subnet

Complex networked plants

During the configuration of the station, you already have the option of creating subnets and connecting modules (more precisely their interfaces) to a subnet. You are already familiar with this option. With complex networked plants it is better to work in the network view (NetPro). This is described below.

Procedure 1. Select the station in the component view of the SIMATIC Manager. 2. Select the menu command Options > Configure Network. Result: NetPro opens and the network configuration of the selected project is displayed. 3. Click on "Subnets" in the "Catalog" window. If the "Catalog" Windows is not visible, operate with the menu command View > Catalog. 4. Click on the required subnet, whole down the mouse button and drag the subnet to the window for the graphic network view. A mouse cursor in the shape of a "Forbidden" sign indicates locations where it is not possible to position the subnet. Result: The subnet is displayed as a horizontal line. 5. Double-click on the symbol of the subnet. Result: The properties dialog of the subnet opens. 6. Set the parameters for the subnet (for example, assign a unique name).

Tip: If you hold the cursor over the symbol of the subnet, a tooltip with information on the properties of the subnet is displayed.

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7.9.3

How to Create and Assign Parameters for the Network Attachment of a Station

Requirement NetPro is open and the configured stations are visible.

Procedure 1. Click on the icon for the interface of the node (small box in the color of the corresponding network type), whole down the mouse key and drag the mouse pointer to the subnet. If an attachment is not possible (for example: attachment of an MPI interface to an Ethernet type subnet), the mouse pointer takes shape of a "Forbidden" sign. Result: The network attachment is displayed as a vertical line between the station/DP slave and subnet. 2. Select the network attachment and select the menu command Edit > Object Properties. 3. Double-click on the icon for the network attachment or on the icon for the interface. Result: The properties dialog of the subnet node opens. 4. Make the settings for the node properties (for example, name and address of the node).

Tip: If you hold the mouse cursor over the icon for the interface, a tooltip is displayed with the properties of the interface (name of the module, subnet type, and, if already networked, the node address).


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7.9.4

How to Change the Node Address You specify the node address in the object properties of the Ethernet CP. The following properties are defined: •

MAC address

•

additional for the IP protocol. IP address/subnet mask/address of the gateway

MAC Address Each Ethernet module is assigned a unique MAC address. You will find the MAC address on the module. Please note that when using PC modules with a fixed MAC address, you must accept this MAC address. The freely available MAC address initially proposed by the system may differ from the address of the module. With more recent CPUs, a check box allows you to decide whether you want to set the MAC address and use the ISO protocol. You only need to enter a MAC address if you intend to use the ISO protocol. Otherwise, the field remains disabled; the address assigned to the CP in the factory is then not overwritten when you download the configuration data.

IP Protocol The IP parameters are displayed only when the current module supports the TCP/IP protocol. STEP 7 assigns default settings for "IP address", "Subnet mask" and the address of the gateway for the interface of the node depending on the subnet mask and gateway of the subnet. Enter a new IP address/subnet mask/address of the gateway if you do not want to use the default setting.

Requirement NetPro is open and the configured stations are visible.

Procedure 1. Select the CP whose addressing you want to change. 2. Select the menu command Edit > Object Properties. 3. Select the "General" tabbing the properties dialog and click the "Properties" button. 4. Enter the MAC address, IP address and, if applicable, the subnet mask in the dialog that opens. 5. Confirm the dialogs with "OK".


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Configuring PCS 7

7.9.5

How to Save the Network Configuration

Introduction To save the network configuration and the connection tables, you can use the menu commands Network > Slave and Network > Save and Compile.

Saving When you have created network objects in NetPro or changed their properties in NetPro, NetPro saves the following: •

Node addresses

•

Subnet properties (for example transmission rate)

•

Connections

•

Modified module parameters (for example of CPUs)

Save and Compile If you select the menu command Network > Save and Compile..., a further dialog opens in which you can decide whether to compile everything or only the changes. Regardless of the option you select, NetPro checks the consistency of the configuration data throughout the project; messages are displayed in a separate window. Option?

What?

Compile and check everything

Loadable system data block (SDBs) of the complete network configuration are generated; these contain all the connections, node addresses, subnet properties, input/output addresses and module parameter assignments.

Compile changes only

Loadable system data block (SDBs) of modified connections, node addresses, subnet properties, input/output addresses or module parameter assignments are created.


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7.9.6

How to Check the Consistency of the Network Before you save, you should check the consistency of the network configuration. The following, for example, is reported: •

Nodes that are not connected to a subnet (Exception: non-networked MPI nodes)

•

Subnets with only one node

•

Inconsistent connections

Alternative Procedures A consistency check is running when you perform the following actions: •

Menu command Network > Check Consistency

•

Menu command Network > Check Consistency Project-wide

•

Menu command Network > Save and Compile (in the next dialog, select the option "Compile and check everything")

•

Download to the target system (consistency check of the stations and connections to be downloaded)

Procedure Select the menu command Network > Check Consistency in NetPro. Result: The consistency check is run. Following this, the window "Outputs for consistency check for opens. Any errors and warnings are displayed here (these can relate to the hardware configuration, network or connection configuration).

Messages in the "Outputs for Consistency Check" Window Messages are displayed as Error, is no system data (SDBs) can be generated by saving compiling or prior to download to the target system. Without generated system data, the hardware/network and connection configuration cannot be downloaded to the target system. Messages are displayed as Warning, when the reported problem nevertheless allows generation of system data (SDBs). To obtain help on an error or warning, select the error or warning and press the F1 key. Tip: The window with the results of the last consistency check can be opened at any time with the menu command View > Outputs.

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Consistency of Cross-Project Subnets After merging the subnets in the multiproject (refer to the section "Cross-project Networks") and prior to downloading, you should use the Network > Check Crossproject Consistency menu command in NetPro to check consistency throughout the multiproject. In this check, all projects of the multiproject are subjected to a "total consistency check" one after the other. This takes into account all the objects in the multiproject. The quality of the consistency check is the same for both menu commands (Network > Check Consistency and network > Check Consistency Projectwide). In both cases, duplicate node addresses are searched for in merged subnets. When checking connections for consistency, cross-project connections are also taken into account in both cases.

7.9.7

Cross-project Networks

Cross-project Networks With PCS 7, you can configure cross-project Ethernet networks and then configure connections over them. Networks included in more than one project are not created in one step. The subnets configured in the individual projects are merged in the multiproject and assigned to a logical "entire network" that represents the common properties of all the assigned subnets. The individual subnets of a merged network continue to be retained. Merged and therefore cross-project networks have the same subnet type and identical S7 subnet IDs. They are represented in NetPro by the name extension "Part of: Ethernet Interproject".

Cross-Project Network View To achieve a better overview, you can activate the cross-project network view in NetPro: menu command View > Cross-project Network View. This is an advantage particularly in the multiproject.


Section "How to Merge Subnets from Different Projects into a Multiproject"

•

Online help on NetPro


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7.9.8

Configuring Redundant Networks

Redundant Networks Both the fieldbus (PROFIBUS DP for the connection between the AS and distributed I/O) and the plant bus (Industrial Ethernet for the connection between AS and OS server) can be designed redundantly.

Basic Procedure 1. Create a project (single project) with the PC Station Wizard (CPU 414H or CPU 417H). Result: A SIMATIC H station and two PROFIBUS systems are created in the project and the PROFIBUS systems are already connected to the DP interface of the CPU. 2. Add a CP 443-1 to each subsystem of the H station and in HW Config and create a new Ethernet subnet for each CP. As a result, you have both a redundant fieldbus system and a redundant plant bus system. When you continue with the configuration, make sure that you assign other redundant components (for example redundant OS server) to the correct plant bus.


7.9.9

Function manual Process Control System PCS 7; Fault-tolerant Process Control Systems.

Tips on Editing the Network Configuration

Highlighting the Communication Partners of a Module If you have already configured connections: 1. Select a programmable module (CPU, FM) in the network view. 2. Select the menu command View > Highlight > Connections. Note: You can only highlight the communication partners of one programmable module.

Displaying/Modifying the Properties of Components To display or modify the properties of stations or modules, follow the steps outlined below: 1. Select the component (station icon or module) 2. Select the menu command Edit > Object Properties.

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Copying Subnets and Stations 1. Select the network objects you want to copy by left-clicking them. If you want to copy several network objects that the same time, other network objects with the left mouse button while holding down the SHIFT key. 2. Select the menu command Edit > Copy. 3. Click on the location in the network view where you want to position the copy and select the menu command Edit > Insert.

Note You can copy individual network objects or entire subnets with network attachments, stations, and DP slaves. When copying, remember that all the nodes of a subnet must have a different node address. If necessary, you must change the node addresses.

Deleting Network Attachments, Stations and Subnets 1. Select the symbol of the network attachment or subnet. 2. Select the menu command Edit > Delete. When you delete a subnet, the stations previously connected to the subnet are retained and can, if required, the connected to another subnet.


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7.10

Creating the SIMATIC Connections In medium to large plants, several automation systems are used in one plant section and share the automation tasks. As a result, data exchange between the automation systems themselves becomes a requirement. Data exchange between the automation systems and the operator station is also necessary. The following sections explain how to define these communication connections and which special features must be taken into account.

7.10.1

Connection Types and Connection Partners

Introduction Communication connections or simply connections must always be configured, when data exchange between the automation systems or the automation system and an operator station is required in the user program using communication blocks.

What is a Connection? A connection is a logical assignment between two communication partners for executing communication services (for example exchange of process values). A connection specifies the following: •

The communication partners involved (for example two SIMATIC 400 stations)

•

The connection type (S7 connection, S7 connection fault-tolerant)

•

Special properties (for example whether a connection remains permanently established; which of the partners initializes connection establishment; whether operating state messages will be sent).

What Happens during Connection Configuration? During connection configuration, a unique local identifier is assigned per connection, the "local ID". The local ID can also be a symbolic name (named connection). This local ID is required when assigning parameters to the communication blocks. For each programmable module that can be the endpoint of a connection, there is a separate connection table.

Special Feature PCS 7 automatically assigns a local ID for both endpoints of the connection if both communication partners are S7-400 stations or when one of the communication partners is an S7-400 station and the other is a SIMATIC PC station. You configure the connection only in the connection table of one partner; the other communication partner then automatically has the matching entry in its connection table.

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Selecting the Connection Type The connection type depends on the subnet and the transmission protocol with which the connection is established. Which communication blocks you use depends on the connection type. In PCS 7, the following connection types are used: •

S7 connection

•

S7 connection, fault-tolerant


Section "Blocks for Different Connection Types"


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7.10.2

How to Configure Connections between Two SIMATIC 400 Stations

Requirement Two SIMATIC 400 stations have already been created.

Note Make sure that there are no duplicate "PROFIBUS-DP" or "Industrial Ethernet" node addresses in your project (if uncertain, check with NetPro).

Procedure 1. Select the required project in the component view of the SIMATIC Manager. 2. Select the menu command Options > Configure Network. Result: The network view is opened with the SIMATIC 400 stations, the corresponding ET 200M I/O devices, the operator station and the networks in your project. 3. Double-click on a SIMATIC 400 station in your project in the SIMATIC Manager and select the CPU.

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4. Select the module for which the connection is to be created in the network view, for example, the CPU of the SIMATIC 400(1). Result: The connection table of the selected module is displayed in the lower part of the network view.

5. Select an empty row in the connection table and select the menu command "Insert > New Connection". 6. Select the required connection partner in the "Insert New Connection" dialog box. Here, select the CPU of the SIMATIC 400(2).

Note If you create a connection to a partner in another project of the multiproject, you must enter a connection name (reference). Based on the connection name, crossproject connections can later be merged. You enter the connection name in the properties dialog of the connection when configuring the corresponding PC station (OS) (area: "Connection Identification"; field: "Local ID").


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7. Specify the type of the connection as "S7 connection". 8. Activate the check box "Display properties before inserting" if you want to review or change the properties of the connection after "OK" or "Add". The content of the "Properties..." dialog box depends on the selected connection. Result: PCS 7 enters the connection in the connection table of the local (in other words the selected) node and assigns the local ID (can be changed) for this connection and, if required, the partner ID you require to program the communication function blocks (value for the "ID" block parameter). For help on completing the dialog, refer to the online help for the individual dialog boxes.

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9. After configuring a new connection, this must still be downloaded to the CPU of the relevant stations. - Select the CPU in a station in which you configured the connection. - Select the menu command PLC > Download in the current project > Connections and Gateways Result: All connections and gateways are downloaded. Note The configuration data of the partner station must also be downloaded.


Section "Cross-Project Connections in a Multiproject "

•

In the online help for the dialog


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7.10.3

How to Configure a Connection between a PC and SIMATIC 400 Station (Named Connection)

Symbolic Connection Name (Named Connection) Instead of a connection ID, you can specify a symbolic name for a connection between an OS and an AS (Named Connection - recommendation: specify name of AS). You will find this name in the SIMATIC S7 Protocol Suite" after the OS compilation. Refer to the configuration manual Process Control System PCS 7; Operator Station for more information. Note If several PC station connections are configured on one AS, all these connections must have the same name (Recommendation: specify name of AS).

Procedure 1. Select the required project in the component view of the SIMATIC Manager. 2. Select the menu command Options > Configure Network. Result: The network view is opened with the SIMATIC 400 stations, the corresponding ET 200M I/O devices, the operator station and the networks in your project. 3. Select "WinCC Application" in the symbol of the "SIMATIC PC station". Result: The connection table is displayed in the lower part of the NetPro window.

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4. To insert a new connection, select the menu command Insert > New Connection. Result: The "New Connection" dialog box opens.

5. In the "Connection partner" field, select the CPU that will be connected to the OS and make sure that the option "Display properties dialog before inserting" is selected.

Note If you are working in a multiproject, you must select the target project using the multiproject folder and select the required CPU.


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6. Click the "Apply" button. Result: The following properties dialog appears

7. In "Local ID:", a connection name was entered as default (S7connection_1). You can adapt this name to suit your project. You will find the connection name once again in the connection table (named connection). Result: When you compile the OS, the corresponding S7 program can now be transferred to the OS over this path (depending on the settings for compiling the OS).

Note To avoid errors and improve clarity, you should change the default connection name (S7connection_1) to suit your project (for example, name of the AS).

8. Close the connection configuration with the Network > Save and Compile menu command.

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9. Select the PC station and download the configuration with the menu command PLC > Download in the current project > Selected Station.

Note Once you have downloaded the hardware configuration for the first time from HW Config (STOP), changes to the configuration should then only be downloaded using "Compile and Download Objects" or from within NetPro.

Note Change local ID only: You can change the local ID directly in the "Local ID" column of the connection table. Go to partner station: When you are editing in the connection table, you can change easily to the connection table of a connection partner: Select a connection in the connection table. Select the menu command Edit > Go to Partner Connection. This function is also possible for cross-project connections in the multiproject. The project in which the connection partner is located must be open and the subnets of the projects involved must already have been merged.

Note To avoid the AS generating messages during operation when the OS simulation is started or terminated on the engineering station, the connection ID for the engineering station should be higher than 0xc00.


Section "Cross-Project Connections in a Multiproject "


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7.10.4

How to Work with the Connection Table

Requirements •

NetPro is open.

•

A CPU or a WinCC application is selected.

Showing and Hiding Columns 1. Point to the connection table with the mouse pointer and right-click. Result: The context-sensitive menu opens. 2. From the context-sensitive menu, select the Display/Hide Columns> ... menu command and select the name of the column you want to show or hide in the next context menu. The names of the visible columns are indicated by a check mark. If you select a visible column, the check mark disappears and the column is hidden.

Optimizing the Column Width To adapt the column width to the content (all texts legible), follow the steps outlined below: 1. Position the mouse pointer in the header row of the connection table on the right beside the column you want to optimize until the mouse pointer changes to two parallel lines (as if you wanted to change the width of the column by dragging with the mouse pointer). 2. At this position, double-click.

Tip: If the columns are set too narrow, the entire content of individual fields is displayed if you position the mouse pointer briefly over a field.

Sorting the Connection Table To start the connection table in ascending order according to a particular column, click on the title of the column. Clicking on the title of the column again sorts the connection table in the opposite order.

Note The column widths and the visible columns are saved for the particular project when you close the project; in other words if you open the project on a different computer, the settings remain valid there.

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Changing Properties of the Connection If you want to change a connection that has already been configured, for example to set a different connection path (interface), follow the steps outlined below: 1. Select the connection you want to modify 2. Select the menu command Edit > Object Properties. In the dialog that opens, you can modify the editable properties of the connection.

Go to Partner Station When you are editing in the connection table, you can go directly to the connection table of a connection partner: 1. Select a connection in the connection table. 2. Select the menu command Edit > Go to Partner Connection. This function is also possible for cross-project connections in the multiproject. The project in which the connection partner is located must be open in NetPro.


7.10.5

For more detailed information on the columns of the connection table, refer to the context-sensitive help.

Cross-Project Connections in a Multiproject

Introduction If cross-project subnets are configured, connections can also be configured over such subnets. The endpoints of these connections can be in different projects. PCS 7 provides support both when creating cross-project connections within the multiproject and when synchronizing connections configured without the multiproject context.

Cross-Project Connections to a Specified Partner Cross-project connections to a specified partner (for example a CPU) are created just like connections within a project. The dialog for selecting the connection partner allows not only the selection of the endpoint (for example module) but also the selection of the project within the multiproject in which the endpoint is located. To allow this, the projects must be part of a multiproject and the subnets must have been merged (for example using the "Synchronize Projects in the Multiproject" wizard of the SIMATIC Manager).


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Properties of Cross-Project Connections The consistency of cross-project connections is retained when manipulating projects of the multiproject. Cross-project connections within a multiproject remain functional and can be compiled even when the project with the connection partner has been removed from multiproject. The following applies to S7 connections: PCS 7 asks whether the connection should be broken before display in the properties dialog only when you display the properties of the connection. The properties of the connection can only be modified when this query is answered with "Yes". If you modify the properties, you must make sure that the connection properties are synchronized yourself.

Note Only the local ID of a connection can be modified without breaking the connection (modification directly in the table). Fault-tolerant S7 connections cannot be broken.

If you have broken connections (at both ends), you can merge them again with the menu command Edit > Merge Connections (see also the online help for the dialog).

Cross-Project Connections to an Unavailable Partner If the connection partner in the multiproject is unavailable, because the relevant project is being created elsewhere or because it is being edited and is therefore locked, select "in unknown project" as the connection partner. In the path the project, "Partner in unknown project" is also selected as the connection partner. This procedure reserves a connection in both projects that can be synchronized with system support when the partner project is later included in the multiproject. To allow this, the same connection name (reference) must be configured in both projects in the properties of the connection. Based on the connection name, it is possible to assign the connection partner and synchronize the connection properties (menu command Edit > Merge Connections). See also the section "How to Merge Cross-Project Connections".

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Points Note when Downloading If you have configured cross-project subnets and connections, you must download the network configuration to all modules involved. These are the endpoints of the connections and the required routers. When you upload (upload to PG), the configured network configurations and connections are automatically merged assuming that the requirements are met (for example both endpoints are uploaded). The download functions in NetPro are not cross-project and are effective only within a project. This affects the functions: •

Download in Current Project > Selected Stations

•

Download in Current Project > Selected and Partner Stations

•

Download in Current Project > Stations on the Subnet

•

Download in Current Project > Selected Connections

•

Download in Current Project > Connections and Gateways

•

Save and compile is also restricted to the currently active project.

If an S7 connection, for example is cross-project, the network configurations of both projects involved must be compiled.


7.10.6

Section "How to Merge Cross-Project Connections"

How to Merge Cross-Project Connections

Requirements To merge connections within a multiproject, the following conditions must be met: •

The corresponding connections in the various projects must have exactly the same connection names (reference).

•

S7 connections to an unspecified partner can be merged to a cross-project S7 connection only in NetPro. These connections are ignored in the SIMATIC Manager.

Merging Connections To merge connections, follow the steps outlined below: 1. Select the required multiproject in the SIMATIC Manager 2. Select the menu command File > Multiproject > Synchronize Projects. The "Synchronize Projects in the Multiproject" dialog opens. 3. In the left-hand window, select the entry "Merge connections". 4. Click the "Execute" button. 5. If the "Result" field does not indicate an error, click on the "Save" button. The connections are merged and synchronized in the multiproject. Process Control System PCS 7 - Engineering System A5E00346923-02

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7.10.7

Configuring Redundant Connections

Redundant Connections The fault-tolerant connection is a separate connection type. The following partners can communicate over fault-tolerant connections: •

S7 H station (two H-CPUs) <-> S7 H station (two H-CPUs)

•

SIMATIC PC station <-> S7 H station (two H-CPUs)

The properties of fault-tolerant connections correspond to those of the S7 connections; however restricted to S7-H-CPUs and OPC servers of SIMATIC PC stations. With a fault-tolerant S7 connection, two connection paths between the connection endpoints are normally possible.

Requirement •

The hardware configuration of the two subsystems of a fault-tolerant system must be identical.

•

The communication partners involved are H-CPUs or a suitably configured PC station.

•

To use fault-tolerant S7 connections between a PC station and a fault-tolerant automation system, the software package S7- REDCONNECT must be installed on the PC station.

Basic Procedure 1. Select the CPU of an age station (H-CPU) from which you want to configure a new connection. 2. Select the menu command Insert > New Connection. 3. Select the required connection partner in the "Insert New Connection" dialog box. 4. Select the connection type "S7 connection fault-tolerant". 5. The remaining steps are the same as for configuring an S7 connection.


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Manual Process Control System PCS 7, Fault-Tolerant Process Control Systems


Configuring PCS 7

7.11

Configuring AS Functions

Overview After creating the S7 programs including the chart folder in the component view, all the resources exist for specifying the AS functions in the plant hierarchy by inserting and programming CFC charts and SFC charts. The following table provides you with an overview of the basic steps in programming that are then described in greater detail below. What? Creating CFC Charts (General)

must

can

X

Programming SIMATIC Connections

X With AS-AS and AS/OS communication

Programming the interface to the I/O (driver blocks)

X

Creating Process Tags from Process Tag Types (Multiproject) Creating Sequential Control Systems (SFC) Creating Models (Multiproject)

X With mass data processing X X With mass data processing

You will also find information on the following topics: •

Configuration by Several Users (Textual Interconnections)

•

Editing Mass Data in the Process Object View

•


Versioning CFC and SFC Charts In the Object Properties for each CFC/SFC chart, you can assign a version number (range 0.1 through 15.15). The version number is automatically set to "0.1" when you create CFC/SFC charts and is then managed by the user. The Object Properties of a CFC/SFC chart also include information on the software version used to create the charts (PCS 7 Vx.y).


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7.11.1

Configuration by Several Users (Textual Interconnections)

Overview Prior to programming the CFC and SFC charts, you should decide whether the project will be edited by more than one engineer. To allow this, branching and merging at the chart level is possible (S7 program). The distribution within the project is made according to technological aspects (for example unit with the relevant charts is copied to a different project). Existing cross-chart interconnections are automatically replaced by textual interconnections. On completion of editing, the parts are copied back to the original project. Charts with the same name are replaced (following a prompt for confirmation). The textual interconnections are then re-established. If textual interconnections cannot be closed, for example because a block was deleted, they are reported in a log and can be edited manually later.

Procedure - Branching and Merging the Project Data 1. Copy a technological part of the project (for example, PH folder, several charts) to a different project. Result: The copy contains textual interconnections to all sources that were not copied. 2. Edit the copied section separately (add, delete, modify blocks and charts). 3. Copy this edited technological section back to the original project. Result: The system first deletes the charts with the same names in the original project. There are now textual interconnections in all charts that had connections to the deleted charts. The system then copies the chart or charts from the other project. 4. Close all "open" interconnections with the menu command Options > Make Textual Interconnections. Result: The interconnections are established again both in the charts edited in the other project and in the original project in which textual interconnections arose as a result of deleting charts.

Rules for Textual and Connections

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Charts should be inserted in other projects by copying them. The advantage of copying is that you retain a fully functional original project until the edited charts are returned.

•

When an interconnection is broken, neither of the interconnection partners must be renamed, otherwise the textual interconnection cannot be closed again.

•

Changes to charts in the original project are discarded when charts of the same name are returned to the original project from temporary projects.


Configuring PCS 7

•

An unwanted interconnection can result in the original project if, for example, cross-chart interconnections are modified in the temporary project and only one of the charts involved is returned to the original project. Example: Chart CFC_A as an interconnection to a block in chart CFC_B. Both charts are copied to a temporary project and edited. During editing, the interconnection between the charts is deleted. Only CFC_A is returned to the original project. A textual interconnection results in CFC_B of the original project, that can actually be closed. Result: The interconnection deleted in the temporary project reappears in the original project.

•

Textual interconnections created before copying/moving are included in the target project (temporary project). This might be a concrete path reference (that can be closed) or a character string (required connection that will only be configured in the target project).

Procedure - Merging Several S7 Programs into One S7 Program To merge S7 programs on workstations that are not networked, the individual blocks or sources must be copied and inserted in the target. Global data for the project, such as the symbol table of variable table must be edited manually. Follow the steps outlined below: 1. In the SIMATIC Manager, copy the blocks and sources to the appropriate folders of an S7 program. 2. Export the symbol tables of the individual S7 programs in ASCII format and import them into the symbol table of the merged S7 program. 3. Check whether any symbols are used twice. Tip: You can also integrate short symbol tables using the clipboard (copy and paste). 4. Copy the variable tables you want to use or integrate the various variable tables using the clipboard (copy and paste) into a new variable table.

Copying S7 Programs with Message Attributes If you have assigned message attributes to blocks, remember the following restrictions when copying S7 programs: Project-Wide Assignment of Message Numbers There may be overlaps in the message numbers. To avoid conflicts, follow the steps outlined below: •

Assign a fixed message number range to each S7 program with the menu command Edit > Special Object Properties > Message Numbers.

•

When copying S7 program is make sure that S7 programs are not overwritten.

•

Remember that only message types (FBs) can be programmed separate from the S7 program.

CPU-Wide Assignment of Message Numbers •

Programs can be copied within the project and from other projects without changing the message numbers.

•

When copying individual blocks, the message number changes and you must recompile the block to link the modified message number into the program.


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Copying a Program with Project-Wide Assignment of Message Numbers to a Project with CPU-Wide Assignment of Message Numbers •

If you want to copy a program in which message numbers were assigned project-wide to another project in which the message numbers were assigned CPU-wide, select the required program and then select the menu command File > Save As... and activate the "With Reorganization" option. This also applies if the project contains more than one program (more than one AS).

•

Default entries are made for the message attributes when they are copied.

Copying a program with CPU-wide assignment of message numbers into a project with project-wide assignment of message numbers You can only copy individual FBs with messages.

Caution The assignment of message numbers in the programs must be uniform within a project! If a block with messages that references a text library is copied to another program, you must also copy the corresponding text libraries or create another text library with the same name or change the reference in the message text.

Procedure - S7 Connections to Unspecified Connection Partners If you insert existing projects with S7 connections to unspecified partners into a multiproject, you can easily convert these S7 connections to cross-project S7 connections: 1. Merge the subnets over which the S7 connection runs, see "How to Merge Subnets from Different Projects into a Multiproject". 2. Open the "NetPro" application with the menu command Options > Configure Network. 3. Select the menu command Edit > Merge Connections. Result: PCS 7 automatically merges matching S7 connections.


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7.11.2

Creating CFC Charts (General)

CFC Charts and the CFC Editor To configure continuous processes in a plant, you use CFC charts that you create and edit with the CFC Editor. In these CFC charts, you insert blocks from the master data library or directly from the "PCS 7 Library Vx.x". The library includes blocks such as blocks for controlling a process or for monitoring measured values. The inputs and outputs of these blocks are interconnected directly in the CFC Editor and are given parameter values. While doing this, you are supported by the user-friendly graphic user interface of the CFC Editor. You will find the CFC charts in the plant hierarchy. They are always located in the hierarchy folders in which they have their technological significance. The "PCS 7 Library" also provides process tag types: These represent complete CFC charts for various process tags such as motors and valves.

Note You should store all the blocks, charts, process tag types etc used in the project in the master data library and then only access the master data library during configuration. This applies in particular to objects you have copied from a library and then modified for the project.

Note For detailed information on the CFC Editor or on the programming languages, refer to the online help and the relevant manuals.

Functions in the Form of Blocks In CFC, you work with ready-made blocks that have a specific function. You place these function blocks in the CFC chart, interconnect them, and assign parameters to them.

Block Type A type definition that specifies the algorithm, the type name, and the data interface (the input and output parameters) exists for each function block. The type definition also specifies the data types of the input and output parameters. These input and output parameters are known as block inputs and block outputs since this is how they appear in the graphic display of the block.


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Block Instance If you now place a block in your CFC chart, by inserting it in your chart, you create a block instance of this block type. Instance in this sense means that it is a usage of the selected block type. You can create any number of block instances from a particular block type. You can assign names to these block instances, interconnect them, and assign parameters to them without changing the functionality specific to the type. One useful aspect of this type instance concept, for example, is that following later central changes to the block type, these changes can be automatically made in all block instances.

Multiple Instance Blocks Functions can also be put together using different subfunctions. These subfunctions themselves are blocks and are put together to create a complex block (for example a closed loop control block that itself contains blocks including a signaling block and a control block. Multiple instance blocks can be created in CFC by interconnecting different blocks (functions) and assigning suitable parameters. This chart is then compiled as a block type.

Master Data Library In multiproject engineering, you work with the master data library. This contains the project master data (block types, process tag types etc.) for all projects of this multiproject. Please refer to the section "Introduction - Master Data Library".

Further information

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Manual CFC for S7; Continuous Function Chart and in the online help.

•

Section "Creating Process Tags from Process Tag Types (Multiproject)"


Configuring PCS 7

7.11.2.1

Overview of the Steps in Configuration

Requirement You have created a project structure (plant view) in the SIMATIC Manager in which you can configure CFC/SFC charts.

Procedure The following table lists the steps required to create the configuration. Step

Activity

Description

1

Creating the project structure

To work with CFC, you must have created a chart folder below the hierarchy level of the program folder with the SIMATIC Manager. CFC charts are stored in the chart folder.

Create blocks (optional) CFC works with ready-made blocks. These can be blocks from libraries, other programs, or types you created yourself. By compiling charts, you can create block types in CFC. 2

Import blocks (if they were not imported automatically by inserting blocks)

The way in which block types required for the project are included and in some cases imported depends on the PLC. By importing blocks, they are made known to CFC. The block types should be stored in the master data library.

3

Inserting blocks (into a CFC chart)

Blocks are inserted in the CFC chart by dragging them from a catalog. This creates a block instance with a name that is unique throughout the chart. You can create any number of block instances from each block type.

4

Set parameters for the blocks and interconnect them

You can assign parameters to or interconnect the inputs and outputs of the blocks: either with other blocks, nested charts or with shared addresses. You can specify textual interconnections at block/chart inputs whose interconnection target is not yet in the chart folder. This interconnection remains open until the referenced interconnected partner exists and the interconnection is then made using a menu command. Interconnecting means that values are transferred from one output to one or more inputs during communication between the blocks or other objects.

5

Adapt the runtime properties

The runtime properties of a block decide how the block is included in the run sequence within the entire structure of the PLC. These properties are decisive for the response of the target system in terms of reaction times, dead times, or the stability of time-dependent structures, for example closed loops. When it is inserted, each block is assigned default runtime properties. The block is installed in a task at a position that you yourself can select. You can change the position at which the block is installed and other attributes later if necessary.

6

Compiling CFC charts

During compilation as a program, all the charts of the active CPU are converted to machine code (compiler). If you compile as a block type, only the individual chart is compiled.

7

Downloading the CFC program

After compilation, you can download the CFC program to the target system.


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Interaction of CFC and the SIMATIC Manager When working with the SIMATIC Manager, remember the following points: •

You can only delete charts, chart folders and projects in the SIMATIC Manager when no chart in the particular chart folder or project is currently being edited in CFC.

•

Projects with CFC charts must not be saved on data media, neither using the "New Project" nor the "Save Project As" functions.

•

You should only generate the chart reference data using CFC. If you generate the reference data with the SIMATIC Manager, you will no longer be able to download changes to this program online.

Further information

7.11.2.2

•

Online help on CFC

•

Manual CFC for S7; Continuous Function Chart

•

Getting Started CFC for S7; Continuous Function Chart

How to Create a new CFC Chart

Creating the project structure The project structure is specified when you create the plant hierarchy. Here, you will find all the CFC charts. The assignment to the plant sections is specified in the plant view.

Requirement project with an S7 program has been created in the SIMATIC Manager.

Procedure How to create an empty CFC chart: 1. Select the required hierarchy folder in the plant view of the SIMATIC Manager. 2. Select the menu command Insert> Technological Objects > CFC. Result: An empty CFC chart with a default name is created and you can change it to meet your requirements. A new CFC chart consists of a chart partition with 6 sheets without further chart partitions.

Note The maximum length of a chart name is 22 characters. The name must not include the following characters: \ / . " %.

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Inserting a Chart in a Chart You can give a CFC chart I/Os so that, for example, it can be inserted in other charts and interconnected with blocks or CFC charts. By inserting charts in charts, you can create nested charts. A chart can also be inserted into another CFC chart without chart I/Os (for example when you want to create the chart I/Os later).

Further information

7.11.2.3

•

Online help on CFC

•

Section "How to Define CFC Chart I/Os"

•

Charts in charts: Manual Process Control System PCS 7; Getting Started Part 2

How to Insert Blocks into the CFC Chart.

Inserting Blocks in a CFC Chart Inserting a block involves selecting a block type in the master data library and positioning it in the CFC chart. You can insert blocks conveniently by dragging them from the master data library (or from the block catalog). When a block is inserted, it is assigned a name that is unique within the chart. The block that is inserted is an instance of the block type. You can create any number of block instances from each block type.

Note The comment of the block type is not included in the block instance.

Procedure 1. Select the CFC chart in the SIMATIC Manager 2. Select the menu command Edit> Open Object. Result: The CFC chart is opened in the CFC Editor. A new CFC chart consists of a chart partition with 6 sheets without further chart partitions. 3. Go to the "Libraries" tab in the catalog. Here, you will also see the master data library. 4. In the master data library, select the block type you want to insert and drag it to the chart. Result: An instance of the block type is created in the CFC chart. 5. Insert further blocks into the CFC chart in the same way.


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Each inserted block is given default runtime properties (these can be changed; refer to the section "Runtime Groups and Runtime Properties").

Note You can search for a block by specifying a block name in the input field of the catalog and then searching for it using the Find button (binoculars). If the text you entered is not found as a block name, CFC searches for a block with a corresponding comment. The folder (for example of the block family) in which the block is located is opened and the block is selected. With the "Find initial letter" check box, you can decide whether or not the search starts at the initial letters (restricted search) or whether part of a name or comment should be searched for (default: free search).

The Catalog in the CFC Editor If it is not already open, open the catalog using the menu command View> Catalog. In the catalog you will see three tabs: •

Blocks here you will find blocks sorted according to block families. You also find the blocks already being used below the name of the S7 program.

•

Charts: Here, you will find all the charts you created in the plant hierarchy. The chart currently open and displayed in the CFC editor is shown like a small open folder.

•

Libraries; Here, you will find all the libraries provided by PCS 7 and, of course, your master data library. If you have already made all the libraries you do not require in your project invisible with the "Hide" function, only the master data library is displayed.


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Configuring PCS 7

7.11.2.4

How to Assign Parameters and Interconnect the Blocks

I/Os of the Blocks Each block has a number of different I/Os. The I/Os of a block can be both visible or invisible: You can only see invisible parameters in the properties of the block but not in the representation in the CFC chart. To find an I/O quickly, you can click in the column head of the table and sort the column in ascending or descending order. You can specify which I/Os in the CFC chart will be visible and which will be invisible. You specify this in the properties of the block in the "Not Displayed" column by unchecking the check box of the relevant I/O to make the I/O visible in the CFC chart.

Procedure 1. Select the block in the CFC chart and select the menu command Edit> Object Properties. Result: The "Properties - Block" dialog box opens and the "General" tab is active. 2. Enter a unique name for the block instance in the "Name" box. The names of block instances must be unique in a CFC chart.

Note For blocks, the maximum length of the name is 16 characters (for nested charts 22 characters). The name must not include the following characters: \ / . " %.

3. Select the "Inputs/Outputs" tab. Here, you can set the parameters for all the I/Os of a block (values of the I/Os, hidden/visible, released for testing, relevant for archiving etc.). The "Name" column lists the names of all inputs and outputs.

Note If you change units or operator texts, these are no longer taken into account during block type import.

4. Once you have made all the parameter settings, confirm your entries with "OK". Result: The name is now displayed in the CFC chart in the header of the block. 5. Follow the same procedure to place further blocks in the CFC chart. 6. To interconnect, click on the required output of the block.


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7. Now click on the input of the block with which you want to interconnect the output. Result: The CFC Editor automatically creates a line indicating the interconnection.

Note The order of steps 6 and 7 can also be swapped. You can create further interconnections in the context-sensitive menu if the I/O is selected: •

Interconnection to address ...

•

Interconnection to runtime group ...

8. Make the other parameters settings and create the interconnections in the same way.

Note To make tracking easier, a connecting line can be displayed (this flashes in a different color both in the chart and in the chart overview). Flashing can be canceled again by clicking on the chart.

Configuring Archive Tags As of PCS 7 V6.1, block I/Os intended for operator control and monitoring can be marked for archiving in WinCC. You make the setting in the "Inputs/Outputs" tab in the "Archive" column. Possible identifiers are: •

No archiving

•

Archiving

•

Long-term archiving

The I/Os marked as relevant for archiving are created as archive tags when the OS is compiled and, if it does not already exist, a process value archive with the name "System archive" is created automatically and is used to store these archive tags.

Interconnecting with Process Pictures When you create the process pictures, you will interconnect the I/Os of the blocks from the CFC charts with objects in the process pictures. The name of tags is formed from the plant hierarchy, the CFC chart name, and the block name. You will find the name again as part of the tag name. The values of the I/Os are entered. After compilation, you will find the tag names in the WinCC tag management. When you compile (with the option active), the block icons are created in the pictures and the block instances interconnected to the process pictures.

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Further information

7.11.2.5

•

Online help on CFC

•

Interconnection with process pictures: Manual Process Control System PCS 7; Getting Started - Part 2

•

Archive tags: Configuration manual Process Control System PCS 7; Operator Station

•

Section "How to Assign Parameters and Interconnect the Blocks"

Runtime Groups and Runtime Properties

Creating Runtime Groups One runtime group is created automatically per CFC chart. All blocks of a chart are installed in the respective runtime group. This achieves shorter times when compiling changes to the CFC charts. The run sequence can be optimized by PCS 7. A run sequence optimized in this way should only be modified in exceptional circumstances. The sequence model available as of PCS 7 V6.0, provides optimum support when configuring the run sequence, multiuser projects and therefore distributed engineering. For more detailed information: refer to the section "How to Adapt the Run Sequence".

Optimizing the Run Sequence With this function, you can optimize the run sequence of a program according to the data flow so that there is as little dead time as possible when executing on the CPU. The optimization is separate for OBs/tasks and run-time groups. For more detailed information, refer to the section "How to Optimize the Run Sequence"


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7.11.2.6

Runtime Properties of the Blocks

Introduction This section describes some of the basics required to understand the runtime properties of blocks.

Runtime Properties The runtime properties of a block decide how the block is included in the run sequence within the entire structure of the CPU. These properties are decisive for the response of the target system in terms of reaction times, dead times, or the stability of time-dependent structures, for example closed loops. The runtime properties of the blocks have default settings but these can be adapted individually for each block. When it is inserted, each block is assigned default runtime properties. It is therefore installed in a run sequence in a task (OB). The tasks form the interface between the operating system of the CPU and the S7 program. Blocks can also be installed in run-time groups that are themselves installed in tasks (OBs).

Note When you create new chart, a runtime group is created automatically in which all the blocks of this chart will be installed.

Runtime Groups Runtime groups are used to structure tasks (OBs). The blocks are installed sequentially in the runtime groups. Runtime groups allow the blocks of a CFC chart to be handled individually. You can do the following with runtime groups:

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Deactivate or activate selected blocks of an OB. (Runtime groups are activated or deactivated using a block output of the data type "BOOL"). If a run-time group is deactivated, the blocks it contains are no longer executed.

•

Execute selected blocks with a specific scan rate (every nth number of cycles) and/or with a phase offset to achieve better load balance on the CPU.


Configuring PCS 7

•

If OBs contain a large number of installed blocks, these can be put together in smaller units. Advantage: Instead of creating one "large" FC when you compile each OB, "smaller" FCs are created depending on the number of runtime groups. If the program is modified later, only the runtime groups/FCs that actually contain modified blocks are given the "modified ID". This means that later compilations and online downloads of changes take far less time.

Note For the reasons listed above, make sure that you do not install too many blocks in an OB or in a runtime group. Otherwise, there will be no noticeable improvement in performance when you compile or download changes only compared with compiling and downloading the entire program. You must also take into account the startup OB (100), the error OBs (OB 8x) and any special OBs you may use.

Insert Point When you insert a block, the insert point of the block in the run sequence is fixed. As default, the rule is as follows: The block is inserted after the block displayed in the status bar of the CFC. One of the following is displayed in the status bar: •

When you first create a chart, the default of the specific PLC

•

The last newly inserted block (color code: black font on light-green background)

•

The block specified by the run sequence

The current insert point is displayed to the right in the status bar. It displays the task name (OBx), the chart and block name after which the next block will be installed in the run sequence when a block is inserted in the CFC chart.

Displaying Runtime Properties There are various ways in which you can display information about runtime properties •

Either for an individual block

•

Or for the entire CPU


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Runtime Properties of Single Blocks The runtime properties of each block are displayed in the part of the block header on a colored background.

•

Upper row: Name of the task in which the block is installed

•

Lower row (to the left of the slash): Position of the block or the runtime group in the task

•

Lower row (to the right of the slash): If the block is installed in a runtime group, position of the block in the runtime group; otherwise "-"

If a block is installed more than once, information is displayed for only one location of this block; this is the block in the task located first alphabetically. The block header can also include additional colored icons at the top left that indicate the processing status of the block: •

White exclamation point on a red background -> not being processed Example: EN input is static 0.

•

Black question mark on a yellow background -> processing unclear Example: EN input is interconnected.

Double-clicking on the field opens the execution order of the blocks. The block on which you double-clicked is selected. In the execution order, you can change the runtime properties of the blocks directly. (See Section "How to Adapt the Run Sequence")

Runtime Properties of all Blocks of a CPU You can obtain a total view of the run sequence with Edit > Run Sequence... (you can also edit the run sequence in this window) or with Options > Chart Reference Data... in the "Run Sequence" window.


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Configuring PCS 7

7.11.2.7

How to Adapt the Run Sequence

Introduction When you insert blocks in the chart, they are automatically installed in the run sequence. The installation position is decided by the "Predecessor for Installation". Certain blocks are also installed more than once in tasks depending on the entry in the task list assigned to the block type by the system attribute (S7_tasklist). Blocks with startup characteristics are, for example, also installed in OB100. You can see the other tasks in which the block is also installed in the dialog box of the properties, "General" tab under "To be installed in OBs/tasks".

Chart Installation Pointer The installation pointer decides the next insert point for installation in the run sequence. The following are distinguished •

Chart installation pointer

•

Block installation pointer

Procedure – Adapting the Run Sequence Start the run sequence editor in the CFC Editor with the menu command Edit > Run Sequence... Here, you can make the following adaptations: •

Move objects: SFC chart, runtime group or block

•

Remove a block

•

Install blocks

•

Set installation pointers

Moving Objects You move an object by selecting it (SFC chart, runtime group, or block) in the right or left window and then dragging it to the object after which you want to install it. If you drag an object to a run-time group, •

the object is installed at the first position within the runtime group when the structure is expanded [-].

•

the object is installed after the runtime group is the structure is not expanded [+].

•

and the runtime group is empty, you will be asked whether or not you want to install the block within the runtime group. If you answer with "yes", it is installed inside the run-time group, if you answer with "no" it is installed after the runtime group.


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If you drag an object to a task, it is installed before the objects already installed.

Note When moving blocks, remember that according to the improved run sequence model as of PCS 7 V6.0, all blocks of a chart are located only in the corresponding runtime group. After moving a block to another group, the chart-oriented structure no longer exists and would make it difficult or even impossible to work on a chartby-chart basis in multiuser engineering.

Removing a Block You can only remove (delete) blocks from a task if it is installed more than once in the run sequence. At least one insert point must remain. If this was the only block installed, it will not be deleted. Otherwise, the block is deleted and the run sequence of the blocks following it are adapted.

Installing Blocks: You can also install blocks, runtime groups, or SFC charts more than once by copying and pasting using the relevant menu commands or the buttons in the toolbar or by dragging them while holding down the Ctrl key (see also: Moving Objects). You can also install blocks (if you have the windows displayed simultaneously) by dragging them directly from a CFC chart to the required position in the run sequence.

Note Objects with the "@" system identifier were automatically installed in the run sequence when the module drivers were generated and should only be manipulated with the function in the SIMATIC Manager Options > Charts > Generate Module Drivers...; in other words, they should not be moved or deleted manually.

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Setting Installation Pointers You can modify the installation pointers as follows: •

Chart installation pointer (default OB35) To modify the chart installation pointer, open the runtime editor and select the required OB or a block at the OB level (not within a runtime group) or a runtime group within the OB. In the runtime editor, select the menu command "Edit > Predecessor for Installation".

•

Block installation pointer You cannot set the block installation pointer in the runtime editor. To modify the block installation pointer, open the CFC Editor and select the block after which all other blocks will be inserted. In the chart, select the menu command Edit > Predecessor for Installation.

If the block selected as the predecessor for installation is deleted, the block installation pointer is decremented; in other words, set to the block installed before the deleted block. This also applies if the block is moved to a different chart. The block installation pointer in the destination chart is not changed. The moved block retains the installation position it had in the previous chart.


7.11.2.8

Online help on CFC

How to Optimize the Run Sequence

Note When you insert blocks in the CFC chart, they are automatically installed in the run sequence.

Procedure You start the optimization in the runtime editor using the menu command Options > Optimize Run Sequence.

Selecting Individual Elements In the runtime editor, you can enable or disable elements for optimization. You make this selection for the selected task in the Object Properties. In the runtime editor, the selection is indicated by an additional symbol (blue circle with slash) on the element icon. You have the following options: •

Optimizing an entire task including all enabled runtime groups (option: OB/task and runtime groups). This is the default setting.

•

Optimizing only the enabled runtime groups of a task (option: Runtime groups only).


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•

Excluding the entire task including the runtime groups it contains from the optimization (option: None).

Note • You can enable optimization of an individual runtime group in the Object Properties of the runtime group, option: Optimization run sequence (this option is set as default). This means that you can remove individual runtime groups from the optimization by resetting this option. •

The content of runtime groups, created by the driver generator ("Generate Module Drivers" @......) are not optimized since the correct order is already set here.

•

If you optimize before creating the module drivers, there is no guarantee that the runtime groups of the driver blocks are in the order specified by the driver generator. The module driver is therefore started again the next time you compile (option "Generate Module Drivers" is set and cannot be deselected).

What Happens during Optimization? This is handled separately for each task. Within a task, the run-time groups are handled extra. The scan rate and phase offset of a run-time group are ignored. The data flow is obtained from the interconnections. These include all block-block interconnections as well as those two SFC charts and interconnections of block outputs to ENABLE a run-time group. Global and textual and connections are not taken into account. Interconnections to the chart interface contract as far as the actual source of the interconnection. Interconnections into a runtime group or out of a runtime group are considered to be interconnections of the runtime group itself. Interconnections between the blocks of a run-time group are used only for optimization within the run-time group. This ensures that the run-time groups are correctly arranged on themselves and that the run-time group itself is placed at the optimum position within the task. Subsequent optimizations are designed so that no unnecessary changes are made and that the scope of changes is kept as limited as possible when changes are compiled and downloaded.

Caution If blocks are interconnected over INOUT parameters, the data flow may be reversed; in other words, from input to output. This cannot be taken into account when optimizing the run sequence. Remedy: In this case, you must optimize the order yourself and exclude the relevant runtime group from the optimization.

Caution With cascaded interconnections and other connections with several return jumps, runtime group optimization should be deactivated for the runtime group.

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7.11.2.9

How to Define CFC Chart I/Os

Creating a Chart with a Chart I/Os You can provide a chart with I/Os to extend your options such as •

Inserting in a different path and interconnecting with other charts all blocks (chart-in-chart technique).

•

Compiling as block type.

There are two methods, as follows: •

Creating chart I/Os without an assignment

•

Creating the chart I/Os with the interconnection

Procedure - Creating Chart I/Os without an Assignment In the first step, you create the I/Os for a chart without reference to any parameters (for example because the chart does not yet contain blocks and/or further nested charts. You assign the names, attributes, and defaults to the chart I/Os. In the second step, you place the blocks/charts in the chart, interconnect them and then assign the I/Os of the objects in the chart to the chart I/Os. 1. Select the menu command View > Chart I/Os. Result: The dialog for editing chart I/Os is opened and "docked" to the upper part of the chart window. 2. In the hierarchy window on the left, select the required I/O type (IN, OUT or INOUT). 3. In the detailed window on the right, edit the empty declaration line for the particular I/O type (name, data type, initial value, comment). You select the data type from a drop-down list box. Note If you use this method, the attributes (for example S7_m_c) of the block I/O are not adopted. You must then assign the attributes to the chart I/Os yourself.

Procedure - Interconnecting Chart I/Os 1. Drag an I/O of the block/chart to one of the chart I/Os with a compatible data type. As an alternative with existing chart I/Os: You can assign the I/Os of the blocks placed in the chart and/or nested charts to the existing chart I/Os without needing to open the chart inputs/outputs dialog. 1. Select the I/O and select the menu command Insert > Interconnection to Chart I/O... Result: A dialog opens with a list of all the available I/Os of the I/O type. 2. Select the required chart I/O and close the dialog box with "OK". Note You can only assign unconnected I/Os with a compatible data type.


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Procedure - Creating the Chart I/Os with the Interconnection In the first step, you create the chart itself; in other words, you insert blocks/charts and interconnect them. In the second step, you open the window of the chart inputs/outputs and define the chart I/Os by connecting them to I/Os of blocks/charts placed in the chart. A new row is always inserted and all the properties of the connected I/O are adopted for the chart I/O (name, attribute and initial value). If naming conflicts occur, for example because the same names are used in different blocks, the name is made unique in the chart I/O by incrementing it. Create chart I/Os by connecting with drag and drop: 1. Select the menu command View > Chart I/Os. Result: The dialog for editing chart I/Os is opened and "docked" to the upper part of the chart window. 2. In the hierarchy window on the left, click the I/O type you require (IN, OUT or INOUT). Result: The rows with I/Os are displayed in the detailed window on the right (this is still empty if you are creating new chart I/Os). 3. In the working field of the chart, select the required I/O of the block and drag the I/O to the right-hand window of the chart I/Os to the "Name" box. Result: The I/O is then entered with all its properties. Exception: No new assignment is made for interconnected I/Os. 4. Follow the same procedure for all the other I/Os of the blocks/charts in the chart you want to interconnect with the chart inputs/outputs. Drag an I/O that already exists in the chart I/Os to another empty line in the Chart I/Os window; the name automatically has a number added to it so that the I/O name is unique. Drag an internally interconnected I/O (input) to a new line. A copy is made and no interconnection to the internal I/O is made.

Entries in the Sheet Bar The sheet bar displays the I/O names and comments, I/O type, and data type applied to the chart I/Os. The "interface I/O" type of interconnection is indicated by a small white triangle above the interconnection line. Note If an I/O that is connected with the chart interface is made invisible, there is no sheet bar entry. The interconnection can then only be recognized by the object properties of the block (tab: I/Os, column: Interconnection).

Changing Chart I/O Names The chart I/O name does not need to include the name of the assigned block I/O. You can rename it by selecting the name in the "Name" box and entering a new one. As an alternative, you can double-click on the start of the line of the chart I/Os in the right-hand window and enter the new name in the Properties dialog.

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System Attributes Just like the block I/Os, you can also assign system attributes to the individual chart I/Os. The following rules apply: •

If an I/O is reconfigured by dragging it to define it as a chart I/O, it adopts the system attributes of the block I/O.

•

If a predefined chart I/O is interconnected with a block I/O, you must define the system attributes yourself - there are not adopted from the block I/O.

A chart with chart I/Os does not have system attributes itself (apart from those of the I/Os).

Assigning I/Os when the Charts are Already Placed You can also extend a chart with chart I/Os later by adding further chart I/Os. If the chart is a nested chart, in other words, a chart already placed in another chart, the added I/Os may cause positioning conflicts. In this case, the nested chart is displayed as an overlapping chart just like an overlapping block; in other words, light gray and without I/Os. Once the chart is positioned at a free location, the I/Os and interconnections are visible again. If you already placed a chart in the chart and interconnected it and now changed the original chart (for example by adding a further I/O), drag the modified chart over the original chart. The old chart is replaced by the new one. The existing connections are retained.


Online help on CFC

7.11.2.10 How to Compile CFC Charts

Introduction CFC charts must be compiled into a code that the CPU of the AS can understand. Since compilation always includes all the charts of an S7 program, you should only start at the end of the compilation.

Procedure 1. In the CFC Editor, select the menu command Chart > Compile > Charts as Program. Result: the "Compile Program" menu opens. 2. When necessary, activate the following options: -

Update sampling time

-

Delete empty runtime groups

-

Generate module drivers (see also online help)

3. Confirm the dialog box with OK. Process Control System PCS 7 - Engineering System A5E00346923-02

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"Generate module drivers" Option You should only set the "generate module drivers" option if you have changed something in the configuration of the signal-processing blocks and the configuration of the hardware since the last compilation or you have configured something for the first time. If the option is not set, the driver generator is not called and the time required for compiling is shorter. If this option is set, the module drivers for the existing signal-processing blocks are generated by the driver generator and interconnected with them prior to compilation. (You should also refer to the Section "How to Generate Module Drivers").

Note If the check box is disabled (grayed) but the check mark is set, the "Optimize Run Sequence" function was run after the module drivers were generated. The driver blocks are therefore no longer in the prescribed order and the driver generator must be started again prior to compilation. The optimized run sequence of the other blocks and runtime groups is not affected so that optimization does not need to be repeated. If you optimize before creating the module drivers, there is no guarantee that the runtime groups of the driver blocks are in the order specified by the driver generator. The module driver is therefore started again the next time you compile (option "Generate Module Drivers" is set and cannot be deselected).

Customizing the Compiler With the Options > Customize > Compilation/Download... menu command, you open a dialog box in which you will see information about the resources used in conjunction with compiling charts. You have the following options: •

you can decide which warning limits will apply so that possible dangers are detected before you download.

•

you can decide which resources should remain unused during compilation of the charts of the current chart folder. This can, for example, be useful if you want to solve an automation task partly with charts and partly by programming (for example, STL, LAD or SCL programs) and when you have functions (FCs) or data blocks (DBs) from other sources in your user program.

•

view the statistics showing how many resources (DBs, FCs) are available for compiling the charts and how many are already being used.

Note If you work only with CFC and SFC in your program, you can leave the standard compilation settings unchanged. You will find an overview of the blocks generated during compilation in the online help.

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Central Function "Compile and download objects" Note You can compile and download all objects centrally in the SIMATIC Manager with the menu command PLC > Compile and Download Objects. You are supported here by PCS 7. This dialog lists all objects of the multiproject that can be compiled or downloaded. Use this function, the hardware configuration should have been downloaded to the CPU once (initial commission of the automation station).


Section "How to Download CFC Charts to the CPU"

•

Section "Downloading to All CPUs"

•

Online help on CFC

7.11.2.11 How to Download CFC Charts to the CPU

Downloading CFC Charts After compiling the charts, you download them to the CPU and can then view the current process state in test mode. The program is downloaded to the CPU assigned to the active chart.

Requirement Before you can download, there must be a connection between the CPU and your PC.

Procedure 1. Select the menu command PLC > Download in the CFC Editor. Result: A dialog opens in which you can decide how the download will be performed ("Scope" and "Include user data blocks"). 2. Select the scope: -

Entire program The entire content of the "Block" folder is downloaded and, following a prompt, the CPU is set to STOP.

-

Changes only The CPU can be in the "RUN-P" mode. The download of the modified blocks is as safe as possible (bumpless) to avoid the CPU changing to "STOP".


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Note Please remember, however, that it is not possible to fully exclude the risk that the CPU nevertheless changes to STOP. The reasons for this include, for example temporary inconsistencies that cannot be checked by the loader (for example local requirements of blocks that do not include reference lists).

-

Option: Include user data blocks This option is set as the default and is only relevant when you download changes (in other words, when you download the entire program, all the blocks are downloaded including the user data blocks).

3. Complete the dialog with "OK". Result: If download-relevant changes have been made to the user program, a message is displayed indicating that the program must first be compiled and you are asked whether you want to compile and then download.

Note With the programs created in CFC, you must download to the PLC from CFC, since only this download function guarantees the consistency of the configuration data with the CPU data. The same download function is also used when you select the menu command "PLC > Compile and Download Objects" or select the chart folder and PLC > Download in the SIMATIC Manager.

Further information

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•

Section "How to Compile CFC Charts"

•

Section "Downloading to All CPUs"

•

Online help on CFC


Configuring PCS 7

7.11.2.12 How to Test CFC Charts

Introduction The Test mode relates to the CPU belonging to the active CFC chart. To support you during commissioning, the CFC editor provides test functions that allow you to monitor and influence the execution of the blocks on the CPU and, if required, to change settings. As alternatives, the Test mode can be run in two modes: •

Process mode

•

Laboratory mode

Process mode (default setting) In process mode, the communication for online dynamic display of the blocks is restricted and causes only slight extra load on the CP and bus. When Test mode is activated, all blocks have the status "watch off".

Laboratory Mode The laboratory mode allows convenient and efficient testing and commissioning. In the laboratory mode, in contrast to the process mode, communication for online dynamic display of charts is unrestricted. When Test mode is activated, all blocks have the status "watch on".

Requirement Testing is possible only when there is a connection between the CPU and your PC and the program has been downloaded.

Procedure You can select the mode for the test in the CFC Editor using the menu commands in the "Debug" menu. It is not possible to change over once you are in Test mode. •

Activating Test Mode: Select the menu command Debug > Test Mode in CFC. The Test mode is activated. You can now activate the debug menu functions; Most of the functions of the Edit mode become inactive.

•

Deactivating Test Mode Select the menu command Debug > Test Mode in CFC again. The Test mode is deactivated. When you deactivate the Test mode, the debug functions become inactive and the functions of the Edit mode are activated again.


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Troubleshooting From within the CFC chart, you can open the block type belonging to a block instance. In the CFC chart, select the menu command Edit > Go To > Block Type. If the source file of the block is included in the project, the tool with which it was created (LAD/FBD/STL or SCL) opens with which you can edit the block type. If the source file is not in the project, LAD/FBD/STL is nevertheless opened. You can then only read the block information (exception: The system attributes of the I/Os are editable). If an SFC instance is selected in the CFC chart, the corresponding SFC type is opened in the SFC editor.


Online help on CFC

•

Manual Process Control System PCS 7, Getting Started - Part 1

•

Manual CFC for S7; Continuous Function Chart

7.11.2.13 How to Use the Trend Display in Test Mode

Trend Display The trend display is a tool in the CFC editor that allows you to track the values of one or more signals on a CPU qualitatively over time. The trend display shows the signal continuously over time while it is being recorded. The trend display works with any target system that supports normal online operation.

Rules for the Trend Display •

Only one trend display can be active in the trend display window at any one time.

•

A maximum of 8 values can be recorded at any one time.

•

For each CPU, you can create and manage any number of trend display data records. Each display is given a name that must be specified when it is created (this can be changed).

•

Both simple numerical data types (BYTE, INT, DINT, WORD, DWORD, REAL) and Boolean values can be used.

•

In the online display, it must be possible to make the value dynamic in the chart.

•

In each display, the following data is saved in the chart folder:

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-

The name of the display

-

The allocation of the channels

-

The acquisition parameters

-

The display parameters

-

The last curve recorded (if it exists)

The recording cycle can be set in a range from 1 - 90 seconds. Process Control System PCS 7 - Engineering System A5E00346923-02

Configuring PCS 7

Procedure •

Open the trend display The window of the trend display can be opened for each CPU with the menu command View > Trend Display.

•

Set the trend display With the trend display open, set -

the number of measuring points for the time axis in the "Display" area

-

the current mode of the trend display and any abort conditions in the "Recording" area with the "Change" button.

•

Start/hold trend display If test mode is active for the current CPU, recording can be controlled in the "Recording" area with the "Start"/"Hold" button.

•

I/O assignment to a channel The assignment of an input/output to a channel can be specified when the trend display is open using the Debug > Inputs/Outputs > Insert in Trend Display menu command.

•

Export trend display If the trend display is open, the export format can be set using the menu command Options > Settings > Export Trend Data. With the "Export" button, you can export the current trend display in a format that can be read with Excel.


Online help on CFC

7.11.2.14 How to Configure the AS Runtime Measurement

AS Runtime Measurement To avoid runtime errors in new and modified configurations, it is advisable to monitor the execution time of the OBs. In the configuration described below, the warning limits can be set to any value. You can signal the warning limits over the PCS 7 OS. The runtime is measured with the TIME_BEG and TIME_END blocks (known as a block pair below). For the warning limits, you also require the MEAS_MON block.

!

Warning • Only qualified personnel should work on process control systems. •

Keep to the plant-specific and legal regulations when making changes to a plant.

•

Note the plant-specific constraints and adapt the version accordingly.

•

Remember at all times that changes to a plant can have effects on other parts of the plant.


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Procedure 1. Create a new chart in CFC (runtime monitoring ASNo x). 2. Place a block pair in this chart for in every cyclic interrupt OB. 3. Connect the "TM" I/Os of a block pair. Assignment of the Blocks to the Cyclic Interrupt OBs 1. Select a TIME_xxx block. 2. Select the menu command Edit > Run Sequence. The "Runtime Editor" dialog is opened. The selected block is indicated in the block structure. You will also find the other block pairs in this OB. Move one block pair into each cyclic interrupt OB. 3. Place the TIME_BEG block as the first block in the cyclic interrupt OB. 4. Place the TIME_END block as the last block in the cyclic interrupt OB. 5. Place the MEAS_MON block and interconnect it if you also require warning limits. 6. Repeat step 3 (4) or 5 for all blocks of the type TIME_BEG and TIME_END. Assign names to the TIME_BEG and TIME_END blocks Assign the names before distributing to the individual editors. 1. Select a TIME_xxx block. 2. Select the menu command Edit > Object Properties. The "Properties Block" dialog box opens. 3. Enter a symbolic name for the block in the "Name" field (for example cyc36ob and cycob36 for the block pair for measuring the cycle time in OB36). 4. Confirm your entry with "OK". 5. Repeat step 1 through 4 for all blocks of the type TIME_BEG and TIME_END. Displaying the Cycle Time 1. Compile the chart created in step 1 and download to the AS. 2. In the online mode, you will see the runtime of the OB at the output TM_DIFF of the TIME_END block.

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Notes on Troubleshooting You can reduce the execution time of an OB by installing the runtime groups with scan rates and phase offsets, or calling blocks in other OBs. If you can increase the cycle monitoring time, this will be possible in HW Config (Properties of the CPU, "Cycle/Clock Memory" tab). If there is a CPU stop due to failure of I/O components, the use of the SUBNET block can help. The effect of the SUBNET block is that when an error OB (for example OB 86, rack failure) is called, only the driver blocks that signaled the error execute. This reduces the execution time necessary.


Online help on CFC

•

For help on specific blocks, first click the "?" button in CFC and the click on the header of the block.


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7.11.3

Programming SIMATIC Connections You have already configured the connections in NetPro. During the configuration, you decided which AS will exchange data with which AS (AS-AS communication). The values that you send over the connections created in NetPro must now be interconnected with the blocks installed in the CFC charts for sending and receiving the values. The communication blocks required for this are supplied with PCS 7.

7.11.3.1

Blocks for Different Connection Types The following table shows you an overview of the of the communication blocks available in PCS 7 for AS-AS communication (S7 connection). You will find these blocks in CFC in the library (PCS 7 Library V60 > COMM).

Blocks Available for S7 connections Symbolic Name

Brief Description

SEND_BO REC_BO

Exchange of up to 128 binary values between a send SFB and a receive SFB.

SEND_R REC_R

Exchange of up to 32 binary and 32 real values between a send SFB and a receive SFB.

SEND_BO The block sends up to 128 BOOL values over an Industrial Ethernet connection to other S7-CPUs that must then call the function block type "REC_BO" (FB208) of the PCS 7 Communication library to receive the data. The consistent data are available in REC_BO only on completion of the job (in other words, after arrival of the DONE = TRUE acknowledgment). The acknowledgment is recognizable by a signal change to 0 at the output CIW. By applying the value 1 to the FAST parameter, the FB allows the sending of a frame per function block call. It is, however, only practical to use this fast send job sequence when the frame can be transmitted in the time available between two FB calls.

REC_BO The block receives 128 BOOL values over an Industrial Ethernet connection from another S7-CPU that must then call the function block type "SEND_BO" (FB207) of the PCS 7 Communication library to send the data. In STEP 7, a homogeneous transport connection must be set up for this purpose and transferred to the automation system. The data is available only on completion of the job when the signal at output NDR changes from 0 to 1.

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SEND_R The block sends up to 32 BOOL and 32 REAL values change-driven over an Industrial Ethernet connection to another S7-CPU that must then call the function block type "REC_R" (FB210) of the PCS 7 Communication library to receive the data. The consistent data is available in REC_R only on completion of the job (in other words, after arrival of the DONE = TRUE acknowledgment). The acknowledgment is recognizable by a signal change to 0 at the output CIW. By applying the value 1 to the FAST parameter, the FB allows the sending of a frame per function block call. It is, however, only practical to use this fast send job sequence when the frame can be transmitted in the time available between two FB calls.

REC_R The block receives 32 BOOL and 32 REAL values over an Industrial Ethernet connection from another S7-CPU that must then call the function block type "SEND_R" (FB209) of the PCS 7 Communication library to send the data. In STEP 7, a homogeneous transport connection must be set up for this purpose and transferred to the automation system. The data is available only on completion of the job when the signal at output NDR changes from 0 to 1.

7.11.3.2

How to Program the SIMATIC Connections

Introduction You have configure the connection in NetPro, in other words, you have defined that communication will take place between two communication partners. In the CFC configuration, you must place the relevant communication blocks in the CFC chart and assign parameters to them (ID that you assigned in NetPro; frame ID R_ID; data to be transferred etc.).

Connection ID A connection is identified by its ID (connection identifier). Several frames can be exchanged on one connection and they are identified by the R_ID (frame identifier). The ID establishes the connection between the hardware (logical connection on the CP) and the software (FB). Since several jobs (SEND/REC block pairs) can be handled on one connection, the R_ID its used for identification.


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For each frame that is transferred over a connection, a block pair (send, receive) must exist in the CFC chart. This means that you must configure a send block in the sending CPU and a receive block in the receiving CPU. AS2 REC_BO

AS1 SEND_BO R_ID=1

FB 207

Local ID

Remote ID

FB 210

FB 209

FB 209

R_ID=2

REC_R

SEND_R R_ID=3

R_ID=1

SEND_R

REC_R R_ID=2

FB 208

S7 connection ("pipe")

FB 210

R_ID=3

Requirement The connection between the automation systems involved is configured in NetPro.

Principle Procedure 1. Create a CFC chart in the sending CPU with a send block (SEND_BO). 2. Assign parameters to the block and interconnect it (ID, R_ID, BO_00 ... BO_127 etc.). 3. Create a CFC chart in the receiving CPU with a receive block (REC_BO). 4. Assign parameters to the block and interconnect it (ID, R_ID, RD_BO_00 ... RD_BO_127 etc.). 5. Follow the same procedure for each S7 connection you want to configure. 6. Compile, download and, if necessary, test the configuration. Follow the same procedure if you use the SEND_R and REC_R block pair.

Further information

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•

Online help on CFC

•

For help on specific blocks, first click the "?" button in CFC and the click on the header of the block.


Configuring PCS 7

7.11.4

Programming the Connection to the I/O (Driver Blocks)

7.11.4.1

Concept of the Driver Blocks

Introduction The interface to the I/O (driver concept) described below was developed to ensure high performance even in large systems. Care was taken to ensure that configuration was both fast and simple.

Why Use Driver Blocks? In process control systems, diagnostics/signal processing must meet certain requirements. This includes the reading in of a hardware signal to the CPU and also the test information relating to the hardware signals, for example module/channel fault. To allow this, driver blocks are available in the PCS 7 library that implement the interface to the hardware including test functions. The driver blocks therefore have two purposes: •

On one hand, signals from the process must be made available to the AS for further processing

•

On the other hand, modules, DP/PA slaves and DP master systems must be monitored for failure

When the process signals are read in, the driver blocks access the process input image (or process image partition) (PII) and when outputting the process signals, they access the process output image ( or process image partition) (PIQ). The various tasks are performed by different blocks: Refer to the section "List of Driver Blocks".

Driver Concept The driver concept of PCS 7 is characterized by the separation of user data processing (channel blocks) and diagnostic processing (module blocks), the symbolic addressing of I/O signals and the automatic generation of module blocks by CFC.

Time-optimized Processing To allow time-optimized processing during runtime, the organization blocks for error handling (for example OB85, OB86 etc.) are automatically divided into runtime groups and the driver blocks installed in the relevant runtime groups. If an error or fault occurs, the SUBNET block activates the relevant runtime group, the RACK block or module block contained in the runtime group detects the problem, evaluates it and outputs a control system message to the OS. The diagnostic information of the module block is also transferred (output OMODE_xx) to the corresponding CHANNEL block (input MODE). If necessary, this information can be displayed in a process picture (color of the measured value changes or flashing display etc.) by a PCS 7 block that can be operated and monitored on the OS or by a user block. Process Control System PCS 7 - Engineering System A5E00346923-02

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7.11.4.2

List of Driver Blocks The following tables define the distribution of functions of the driver blocks and the signal-processing blocks: Driver Blocks

Block Description

Purpose

How They Are Generated

OB_BEGIN, OB_END

CPU diagnostics and connection diagnostics

1)

SUBNET

Monitoring of DP master system

1)

RACK

Monitoring of station/rack and DP slaves

1)

MOD_1, MOD_2, MOD_3, MOD_4, MOD_D1, MOD_D2, MOD_MS, MOD_CP, MOD_HA

Monitoring of I/O modules, motor starters, communication module, HART field devices

1)

CONEC

Monitors the status of the connection of an AS and reports error events

1)

OB_DIAG1

Interface of a block for DP/PA slaves complying with DPV0/V1

1)

DPDIAGV0

Monitors the status of the modules of an ET 200S as DP V0 slave (IM 151-1 High Feature) downstream of a Y-Link

1)

IM_DRV

Transmission of time-stamped process signal changes and non signal-specific events (special messages) to the OS

1)

PO_UPDATE

Executes the functions "Hold last value" and "Use substitute value" of the output modules when a CPU is restarted (OB100)

PS

Monitors the status of a power supply of a rack and reports error events

1)

PADP_L00, PADP_L01, PADP_L02

Monitoring of DP/PA field devices (DPV0 slaves) downstream from a DP/PA or Y link operated as a DPV0 slave.

1)

PADP_L10, MOD_PAX0, Monitoring of PA field devices (DPV0 slaves) downstream MOD_PAL0 from a DP/PA or Y link operated as a DPV1 slave.

1)

PA_TOT

Processes the cyclic parameters of the "Totalizer" PA profile of a PA Field device complying with Profibus PA 3.0 class A and B

1)

DPAY_V1

Monitoring of DP/PA and Y link as DPV1 slave

1)

DPAY_V0

Monitoring of DP/PA and Y link as DPV0 slave

1)

DREP, DREP_L

Evaluation of the diagnostic data of a SIMATIC diagnostic repeater for PROFIBUS-DP

1)

FM_CNT

Parameter assignment and control of FM 350-1 and FM 350-2 modules

1)

OR_M_16, OR_M_32

Obtains the value status from a redundant signal module pair

1)

RCV_341

Serial reception with the CP 341

1)

SND_341

Serial transmission with the CP 341

1)

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Signal-processing Blocks Block Description

Purpose

No. Created

CH_U_AI, CH_U_AO, CH_U_DI, CH_U_DO

Signal processing of S7-300/400 SM I/O modules or a PA field device.

2)

CH_AI, CH_AO, CH_DI, CH_DO, CH_CNT, CH_CNT1, CH_MS

Signal processing of S7-300/400 SM I/O modules.

2)

PA_AI, PA_AO, PA_DI, PA_DO, PA_TOT

Signal processing of PA field devices with PA profile

2)

1) Created automatically with the "Generate Module Drivers" option 2) Performed automatically with the option "Generate Module Drivers"; the parameter assignment/interconnection is made in the CFC chart

7.11.4.3

How to Generate Module Drivers

Automatic Generation of Module Drivers You can have the required module drivers and corresponding interconnections of the signal-processing blocks of a selected chart folder generated automatically. This automatic generation must be activated.

Procedure 1. Open the SIMATIC Manager and the project in which you want to generate the drivers. 2. Select the chart folder of an S7 program in the component view (make sure no charts are selected in this chart folder). 3. Select the menu command Options > Charts > Generate Module Drivers. As an alternative, you can set the option "Generate Module Drivers" in the "Charts as Program" dialog in CFC when compiling CFC/SFC charts. Each time you recompile, the required module drivers will be generated or updated. 4. Select the required options and confirm with "OK".

Caution If modifications are made to the driver blocks during configuration (for example extension of existing blocks or installation of new blocks etc.), the menu command "Generate Module Drivers..." must be activated again at the latest on completion of the configuration.


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Compiling Note You should only set this "generate module drivers" option if you have changed something in the configuration of the signal-processing blocks and the configuration of the hardware since the last compilation or you have configured something for the first time. If the option is not set, the driver generator is not called and the time required for compiling is shorter. If the option is disabled (grayed) but the check mark is set, the "Optimize Run Sequence" function was run after the module drivers were generated. The driver blocks are therefore no longer in the prescribed order and the driver generator must be started again prior to compilation. The optimized run sequence of the other blocks and runtime groups is not affected so that optimization does not need to be repeated.

How the Function Works The "Generate Module Drivers" function generates new system charts (with the name "@..." assigned by the system) in which only driver blocks are inserted by the driver generator that are assigned parameters and interconnected according to the hardware configuration. In addition to this, the channel blocks installed in the user charts are interconnected with the driver blocks by the driver generator if the symbolic interconnection information exists. Each system chart can contain a maximum of 52 blocks. The OB_BEGIN-/OB_END blocks for one CPU, RACK blocks for one rack and the MODUL blocks are installed in runtime groups. The runtime groups created by the driver generator are assigned an ID, so that, for example, they can be deleted automatically again when they no longer contain blocks. Run-time groups without this ID are not processed by the driver generator. If RACK/MODULE blocks are installed in a different run-time group by the user, they are moved to the run-time groups with the relevant ID by the driver generator. Caution There must be no intervention in the system charts since these involve system functions (indicated by "@"). This also applies to changes to the installation in OBs or runtime groups.

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Parameter Assignment/in Connection in a CFC Chart The assignment of the signal-processing blocks (channel blocks) to the channels of the modules is based on symbolic names. You have already assigned a symbolic name for each channel of a module in the hardware configuration. The signal-processing blocks have a block I/O labeled "VALUE". You specify the symbolic name of the module channel at this I/O (select the I/O in CFC > press the right mouse button > Interconnection to Address...).


7.11.4.4

Section "How to Configure the Distributed I/O"

How to Create Your Own Driver Blocks

Drivers for Peripheral Devices or I/O Modules not Integrated for Use in PCS 7 The driver concept covers the I/O devices and I/O modules currently released for use in PCS 7. You will find the released I/O devices and I/O modules in the hardware list "PCS 7 - Released Modules.pdf" on the Toolset CD "Process Control System PCS 7 Software".

Procedure If you want to connect other peripheral devices or I/O modules to the AS in a concrete configuration, you can create the driver blocks yourself using the driver concept (one block per device with user data and diagnostic data processing). You then store the driver blocks you have created in the master data library. You can then use them in the same way as the supplied driver blocks (signalprocessing blocks and diagnostic blocks).


Manual Process Control System PCS 7; Programming Instructions Driver Blocks


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7.11.5

Creating Process Tags from Process Tag Types (Multiproject)

Introduction Using the wizard for process tag types, the process tag type is copied from the master data library to the specified target projects as a process tag and the corresponding data is then imported. This is based on an import file. Depending on the entries in the import file, you can create any number of process tags in one import action. As a result of the import, a process tag of this process tag type is created in the target project for every row of the import file according to the specified hierarchy path in the plant hierarchy.

Sources for Process Tag Types You can store the following in the master data library: •

Standardized process tag types from the control system library PCS 7 Library, for example for motors, valves, PID controllers etc.

•

User-created process tag types from CFC charts

Overview Creating process tags from process tag types and subsequent editing of the tags involves the following topics:

7.11.5.1

•

How to Create a Process Tag Type from a CFC Chart

•

How to Modify a Process Tag Type

•

How to Add a Process Tag Type to a Project

•

Automatic Creation of a Number of Process Tags

•

How to Edit a Process Tag

•

How to Adopt Process Tags

•

How to Synchronize Process Tags with the Process Tag Type

•

How to Restore Lost Process Tag Type Assignments

How to Create a Process Tag Type from a CFC Chart

Options for Creating a Process Tag Type You have the following options: •

Creating a process tag type with a new or existing CFC chart.

•

Modifying and existing process tag type; in other words, adding or removing I/Os or messages. These modifications may be necessary due to a change of the functionality in the CFC (for example interconnections or parameter assignment changed, blocks added or deleted). The starting point can be either the process tag type in the master data library or a process tag already contained in the project.

•

Creating a deleted process tag type from a process tag.

The newly created process tag type is stored in the master data library.

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Requirement A CFC chart has been created in the project or in the master data library that contains the automation functions, parameters, and messages of the process tag to be implemented according to a specified process tag description.

Procedure 1. Select the intended CFC chart in the SIMATIC Manager (any view). 2. Select the menu command Options > Process Tags > Create/Modify Process Tag Type... Result: The wizard is started and the "Introduction" page is displayed. The current master data library is displayed. 3. Click the "Next" button. Result: The dialog for copying the chart to the master data library as a process tag type opens. 4. Confirm the dialog box with OK. Result: The wizard changes to the "Which I/Os do you want to assign to the process tag type?" 5. In the left-hand window "I/Os in the chart of the process tag type", select the flagged I/O for "Parameter" and "Signal". (By double-clicking or selecting and clicking the "Arrow" button). Result: The flagged I/O is adopted and displayed bold. 6. In the right-hand window "I/O points for parameters/signals", you can edit the selected flagged I/Os. The "Parameter/Signal" columns can be edited (using a drop-down list box), "Process tag interface" and "Category" (using a drop-down list box). The drop-down list box appears when you click the input field. 7. In the left-hand window, "I/Os in the chart of the process tag type", select the messages of the relevant blocks. Al the messages are displayed in the "I/O points for messages" window. 8. Check the selection and click on the "Next" button and then "Finish". Result: The new process tag type is stored in the master data library. The CFC chart that was the origin of the process tag type is located in the S7 program and can continue to be used there or, if it is no longer required, can be deleted.




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7.11.5.2

How to Modify a Process Tag Type

Requirement The CFC chart is stored in the master data library.

Procedure 1. Select the intended CFC chart in the SIMATIC Manager (plant view). 2. Select the menu command Options > Process Tags > Create/Modify Process Tag Type... Result: The wizard is started and the "Introduction" page is displayed. The current master data library is displayed. 3. Click the "Next" button. Result: The wizard changes to the "Which I/Os do you want to assign to the process tag type?" 4. In the left-hand window "I/Os in the chart of the process tag type", select the flagged I/O for "Parameter" and "Signal". (By double-clicking or selecting and clicking the button). The flagged I/O is adopted and displayed bold. 5. In the right-hand window "I/O points for parameters/signals", you can edit the selected flagged I/Os. You can edit the columns "Parameter/signal" (using a drop-down list box), "Process tag connector" and "Category" (using a dropdown list box). The drop-down list box appears when you click the input field. 6. In the left-hand window, "I/Os in the chart of the process tag type", select the messages of the relevant blocks. Al the messages are displayed in the "I/O points for messages" window. 7. If there are no process tags of the modified process tag type, click on "Next" and then "Finish". Result: The Wizard is closed. Otherwise: 8. Click the "Next" button. Result: You will see dialog page 3(3) "Do you want to complete the process tag type and apply changes to the existing process tags?". 9. Click the "Finish" button. Result: You obtain the log of the changes. 10. Click the "Exit" button. Result: The changes to the process tag type and the process tags are completed; the wizard is closed

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Changes in the Chart of the Process Tag Type Note Modifications that you make in the chart of the process tag type are not taken into account when the process tags are synchronized. In this case, you must run a new import for the modified process tag type. In the import file, add the keyword "delete" for each process tag to be deleted in the "Import mode" column of the "General column group". To create a new process tag, insert an additional row in which the field of the "Import mode" column remains empty. If there were already interconnections to these process tags, they are lost. You can also delete process tags manually in the SIMATIC Manager. If I/Os were added during the modifications, the import file must also be extended accordingly.


7.11.5.3


How to Add a Process Tag Type to a Project

Procedure To insert process tags into a project, you have the following options (in the SIMATIC Manager): •

Using the menu command Insert > Process Tag (from library), open the "Process Tag Types" catalog in the process object view. The catalog lists all the process tag types of the master data library. - You can drag the process tag type to a hierarchy folder in the process object view or in the plant view. This creates a process tag in this hierarchy folder. - Another option is to copy a process tag type in the catalog using Ctrl + C and then paste it into one or more hierarchy folders one after the other with Ctrl + V.

•

With the menu command Options > Process Tags > Import... (with a process tag type selected in the master data library), you can run an import and generate any number of process tags from a process tag type (refer to the section "Automatic Creation of a Number of Process Tags").

•

Drag existing process tags to a hierarchy folder of another project (or use "Copy" and "Paste"). If you paste into the same project, you will be asked whether you want to overwrite or rename the existing object. Remember that the chart name must only occur once.

Note If you create process tags by copying and pasting, you still need to assign parameters for them and interconnect them. If you work with the import file, the data relating to the parameter assignment and interconnection is taken from the import file.


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7.11.5.4

How to Assign an Import File to the Process Tag Type (Create an Import File) To generate process tags, an import file must be assigned to the relevant process tag type. With the "assign import file to a process tag type" assistant, you can do the following: •


•


•

Create and assign a new import file.

Procedure 1. Select the intended process tag type in the SIMATIC Manager (plant view). 2. Select the menu command Options > Process Tags > Assign/Create Import File.... The assistant starts and displays the "Introduction" page. The current master data library is displayed. 3. Click on "Next": The assistant changes to the "Which import file do you want to assign to the process tag type?" page. The "Import file" combo box displays either a file or if no assignment has been made yet, it displays the text . 4. The following options are now available: -

To check an assigned import file to find out whether all the information is accurate, you can open the file ("Open File" button) and then edit the file with the IEA file editor.

-

To assign an import file that exists in the project, click the "Other File..." button and select the required file in the dialog.

-

To create a new import file, click on "Create Template File..." and select the required columns/column groups in the dialog. Then edit the template with the IEA file editor that you open with the "Open File" button.

Note The "Column title" column can be edited if you select the text in the "Import file" combo box. You can change the titles and then generate the template file. In the "Importing" column, a check mark indicates which flagged I/Os exist in the import file. If the check mark is not there, the flagged I/O exists in the process tag type but not in the currently assigned import file.

5. Click on "Finish". The import file is assigned to the process tag type.

Further information

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•

Section "Creating/Editing Import Files with the IEA File Editor"


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7.11.5.5

How to Create an Import File or Assign it to the Process Tag Type To generate process tags, an import file must be assigned to the relevant process tag type. With the "assign import file to a process tag type" assistant, you can do the following: •


•


•

Create and assign a new import file

Procedure – Creating and Assigning an Import File 1. Select the process tag type in the master data library. 2. Select the menu command Options > Process Tags > Assign/Create Import File.... Result: The wizard starts and the current master data library is displayed. 3. Click the "Next" button. Result: The assistant changes to the "Which import file do you want to assign to the process tag type?" The "Import file" combo box displays either a file or if no assignment has been made yet, it displays the text . 4. The following options are now available: -

To check an assigned import file to find out whether all the information is accurate, you can open the file ("Open File" button) and then edit the file with the IEA file editor.

-

To assign an import file that exists in the project, click the "Other File..." button and select the required file in the dialog.

-

To create a new import file, click on "Create Template File..." and select the required columns/column groups in the dialog. Then edit the template with the IEA file editor that you open with the "Open File" button.

Note The "Column title" column can be edited if you select the text in the "Import file" combo box. You can change the titles and then generate the template file. In the "Importing" column, a check mark indicates which flagged I/Os exist in the import file. If the check mark is not there, the flagged I/O exists in the process tag type but not in the currently assigned import file. 5. Click on the "Finish" button. Result: The import file is assigned to the process tag type.


Section "Creating/Editing Import Files with the IEA File Editor"

•

Online help on the PH, IEA, and PO


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7.11.5.6

Automatic Creation of a Number of Process Tags

Requirement To create process tags from process tag types, the relevant process tag types must have an import file assigned to them.

Further Reading You will find a detailed description of the settings of the import files in the section "Importing/Exporting Process Tags/Models". Below, you will find a description of the basic procedure for existing assigned import files.

Procedure 1. Select the required hierarchy folder, project node or process tag library (hierarchy folder in the master data library) or the process tag type. 2. Select the menu command Options > Process Tags > Import... Result: The import dialog opens. After starting the function, the wizard searches for the process tag types and corresponding import files (in all hierarchy subfolders as well) and displays them. The import function will include all listed import files. 3. If you do not want to import certain files, you can select them and remove them from the list with the "Remove" button. With the "Other File" button, you can browse for a different import file and select it instead of the selected file. 4. Start the actual import with the "Next" button followed by "Finish". Result: Depending on the options selected, the complete list of import activities or only the errors that occurred are displayed in the log window. The log is saved in a log file and the name and path of the file are displayed below the log window. You can modify this setting with the "Browse" button.


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Configuring PCS 7

7.11.5.7

How to Edit a Process Tag In the process object view, you can edit individual process tags of the project, for example comments, values, interconnections etc. (as long as these are defined as "Parameter" or "Signal").

Procedure 1. Open the process object view with the menu command View > Process Object View. 2. Select the required process tag in the tree structure (left-hand window). 3. In the table on the right, select the required tab and make your modifications there (in the writable cells). Example: You want to interconnect an I/O with another I/O. Follow the steps below: Requirement for the example: The I/O of the block is defined as a parameter. 1. Select the process tag. 2. Select the "Parameter" tab. 3. Select the cell for the required I/O in the "Interconnection" column. 4. Select "Insert Interconnection..." in the context-sensitive menu. Result: The "Insert Interconnections" dialog box opens. 5. Select the process tag in the tree structure and the block containing the I/O you want to interconnect. 6. Click "Apply". (As an alternative, you can double-click on the I/O or drag the I/O to the selected cell in the process object.) Result: The interconnection is entered; the dialog box remains open. The next cell of the column is selected.

7.11.5.8

How to Adopt Process Tags You can reassign CFC charts that have no assignment to the process tag type during import if the constraints are kept to.

Requirements A check is made to establish whether the following criteria of the CFC chart match those of the process tag type: •

I/Os that are identified as parameters/signals.

•

Blocks identified for messages.

The names of the blocks and I/Os must match.


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Situation 1: Identifying Existing Charts as Process Tags You have created a CFC chart, for example configured a motor control and have copied this chart several times manually. You have changed or adapted the copies to deal with different situations. In future, you want to use the functions of the assistant and create further process tags by importing. You want to continue using the previously created charts and want them to be identified as process tags.

Principle Procedure 1. Create a process tag type from one of the existing charts using the menu command Options > Process Tags > Create/Change Process Tag Type.... Refer to the section "How to Create a Process Tag Type from a CFC Chart". 2. Assign a suitable import file to the process tag type with the menu command Options > Process Tags > Assign/Create Import File.... 3. Start the import with the menu command Options > Process Tags > Import... and open the import file in the dialog (Page 2(3)) using the "Open File" button. 4. Add each chart to be adopted to a row in the file. Continue until the import can be finalized.

Note • Make sure that the charts you adopt are located in the folder entered in the "Hierarchy" column of the import file. •

If you want to retain the values of the charts; in other words you do not want them to be overwritten with the values of the process tag type, delete the relevant fields in the import file.

Result: If the conditions for adopting the process tags are met, the CFC chart becomes the process tag of the imported process tag type and the I/O name and category is adopted from the process tag type. Any additional process tag identifiers (message block or block I/Os) are reset. Additional blocks and I/Os that are not in the process tag type are tolerated and ignored. If the adopted process tag is part of the replica of a model, the IEA flags remain unchanged. If it is not part of a replica, set IEA flags may be reset.

Situation 2: Chart Has Lost its Assignment to the Process Tag Type You have canceled the assignment of a CFC chart that was already a process tag to the process tag type in its object properties (Object Properties > Tab: Process Tag Type, chart selected, "Clear" button). Follow steps 3. and 4. as described for situation 1.

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Situation 3: Process tag type was copied manually A process tag type was inserted by copying and pasting several times within the project or from the master data library. You now want to assign these copies to the process tag type and create or extend the IEA file.

Principle Procedure 1. Select the process tag type in the PH. 2. Select the menu command Options > Process Tags > Export. Result: The "Import/Export Assistant Export Process Tags" dialog opens. 3. Select "Next" and in the next dialog select the export file ("Open File" or "New File") and confirm with "Next" 4. If required, select the path and name of the log file and confirm with "Finish". The export is made and the export file is created. The actions are logged in the window and stored in the log file. 5. Select "Back" to check the export file and open the export file you have just created. Result: All copies of the process tag type are included in the file. You can now uses file to work with, for example by adding entries, and then use it for import.

7.11.5.9

How to Synchronize Process Tags with the Process Tag Type When a process tag type is modified, the process tags existing in the multiproject are automatically synchronized. If actions were taken that caused inconsistencies between the process tag type and process tags (for example when some process tags of the project were not available at the time of the automatic synchronization), synchronization can also be started explicitly.

Requirement Process tags exist in the multiproject and the modified process tag type is in the master data library.

Procedure 1. Select the process tag type (in the master data library) and then select the menu command Options > Process Tags > Update.... Result: The "Update Process Tags" wizard opens and the current master data library is displayed. 2. Click the "Next" button. Result: The wizard changes to the page "Do you want to compare the existing process tags with the process tag type?".


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3. Click the "Finish" button. Result: You obtain the log of the comparison.

Note Modifications that you make in the chart of the process tag type are not taken into account when the process tags are synchronized. In this case, you must run a new import for the modified process tag type. In the import file, add the keyword "delete" for each process tag to be deleted in the "Import mode" column of the "General column group". To create a new process tag, insert an additional row in which the field of the "Import mode" column remains empty.

Subsequent Comparison of Process Tags for Unavailable Process Tags If the name of the process tag type was changed and the comparison was performed at a time when some process tags of this type were unavailable (for example after branching the project for distributed engineering) and if these process tags are later merged back into the project, these process tags cannot be compared according to the method described above. The following procedure allows you to compare them at a later point in time: 1. Change the name of the relevant process tag type. 2. Select the menu command Options > Process Tags > Update... to synchronize all process tags with the modified process tag type. 3. Rename the process tag type with its original name and repeat the synchronization. Result: All the process tags are now adapted to the corresponding process tag type.


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7.11.5.10 How to Restore Lost Process Tag Type Assignments If process tags exist in a project but the corresponding process tag type is no longer in the master data library, it is not possible to import or export these process tags. For import/export, the structure of the import/export file is always required and this is only stored in the process tag type.

Remedy You can create a process tag type from an existing process tag in the project and re-establish the assignment.

Procedure 1. Select the process tag in the project. 2. Select the menu command Options > Process Tags > Create/Modify Process Tag Type... Result: The wizard starts and the current master data library is displayed. 3. Click the "Next" button. Result: The wizard displays an error message and asks whether the selected chart should be created as a process tag type in the master data library. 4. Click on "Yes". Result: The wizard changes to the "Which I/Os do you want to assign to the process tag type?" 5. Click the "Finish" button. Result: The process tag type is created and is stored in the master data library. The assignment of process tags to the process tag type is therefore reestablished. You now still have to assign the import file or create a new import file.

Note During this action, you can, of course, modify the process tag type if this is necessary. Existing process tags are adapted automatically.

Note Please remember that the process tag may have been adapted for a specific technological purpose that is either irrelevant for the process tag type or is not allowed to exist. In this case, you must make the appropriate modifications (for example interconnections, parameter settings) in the CFC chart.


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7.11.6

Creating Sequential Control Systems (SFC)

SFC Charts and SFC Editor An SFC chart is a sequential control system in which up to eight (SFC type 32) sequences that can be started separately can be integrated in the form of sequencers. An SFC chart is assigned uniquely to a CPU and is also executed completely on this CPU. The SFC editor is a tool for creating a sequential control system. For more detailed information, refer to the manual SFC for S7; Sequential Function Chart or the online help.

Sequential Control System A sequential control system is a controller partitioned to ensure step-by-step execution with control passing from one state to the next state dependent on conditions. Sequential control systems can be used, for example, to describe the manufacture of products as event-controlled processes (recipes). With a sequential control system, functions from basic automation (typically created with CFC) are controlled by operating and state changes and executed selectively.

Using Sequential Control Systems The typical applications of sequential control systems involve processes and plants with discontinuous characteristics. Sequential control systems can, nevertheless, also be used for continuous processes and plant, for example for approach and withdrawal movements, operating point changes, and state changes due to faults etc. Sequential control systems can be used at the following levels within a plant:

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Device control level (open valve, start motor .....)

•

Group control level (proportioning, stirring, heating, filling .....)

•

Unit level ( tank, mixer, scales, reactor .....)

•

Plant level (synchronization of units and common resources, for example routing)


Configuring PCS 7

How It Works Using the SFC editor, you create your sequential control system using graphic tools. The SFC elements of the chart are positioned in the sequencer according to fixed rules. You do not need to be aware of details such as algorithms or the assignment of machine resources but can concentrate solely on the technological aspects of your configuration. After creating the chart topology, you move on to configure the object properties where you formulate the properties of the sequencers and the individual steps and transitions; in other words, you configure the actions and conditions. After configuration, you compile the executable machine code with SFC, download it to the PLC and test it with the SFC test functions.

Further information

7.11.6.1

•

Online help on SFC

•

Manual SFC for S7; Sequential Function Chart

•


Advantages and Uses of SFC Types/SFC Instances

The Type/Instance Concept With the type/instance concept is possible to create types of sequential control systems that generate SFC instances when they are placed in a CFC chart. The type/instance concept allows the following to be achieved: •

Central modifiability

•

Reusability

•

Download of changes (it may be necessary to deactivate instances of a type)

SFC Type In SFC, there is not only the object type "SFC chart" but also "SFC type". The SFC type allows the definition of sequential control systems including an interface. The sequence logic of the SFC type is based on the interface I/Os of the SFC type; in other words, in contrast to an SFC chart, an SFC type cannot access all process signals. Alone, the SFC type cannot execute. An SFC type, just like a function block type, must be placed in a CFC chart before it contains an executable object, this case an SFC instance. To run an SFC instance, both the SFC type and the SFC instance are downloaded to the automation system. Note SFC types can also be located in libraries (for example the SFC Library). However, before they can be used, they must be copied from the library's chart folder to the chart folder of the program. The SFC types are then visible in the CFC catalog in the "Blocks" tab and can be placed in the chart from there.


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SFC Instance An SFC instance is derived from an SFC type. To achieve this, the SFC type is inserted in a CFC chart in the same way as a function block type in CFC. The SFC instances are therefore always assigned to a CFC chart and are addressed via the chart. SFC instances are represented as blocks like CFC instances; in other words the interface is visible in the CFC chart. SFC instances are not displayed in the SIMATIC Manager since they can only be addressed via the CFC chart. With the assignment of the CFC chart to the plant hierarchy, the SFC instances it contains are also indirectly assigned to the plant hierarchy.

Basics of Configuration 1. The SFC type is created. At the same time, the sequencers and the interface are configured, refer to the section "How to Create an SFC Type" 2. The SFC instances are generated, assign parameters, and connected in the CFC chart. Refer to the section "How to Create an SFC Instance"

Note • You will find templates of sequences in the "SFC Library". You can copy these templates and modify them for your own use. •

You can control and monitor SFC instances and SFC charts on the OS with the optional package SFC Visualization. You also configure operation and monitoring of SFCs in SFC Visualization.

Further information

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Online help on SFC

•

Manual SFC Visualization for S7


Configuring PCS 7

7.11.6.2

Overview of the Steps in Configuration The steps outlined below are the procedure for configuring sequential control systems (SFC charts) for your PLC: The order also applies to the configuration of SFC types, however here, the I/Os and characteristics are still to be defined.

Requirement You have created a project structure in the SIMATIC Manager in which you can configure CFC/SFC charts.

Procedure Step

Activity

Description

1

Specifying the Chart When you specify the chart properties, you can change the chart name Properties and add a comment.

2

Creating the Topology of the Sequential Control System

Using SFC charts, sequential control systems are configured by inserting the steps and transitions for one or more sequencers and adding for the structure elements as required.

3

Configuring Sequencer Properties

For each sequencer, you configure the start condition, the action for preprocessing and for postprocessing.

4

Configuring Steps (in the Object Properties dialog)

Actions are formulated in the steps. The actions contain statements with which the values of block inputs and shared addresses can be changed or run-time groups or other SFC charts can be activated and deactivated.

5

Configuring Transitions (in the Object Properties dialog)

Conditions are formulated in the transitions. The conditions read the values of block I/Os, of shared addresses or the state (active/inactive) of runtime groups or other SFC charts. If the conditions following the specified logic operations are true, the next step becomes active and its actions are executed.

6

Adapt Operating Parameters and Runtime Properties

By setting the operating parameters, you specify the behavior of the sequential control system, such as the mode (manual, auto), step control mode (T, C, T and C...) and other chart execution options (cyclic operation, time monitoring, autostart, ...). The run-time properties of an SFC chart determine how the SFC chart is included in the execution of the entire structure on the PLC (in the window of the CFC run-time editor).

7

Compiling an SFC Chart

During compilation, the CFC and SFC charts of the active chart folder are converted to an executable user program (Compile: Entire Program/Changes).

8

Downloading the Program:

Following compilation, you can download the program to the CPU (entire program or changes only).

9

Testing the Program After compiling and downloading, you can test the program in process mode or in laboratory mode. Using the SFC test functions, you can run the sequential control system in various operating modes and step control modes and monitor and modify the values of addresses on the CPU. You can also influence the most important operating modes (STOP, clear/reset, RUN, ...) on the CPU.


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7.11.6.3

How to Create a new SFC Chart You can create SFC charts and SFC types in the SIMATIC Manager.

Requirement The required project structure must already exist in the SIMATIC Manager.

Procedure - Creating a Chart in the SIMATIC Manager 1. Select the required hierarchy folder in the plant view of the SIMATIC Manager. 2. Using the Insert > Technological Objects > SFC menu command, insert a chart in the chart folder or hierarchy folder (the hierarchy folder must first be assigned to a chart folder). The SFC chart is therefore automatically assigned to a chart folder. The chart is given a standard name by the system (for example SFC(1)) that you should change to match your situation. The name must be unique on the CPU. This is checked by the system. 3. Double-click on the new SFC chart in the right-hand window (content of the chart folder or hierarchy folder). Result: The SFC editor is started (if it is not already started) and the chart is displayed in its initial state in a window of the SFC editor.

Note • The names of the SFC charts can be up to a maximum of 22 characters long. •

The names of the SFC types can be up to a maximum of 16 characters long. Although you can enter 24 characters in the properties, when the instances are created, only 16 characters are permitted.

•

The following characters are not permitted in names: \, ., /, ", %.


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Configuring PCS 7

7.11.6.4

How to Create the Topology of the Sequential Control System

Chart Layout The newly created SFC chart (SFC type) initially consists of one sequencer that can be expanded to up to 8 (SFC type 32) sequencers. Each sequencer is created in its own working window; you can switch between sequencers using the tabs at the bottom edge of the window. A new sequencer created with the menu command Insert > Sequence > ... is inserted at a selected position in the chart in its initial status consisting of an initial step, transition and final step and a tab is added at the lower edge of the window. Each tab has the name of the sequencer (RUN, SEQ1, ...). If you insert or delete SFC elements in the sequencer, its layout is changed automatically according to predefined rules. These determine the clearance between chart elements, the extent of steps and transitions, the alignment of alternative sequences etc. You can change the display/layout rules at any time with the menu command Options > Customize > Display.... You can center the entire plant topology on the display area. This achieves a uniform distribution of the elements in the chart. With the zoom functions, you can increase or reduce the size of the display (in percentage steps determined by the zoom factor).

Syntax Rules The chart topology is formed by the sequences of steps and transitions. The fundamental rule of the chart topology is that a step (S) must be followed by a transition (T) and a transition must always be followed by a step (sequence : S-T-S or T-S-T). The editor automatically adheres to the rules. Example: If you insert a simultaneous sequence in a sequencer following a transition and before a step, a transition is created automatically before the step since the syntax rules require a transition before and after a simultaneous sequence.


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Overview of the SFC Elements SFC Element

Function

Sequencer

With sequencers, status-dependent and event-driven execution is possible in SFC. An SFC chart can contain up to 8 (SFC type 32) sequencers that can be controlled by defining different start conditions. In SFC, a step allows actions to be executed. There are three types: Initial step, normal step and final step. Each SFC chart has exactly one initial step. When you first create a chart, an initial step, a transition and a final step are created (initial state). The initial step cannot be copied, cut or deleted. You can, however, copy, cut or delete the actions of the initial step. The actions of the initial step are configured just like the actions of any other step. Each SFC chart has exactly one final step. When you first create a chart, an initial step, a transition and a final step are created (initial state). The final step cannot be copied, cut or deleted. You can, however, copy, cut or delete the actions of the final step. The actions of the final step are configured just like the actions of any other step. A transition is a basic element of SFC and contains the conditions according to which a sequential control system passes control from one step to the successor step. A text is an element that can be inserted in charts. You can enter comments in your charts using this element. Texts inserted in charts can be edited, moved, copied, cut, and deleted. Structure element in the SFC containing a sequence of steps and transitions. A simultaneous sequence or an alternative sequence consists of at least two sequences arranged side-by-side and containing at least one element. In SFC, a simultaneous sequence allows several sequences to be run at the same time. The simultaneous sequence is complete when all the sequence paths have been completed (synchronization). A structural element in SFC, that consists of at least two sequences. Only the sequence whose transition condition is satisfied first is processed by the AS. In SFC, a loop allows a jump back to a selected previous point. The return jump is executed when the SFC chart is at the start of the loop and the loop transition is satisfied. In this case, the sequence in the loop is run through again. The jump is a structure element of SFC, with which the execution of an SFC chart can be continued at a different step in the same chart depending on a transition condition.

Step Initial Step

Final Step

Transition Text

Sequence

Simultaneous Sequence Alternative Sequence Loop

Jump

Adding Chart Elements To add further chart elements to the SFC chart, select the icon of the required SFC element in the element bar. The mouse pointer changes its appearance from an arrow to the selected icon with a positioning crosshair. To insert the chart element, position the crosshair at the required position on a link and click the left mouse button. The inserted chart elements are selected and displayed in color.

Data Backup in the SFC Editor All changes made in the SFC editor are saved immediately - there is therefore no extra save option in SFC. This means that you can no longer undo or cancel changes in the SFC editor by closing the editor without saving. For data backup, the entire multiproject or the relevant project should be archived (menu command Select Multiproject > File > Archive).

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7.11.6.5

How to Specify the Sequencer Properties

Introduction With the sequencer properties, you can specify how the sequencer starts (or which of the sequential control systems starts first). The sequencer of a newly created SFC chart (type) already has a start condition (RUN = 1) and is therefore linked with the operating state logic (OSL). For each further sequential control system, you must specify the start conditions yourself. The start conditions and the priorities specify which sequencer starts.

Procedure Select the menu command Edit > Sequencer Properties in the SFC Editor. Result: A dialog opens in which you can set the sequencer properties listed in the following table.

Selectable Sequencer Properties Tab

Property

Meaning

General

Name

Name of the current sequencer. The length is a maximum of 16 characters.

Comment

Comment on the sequencer. You can type in a maximum of 80 characters.

Priority

Priority of the sequencer from 1 through 32. The priority decides which sequencer of an SFC is started when the start conditions of several sequencers are true at the same time. Note: Priority 32 is the highest priority, 1 is the lowest.

Start Condition

Specifies the conditions that must be true to start the sequencer (for example "SFC.RUN = 1" starts the sequencer when the SFC chart is in the "RUN" operating state). To allow a three-stage transition logic, you can combine the conditions logically to create a Boolean expression.

OS Comment

Specifies the properties of the sequencers and the properties of the transitions. In this tab you can enter an OS comment with a maximum length of 256 characters for every condition in the SFC chart/type.

Preprocessing Postprocessing

Defines actions in the SFC chart/type: •

Actions to be executed once prior to executing the sequencer (initialization)

•

Actions to be executed once after executing the sequencer (termination)

(not for SFC instances).


Online help on SFC


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7.11.6.6

How to Configure Steps

Steps Actions are defined in the steps. These contain statements with which, for example, values of block inputs can be modified or other SFC charts activated or deactivated.

Properties of the Steps You can make the following settings in the Properties dialog of the step: Tab

Meaning

General

In this tab, you can edit the general properties of the selected step (for example value, name, comment).

Initialization

In these tabs, you can define the actions for the steps

Processing

•

executed once when the step is activated (Initialization)

Termination

•

executed cyclically when the step is processed (Processing)

•

executed once when the step is exited (Termination)

durchgeführt werden sollen.

The tabs for the processing phases (actions) "Initialization", "Processing" and "Termination" all have the same structure. Here, you configure the statements that will control the process. Each step for which you have defined an action is displayed in dark gray. This means that you can see at a glance whether or not a step has had parameters values assigned to it.

Procedure 1. Select the step you want to edit in the SFC Editor. 2. Select the menu command Edit > Object Properties. Result: The properties dialog of the step opens. 3. Make the entries you require in the "General" tab. 4. In principle, the editing required in the other tabs is identical. Select the required tab and position the mouse pointer in the input field for the left address (the operator) of the required statement line. 5. Click the "Browse" button. Result: The "Browse" dialog is opened. In this dialog box, you can see the CFC charts of the project with the PH assignment, the chart name, and the comment in the first three columns. In the next three columns, you can see all the blocks belonging to the chart selected in the first columns. As soon as you select a block, the last column displays all the relevant I/Os. 6. Select the required CFC chart. Result: All blocks of the chart are displayed.

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7. Select the required block. Result: All I/Os of the block are displayed. 8. Select the required I/O, right click and select the menu command "Apply I/O". Result: The selected block I/O is entered along with its full path. The mouse pointer is automatically position in the input field for the right-hand address. 9. Depending on the left-hand address, you can, for example enter a setpoint for the right-hand address or test for TRUE or FALSE or an interconnection to a further block I/O (menu command "Browse") etc. 10. Click "Apply" to enter the settings and confirm the dialog with "Close". 11. Follow the same procedure if you want to edit more steps.

Note In SFC, the operator combines two addresses in a statement or condition. •

Statement: The first address is assigned the value of the second address.

•

Condition: The addresses are compared with each other. The result is TRUE or FALSE.

Operators are: = (statement), < (less than), <= (less than or equal to), = (equal to), >= (greater than or equal to), > (greater than), <> (not equal to).


Online help on SFC


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7.11.6.7

How to Configure Transitions

Transitions A transition contains the conditions according to which control passes from one step to its successor step or steps. Several conditions can be logically combined using Boolean operators. The result of the logic operation decides whether control is passed to the next step. In principle, you assign parameter values for the transitions in the same way as for the steps.

Properties of Transitions You can make the following settings in the Properties dialog of the transition: Tab

Meaning

General

In this tab, you can edit the general properties for the selected transition (name, comment).

Condition

In this tab, you can define the conditions for the SFC chart/type that cause transitions to pass on control within the sequencer. To allow a three-stage transition logic, you can combine the conditions logically to create a Boolean expression.

OS Comment

In this tab you can enter an OS comment with a maximum length of 256 characters for every condition in the SFC chart/type. The defaults are the conditions formulated in the "Conditions" or "Start Condition" tab.

Conditions Conditions in a transition allow you to do the following: •

Values to be read from block I/Os or shared addresses

•

To logically combine the read values with a constant or another read value using Boolean operators (=, >, <, ...)

The result of a condition is a Boolean variable that can be logically combined with the results of other conditions.

Procedure 1. Select the transition you want to edit in the SFC Editor. 2. Select the menu command Edit > Object Properties. Result: The properties dialog of the transition opens. 3. Make the entries you require in the "General" tab. 4. Select the "Condition" tab and position the mouse pointer in the input field for the left address (the operator) of the required statement line.

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5. Click the "Browse" button. Result: The "Browse" dialog is opened. In this dialog box, you can see the CFC charts of the project with the PH assignment, the chart name, and the comment in the first three columns. In the next three columns, you can see all the blocks belonging to the chart selected in the first columns. As soon as you select a block, the last column displays all the relevant I/Os. 6. Select the required CFC chart. Result: All blocks of the chart are displayed. 7. Select the required block. Result: All I/Os of the block are displayed. 8. Select the required I/O, right click and select the menu command "Apply I/O". Result: The selected block I/O is entered along with its full path. The mouse pointer is automatically position in the input field for the right-hand address. 9. Select the required operator with which the two addresses will be logically combined. 10. Depending on the left-hand address, you can, for example enter a setpoint for the right-hand address or test for TRUE or FALSE or an interconnection to a further block I/O (menu command "Browse") etc. 11. Specify the 3-level transition logic. The Boolean operators are designed as buttons. With a simple mouse click on the operator, you can change it from "AND (&)" to "OR ((=1)". To make a "NAND" from an "AND" and a "NOR" from an "OR", click the output of the operator. The negation is displayed by a period in bold print on the output line. 12. Select the "OS Comment" tab. In this tab you can enter an OS comment with a maximum length of 256 characters for every condition in the SFC chart/type. The defaults are the conditions formulated in the "Conditions" or "Start Condition" tab. When you first open the "OS Comment" dialog, the formulated condition is entered as an OS comment and can then be changed as required. If the OS comment is the formulated condition, in other words the default, this is indicated at the start of the line by the "Link" symbol. 13. Click "Apply" to enter the settings and confirm the dialog with "Close".


Online help on SFC


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7.11.6.8

How to Adapt the Operating Parameters and Runtime Properties You can display and modify the operating parameters and runtime properties for the active SFC chart. With the operating parameters, you specify the initial state of the SFC chart.

Procedure The SFC > Properties... menu command opens a dialog box. Here, you have the choice of three tabs: •

General This tab is used to enter or modify the chart name, the author and the comment.

•

PLC Operating Parameters In this tab, you can do the following:

•

-

Set the defaults for the initial state of the chart. These defaults cover the following: "Step control", "Operating mode", "Command output", "Cyclic operation" and "Time monitoring".

-

Set/reset the options for starting the chart. These are: "Autostart" and "Use defaults of the operating parameters when SFC starts".

OS In this tab, you can set or reset the option for "Transfer chart to OS for visualization".

Operating Mode Default: Manual In the combo box, you can decide whether the control is manual or automatic.

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•

AUTO (process mode): The sequence is controlled automatically; in other words, the commands in the program apply. The commands are decided, for example by the parameter assignment or interconnection of inputs of the SFC external view in the CFC chart. In the "Auto" mode, the step control modes "T" and "T / T and C" can be set.

•

MAN (operator control mode): The sequence is controlled manually by the operator (for example in the SFC test mode or on the OS in SFV). All step control modes are permitted.


Configuring PCS 7

Step Control Mode Default: T In the combo box, you can select the step control mode in which the SFC chart/SFC instance will run. Step Control Mode

Meaning

T

Step control mode: transition only The sequential control system runs controlled by the process (automatically). When a transition is true, control passes to the next step or steps by deactivating predecessor steps and activating successor steps.

C

Step control mode: confirmation by operator The passing of control to the next step is controlled exclusively by the operator. The transitions do not need to be true. For each successor transition of every active step, an operator prompt is set and control passes to the next step or steps only after the operator has confirmed the prompt.

T and C

Step control mode: transition and confirmation by operator The passing of control to the next step is controlled by the transitions (process) and the operator. If the successor transition of an active step is satisfied, an operator prompt is set and control passes to the next step or steps only after the operator has confirmed the prompt.

T or C

Step control mode: transition or confirmation by operator The passing of control to the next step is controlled by the transitions (process) or by the operator. For each successor transition of an active step, an operator prompt is set and control passes to the next step or steps when the operator prompt has been confirmed. If the transition is true before the operator prompt is acknowledged, control passes to the next step or steps without operator intervention (automatically).

T / T and C

Step control mode: step-specific confirmation by operator The sequential control system operates as follows: •

process controlled for steps without the "Confirmation" identifier Each satisfied follow-on transition of a step without this identifier passes on control without operator intervention (corresponds to T).

•

operator-controlled for steps with the "Confirmation" identifier. If the successor transition of an active step with this identifier is satisfied, an operator prompt is set and control passes to the next step or steps after the prompt has been confirmed (corresponds to T and C).

The different step control modes affect the behavior of prepared or true transitions. It is possible to change the step control modes in all operating modes. The individual step control modes are mutually exclusive.


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Run and Start Options Option

Meaning

Command output

Default: On During installation and commissioning, or if errors occur, blocking command output in conjunction with certain operating modes can bring the sequential control system to a defined state without influencing the process. If this option is set (check mark), the actions of active steps are processed, if the option is not set, the actions are not processed.

Cyclic Operation

Default: Off If the option is set (check mark), after the SFC chart or SFC instance generated from this type has run, it changes from the "Completed" to the "Starting" mode; in other words it begins automatically with the start condition.

Time Monitoring

Default: Off If this option is set (check mark), the monitoring times (# 0 ms) set in the object properties of the steps are evaluated. If this time elapses, a message is output (step error).

Autostart

Default: Off If the option is set (check mark), the SFC chart or the SFC instance generated from this type is in the "Starting" mode following a restart on the CPU; in other words, it starts automatically to process the start. If the option is not set, the chart or instance is in the "Idle" mode and is waiting for a start command.

Use default operating Default: Off parameters when SFC If this option is set, all the operating parameters in the "Defaults" group become starts effective again when you start the chart or instance, for example after you made changes in test mode.

7.11.6.9

Working with Charts, Types, and Instances You can create new SFC charts and SFC types, open them to edit and modify properties. This is possible both in the SIMATIC Manager and in the SFC editor. You can copy and delete SFC charts and SFC types only in the SIMATIC Manager. You copy and deleted instances of SFC types in the relevant CFC chart.

Opening SFC Charts, Types, and Instances If you start the SFC Editor explicitly, it opens without a chart window; in other words, no chart is opened (Start > SIMATIC > STEP 7 > SFC – Create Sequential Control Systems). What

How

In the SFC Editor, select the menu command SFC > Open, and then select the required chart. To open an SFC type, you must select "SFC type" from the drop-down list box in the "Object type" field in the "Open" dialog of the SFC editor. Opening an SFC Chart: Select the required chart in the component view or plant view and select the menu command Edit > Open Object. chart/SFC type in the SIMATIC Manager Type: Select the required charts in the component view and then select the menu command Edit > Open Object. Opening SFC Instances To open the SFC instance, select the instance in the CFC chart and then the Open command in the context-sensitive menu. Opening a SFC chart/SFC type in the SFC Editor

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Copying, Moving, and Deleting SFC Charts, Types, and Instances What

How and Where

Copying and moving SFC charts

Copying entire charts allows you to copy structures or substructures you have tested, even to other CPUs. You can copy not only individual charts but also an entire chart folder with all the charts it contains. Note that the name of the chart folder within the multiproject must be unique. Moving entire charts allows you to move structures or substructures you have tested, even to other CPUs. You can move not only individual charts but also an entire chart folder with all the charts it contains.

Copying and moving SFC types

SFC types are copied in the SIMATIC Manager (component view). The sequence objects belonging to the SFC type are also copied. If the generated version of the SFC type is not up-to-date (time stamp of the FB older than the time stamp of the SFC type), a message is displayed. If the SFC type already exists at the destination when you copy the SFC type (SFC type with the same name), this is overwritten after a prompt for confirmation and any differences from the existing type are passed on to the SFC instances. SFC types are moved in the SIMATIC Manager. SFC types can only be moved when no SFC instances of the SFC type exist in the source. The sequence objects belonging to the SFC type are also moved. If the SFC type already exists at the destination (SFC type with the same name), this is overwritten after a prompt for confirmation and any differences to the existing type are passed on to the SFC instances.

Copying and moving SFC instances

If you copy an SFC instance within a CFC chart or between CFC charts of the same chart folder or copy a CFC chart within a chart folder, the SFC instance is copied. The sequence objects belonging to the SFC instance are also copied. When you copy an SFC instance between CFC charts from different chart folders or copy a CFC chart to a different chart folder, the SFC type is also copied. If you move an SFC instance within a CFC chart, only the position of the SFC instance changes. If you move an SFC instance between CFC charts of the same chart folder, the SFC instance is moved. The sequence objects belonging to the SFC instance are retained. When you move a CFC chart to another chart folder, the SFC type is also copied.

Deleting Charts and SFC types

You only delete SFC charts and SFC types in the SIMATIC Manager. You delete SFC charts in the same way as other objects (hierarchy folder, OS pictures, ...); in other words, you select them and click "Delete". SFC types can only be deleted when no SFC instances of the SFC type exist. If instances of an SFC type exist, a message to this effect is displayed. The sequence objects belonging to the SFC type are also deleted.

Deleting SFC instances

You delete SFC instances in the CFC chart or indirectly by deleting the CFC chart in the SIMATIC Manager. The sequence objects belonging to the SFC instance are also deleted.


Online help on SFC


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7.11.6.10 Configuring Messages in SFC

Procedure You can start configuring messages in the SFC Editor with the menu command SFC > Message.... You can configure specific message texts for each SFC chart/SFC type. You can modify the message texts in a dialog (for example to distinguish messages from different charts/types). In this dialog box, you can configure block-related message types and blockrelated messages that will be output on WinCC display devices.

Settings Tab

Meaning

Message name

This column displays the name of the block-related message within the message configuration.

Message class

Select the required message class in this field.

Priority

In this field, you select which messages must be acknowledged with which priority. The higher value, the higher the priority.

Event

Enter the Message text in this field.

Single acknowledgment Click on the check box, if you want the message to be acknowledged as a single message. Info text

Enter the information text in this field. SFC type only ! Whether or not this column is displayed depends on whether you are editing message types on messages. By putting a check mark in this column, you can interlock the text you entered in the column before it.

Note If you edit existing messages, the entries for Origin, OS area, and Batch ID are displayed in red and italics if they were edited in the message configuration and the entries are not uniform. To make the entries uniform, overwrite the displayed text. If you have not yet created a WinCC display device, a display device is created automatically and given an internal name.

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7.11.6.11 How to Create an SFC Type

SFC type The SFC type is an object that can be manipulated in the SIMATIC Manager (component view) in much the same way as the SFC chart. An SFC type does not have any runtime properties, since it is not relevant to execution of the program. An SFC type cannot be installed in the run sequence.

Creating an SFC Type There are two possible methods of creating and modifying an SFC type: •

Creation/modification in a library The advantage of this is that the master for the SFC type is always located in the library and that the test project always remains runnable until a new version of the SFC type is adopted.

•

Creation/modification in a project The advantage of this is that each change to the SFC type can be checked immediately sent you are working directly with the master.

Requirement A PCS 7 project must already exist.

Procedure 1. You create SFC types in the component view of the SIMATIC Manager with a chart folder selected using the menu command Insert > S7 Software > SFC Type. Result: The next free FB number is automatically reserved for the SFC type and is copied to the block folder as the type template with this number. This means that when you create the type, you can configure messages and create instances of the type without needing to compile the type. You can change the FB number later in the Object Properties dialog. When you first create an SFC type, the blocks required for compilation are copied to the current program and then managed in the ES. The blocks are included in the supplied block library. Note SFC types cannot be assigned to a hierarchy folder in the plant view since they themselves are not relevant to execution (from the perspective of the process to be automated). 2. In the properties dialog, adapt the properties of the SFC type to meet your requirements; In the SIMATIC Manager: Edit > Object Properties. 3. Set the properties and the operating parameters. You will find more detailed information in the online help and in the section "How to Adapt the Operating Parameters and Runtime Properties". Process Control System PCS 7 - Engineering System A5E00346923-02

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4. Define the characteristics (in the SFC Editor: menu command View > Characteristics) and add the control strategies, setpoints (note: do not forget the control strategy assignment), process values, block contacts etc. 5. Add sequencers and configure them, edit the start conditions (refer also to the section "How to Specify the Sequencer Properties"). 6. Configure the messages for the SFC type. You can configure seven messages with mandatory acknowledgment and five messages that do not require acknowledgment. The SFC type itself requires the remaining available messages (one per message type and 10 notify messages for BATCH). You should also refer to the Section "Configuring Messages in SFC". 7. Configure a footer (in the SFC Editor: menu command SFC > Footers...). You can configure a footer for an SFC type just as for an SFC chart. 8. ..... You will find other configuration options in the online help on SFC and in the manual SFC for S7; Sequential Function Chart. Note In the "SFC Library", you will find the "TypeStates" SFC type in SFC Library > Blocks+Templates > Templates. This already contains several sequencers for state-oriented execution of the sequential control system. You will also find the "TypeCtrlStrategy" SFC type that contains control strategyoriented execution of the sequential control system. You can copy these templates and modify them for your own use.

Interface of the SFC Type The SFC type has an interface analogous to the SFC chart. This is created when the SFC types generated and already includes the SFC type standard interface derived from the SFC type template. The standard interface is required to provide SFC system functionality (operating modes, operating states, step control modes, etc.) at the interface of the SFC type. The elements of the standard interface cannot be moved or deleted. The initial value, comment, and attributes can be modified. You can add further I/Os to the interface using the interface editor and add characteristics in the Characteristics dialog. The same applies for these elements as for the standard interface. Special feature of block contacts: The interface is extended by the predefined I/Os of a block type. This is possible using the "S7_connect" attribute. (Predefined I/Os for interconnection with the SFC type). The interface can be extended as far as permitted by the CFC chart; in other words, the height must not exceed three chart partitions. During configuration, only the interface I/Os can be used to formulate step assignments or the transition and start conditions. In other words, addresses in assignments or conditions are always references to I/Os of the interface. Here, textual interconnections are also possible. This means that the SFC type is selfcontained and there are no external accesses from the SFC type which bypass the interface.

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7.11.6.12 How to Create an SFC Instance

SFC instance You create an SFC instance by dragging the SFC type from the block catalog to the chart in CFC. The SFC types in the chart folder are displayed in the CFC block catalog (in "All blocks" and in the folder of the family if they are assigned to a family, otherwise in the "Other blocks" folder). The SFC instance is displayed like a CFC instance block. If there is not enough free space to position the SFC instance; in other words, it overlaps one or more objects that have already been placed, it is displayed as an overlapping block (light gray and without visible I/Os). After moving them to a free location in the chart, the overlapping blocks are displayed as normal blocks again. You can assign parameters to the SFC instance and interconnect it in test mode. If you have defined block contacts, when you interconnect an I/O of this block, the other I/Os are automatically interconnected (predefined I/Os for interconnection with the SFC type (S7-Connect" attribute)). In the technological blocks of the PCS 7 library, the most important I/Os are already predefined.

Procedure 1. Open the CFC chart in which you want to interconnect an SFC instance with the blocks of basic control. 2. Select the SFC type in the block catalog (Other blocks) of CFC and place it in the CFC chart. Result: An instance of the SFC type is generated in the chart. 3. Specify the properties of the SFC instance. In the CFC, you can modify the general properties (name, comment) in the object properties of the SFC instance. 4. Adapt the operating parameters and options of the instance. Open the SFC instance in CFC (context-sensitive menu: Open) and in the Properties dialog, adapt the operating parameters that specify how the chart executes (Refer to the section "How to Adapt the Operating Parameters and Runtime Properties"). As an option, you can decide which of the control strategies provided by the SFC type should be used for the SFC instance. 5. Assign parameters and interconnect the interface of the SFC instance. You make the parameter settings for the I/Os of the SFC instance in the CFC using the object properties or in the SFC using the "I/Os" interface editor. In CFC, you interconnect the I/Os of the SFC instance with the I/Os of the CFC blocks or with shared addresses or you create textual interconnections.


Online help on SFC


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7.11.6.13 How to Modify an SFC Type (centrally) SFC types can also be kept in the master data library. However, before they can be used, they must be copied from the library's chart folder to the chart folder of the program. The SFC types are then visible in the CFC catalog, "Blocks" tab (Other blocks) and can be placed in the chart from there (refer to the section "How to Create an SFC Instance"). To run an SFC instance, both the SFC type and the SFC instance are downloaded to the automation system. Changes to the topology (step/transition sequence, changed jump target) or step/transition configurations are made to the SFC type and become effective automatically in the SFC instances following compilation and download.

Changes to the Configuration The basic rule is that changes to the SFC type which prevent or restrict a download of changes in RUN mode can only be made after being confirmed by the user. Modifications to the interface of the SFC type are transferred to the SFC instances immediately. This means that the SFC type and its instances can only be downloaded to the CPU in RUN mode if all the SFC instances of this SFC type are deactivated or are deactivated briefly during downloading The instances are deactivated during the download following operator confirmation and restarted after the download, again following operator confirmation. The execution of the instance then depends on the process state and on the configuration of the instances (especially the start conditions). While changes are being downloaded, the system prevents the SFC instances from being processed on the CPU and prevents access to the SFC instances via the of interconnections in the CFC. Changes to the topology (step/transition sequence, changed jump target) or step/transition configurations are made to the SFC type and become effective in the SFC instances only following compilation and download. For modifications to the topology relating to downloads, the rule is that inactive sequencers can be downloaded at any time, whereas the SFC instances must be deactivated before downloading active sequencers. Changes to the step and transition configuration can be downloaded at any time even if SFC instances of the SFC type are currently being processed on the CPU. Following changes in the configuration, the "Compile OS" function must be used to make sure that the current data is available on the OS.

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Principle Procedure 1. Open the SFC type in the chart folder. Result: The SFC type is opened in the SFC Editor. 2. Make the required modifications in the SFC Editor. Result: The modifications are made to the type and to every existing instance. 3. Compile, download, and test the program. 4. Copy the SFC type to the master data library so that the modified version is available in the CFC catalog. 5. If the modifications you have made are relevant to the parameter assignment or interconnections, these must still be carried out in all the SFC instances. To do this, open the relevant CFC charts and complete them.


Section "How to Download SFC Charts"

•

Manual Process Control System PCS 7; Getting Started - Part 2

7.11.6.14 How to Compile Charts and Types

Compiling When compiling (scope: entire program) all charts (including SFC types) of the current chart folder are converted to the source language and then compiled. After changing the SFC chart (SFC type, SFC instance), you only need to compile the changes (Compile: "Changes only"). During compilation, a consistency check is performed automatically. You can also start this check manually. After you have compiled, you can download the user program to the CPU, test it and start it up.

Customizing the Compiler With the Options > Customize > Compilation/Download... menu command, you open a dialog box in which you will see information about the resources used in conjunction with compiling charts. You have the following options: •

you can decide which warning limits will apply so that possible dangers are detected before you download.

•

you can decide which resources should remain unused during compilation of the charts of the current chart folder. This can, for example, be useful if you want to solve an automation task partly with charts and partly by programming (for example, STL, LAD or SCL programs) and when you have functions (FCs) or data blocks (DBs) from other sources in your user program.


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•

view the statistics showing how many resources (DBs, FCs) are available for compiling the charts and how many are already being used.

Note If you work only with CFC and SFC in your program, you can leave the standard compilation settings unchanged. You will find an overview of the blocks generated during compilation in the online help.

Procedure - Compilation 1. Select the menu command SFC > Compile.... Result: A dialog box opens in which you can choose between the following option buttons: -

Compile "Entire program" (all charts are compile)

-

Compile "Changes" (only the objects changed since the last compilation are compiled).

2. If necessary, select one of the following options: -

Option "Delete empty runtime groups": If this option is set, the empty runtime groups are deleted prior to compilation. These empty runtime groups can result from copying when branching and merging projects. When these empty run-time groups are created, the original names of the run-time groups are lost due to implicit incrementation of the numbers.

-

Option "Close textual interconnections": If this option is set, all the textual interconnections are closed prior to compilation if the referenced interconnection partner exists; in other words, there are converted to real interconnections.

Note If the option is not set or if there are textual interconnections that cannot be closed, substitute values are generated; in other words, the default parameter value of this block type is used.

-

The options "Generate module drivers" and "Update sampling time" are not relevant for SFC and are used by CFC.

3. Select the type of compilation you require ("Entire program" or "Changes only") and start the compilation with "OK". Result: The charts of the current program (chart folder) are checked for consistency and then compiled.

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Saving Settings without Compiling You can save the settings in the dialog box without starting compilation ("Apply" button).

Logs The result of the consistency check and all messages occurring during compilation are displayed automatically following compilation. You can also display the log later and print it out (menu command Options > Logs...).

Note You can also run a consistency check without compiling by selecting the Chart > Consistency Check... menu command.

Consistency check Prior to the actual compilation, the system automatically makes the following consistency checks: •

Checks whether the block types in the user program match the types imported into CFC.

•

Checks whether symbolic references to shared addresses are entered in the symbol table.

•

Checks whether the data blocks (DB) to which there are interconnections actually exist in the user program.

•

Checks whether in/out parameters or block outputs of the type "ANY", "STRING", "DATE_AND_TIME" or "POINTER" are supplied with values (in other words interconnected).

•

Checks whether all the blocks accessed by SFC conditions or statements still exist.


Online help on SFC


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7.11.6.15 How to Download SFC Charts

Downloading Before the graphic charts can be put into operation on a CPU, the charts must first be compiled and downloaded to the CPU. The charts are downloaded to the CPU to which the user program containing the current chart folder is assigned. With the programs created in SFC, you must download to the CPU from SFC (or CFC), since only this download function guarantees the consistency of the configuration data with the CPU data. The same download function is also used when you select the menu command PLC > Compile and Download Objects in the SIMATIC Manager or select the chart folder and then PLC > Download.

Requirements You have already completed the following steps: •

There must be a connection between the CPU and your PG/PC.

•

The edit mode is set (not the test mode).

You can download the entire program (CPU in STOP mode) or changes only (CPU can be in the RUN-P mode).

Procedure 1. Make sure that the conditions listed above are met. 2. In the SFC Editor, select the menu command PLC > Download... and select the type of downloaded in the dialog box, either "Entire program" or "Changes". Result: The program (or only the changes) is downloaded to the CPU.

Note If you have made download-relevant changes in the configuration and have not compiled since you made the changes, you will be prompted to compile before you download. If the compilation is free of errors, the download will be started automatically when compilation is completed.

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Entire Program If you select "Entire program", all the charts of the active chart folder are downloaded to the CPU. After prompting you for confirmation, the CPU is set to "STOP" and all the blocks on the CPU are deleted.

Note Compiling the entire program does not necessarily mean a complete download. If the program was already loaded on the CPU prior to compiling, it is possible to download the changes only. If a full download is aborted, no downloaded changes is possible until the full download is completed. Reason: The blocks on the CPU were deleted prior to the download.

Downloading Changes If you select "Changes only" in the "RUN-P" CPU mode, you can download changes to your configuration to the PLC without having to change the CPU to the STOP mode. With this type of download, you only download changes that have been made since the last download. •

If the chart topology has been changed in the SFC charts (steps or transitions added, deleted, copied, moved, jump destination changed, ...), these charts must be deactivated.

•

Modifications to the interface of the SFC type are transferred to the SFC instances immediately. The SFC instances must therefore be deactivated during downloads and execution stopped on the CPU.

•

If SFC charts have been modified (chart properties, object properties are the steps/transitions) without changing their structure, you can download the charts after they have been compiled while the CPU is in RUN without needing to deactivate be modified SFC chart.

•

If you have not changed the chart itself, but only the objects that are accessed (for example a symbol in the symbol table, runtime groups, block I/O), you do not need to deactivate the chart before it is downloaded.

•

After downloading changes, the halted SFC chart is not started with the property "Autostart: on" but must be started again by the operator.

Note Please note that there is no absolute guarantee that the CPU will not change to the STOP mode when you download changes.


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7.11.6.16 How to Test the SFC Program

Test Functions To support you during commissioning, the SFC editor provides test functions that allow you to monitor and influence the execution of the sequencer on the CPU and, if required, to change setpoints.

Test Modes The Test mode relates to the CPU belonging to the active chart. As alternatives, the Test mode can be run in two modes: Operating Mode

Description

Process mode

In process mode, the communication for online dynamic display of the SFC charts and SFC instances is restricted and causes only slight extra load on the CP and bus. In this test mode, if an overload situation occurs, a message is displayed indicating that the limit for bus load has been reached. In this case, you should stop the test mode for the SFCs that are not absolutely necessary for the test.

Laboratory mode

The laboratory mode allows convenient and efficient testing and commissioning. In the laboratory mode, in contrast to the process mode, communication for online dynamic display of SFCs is unrestricted.

Requirement Testing is possible only when there is a connection between the CPU and your PC and the program has been downloaded.

Activating/Deactivating Test Mode

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Activating Test Mode: Select the menu command Debug > Test Mode. The Test mode is activated. You can now activate the debug menu functions; Most of the functions of the Edit mode become inactive.

•

Deactivating Test Mode Select the menu command Debug > Test Mode again. The Test mode is deactivated. When you deactivate the Test mode, the debug functions become inactive and the functions of the Edit mode are activated again.


Configuring PCS 7

Testing Once you have started the test mode, you can test the functionality of your SFC. The SFC can be started in "manual" mode. You can also influence the operating parameters with which the SFC executes (for example cyclic operation). When the SFC is in "RUN", you see •

which step is currently active

•

which actions are executed in this step

•

which transitions are active and which conditions must be satisfied for this transition.

Changing the Mode You can select the mode for the test in the SFC Editor using the menu commands in the "Debug" menu. It is not possible to change over once you are in Test mode.


Online help on SFC

•


•

Manual SFC for S7; Sequential Function Chart


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7.11.7

Creating Models (Multiproject)

7.11.7.1

How to Create a Model

Introduction Generally a plant is structured by dividing it into smaller functional units that can be classified, for example fixed setpoint controls, motor controllers etc. Instead of implementing new functional units each time they are required, you can create a pool of ready-made functional units (models) in the engineering system that you then only need to copy and modify for the new situation. You can also put the models in your project library so that they can be used again.

Model Note You can only create or modify models in a multiproject.

A model consists of hierarchy folders with CFC/SFC charts, pictures, reports, and additional documents. A model also contains a connection to an import/export file (IEA file). Using the Import/Export Assistant (IEA), you link block/chart I/Os and messages of blocks with the columns of an import file. To ensure that there is only one version of a model throughout a project, all models should be stored centrally in the master data library and all adaptations should be made prior to generating the replicas.

Replicas After linking the model prepared in this way to an import file, the model can be imported with the Import/Export Assistant. The generated replicas are assigned the parameters, interconnections, and messages of the model. Each line in an import file creates a replica in the destination project.

Requirement The functional unit from which you want to create a model has already been tested on the automation system and on the operator station.

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How to Create a Model 1. You select the hierarchy folder containing the CFC chart (or CFC charts, SFC charts etc.) required for the model in the master data library (or a hierarchy folder containing a nested hierarchy folder with a CFC chart). 2. Using the menu command Options > Models > Create/Modify Model... start the Assistant and make the selection shown below in the next dialog steps: -

Select the chart/Block I/Os from which you want to assign descriptions of parameters or signals.

-

Select the blocks with messages to which you want to assign message texts.

-

Select the import file and the columns of the import file you want to assign to the selected I/Os and messages of the blocks.

In the "Which import data do you want to assign to which models?", the text "
How to Create an Import File If the import file does not yet exist or no suitable import file exists, you can create an import file with the "Create Template File..." button from the previously selected model data. Here, there are two possibilities: •

•

You create the import file and at the same time edit the required titles. -

In the "Import file" combo box, select "". The editing mode is now active in the "Column Title" column of the "Model Data" list.

-

Edit the required titles.

-

Continue as described for the second procedure.

You generate the import file with "artificial" column titles since you do not yet want to finalize the texts: -

Click the "Create Template File..." button, select the file name and in the following dialog box select the optional column types or deselect the columns you do not require (for example, FID or LID).

In the structure of the file, the attributes of the I/O flags are evaluated and the entries for Text 0, Text 1, unit, value, and identifier are entered automatically if they exist; interconnections, chart name and hierarchy are entered automatically. Afterwards, only the hierarchy and the chart name must be adapted. If you select the second method, you can edit the assigned file with the IEA file editor by opening it with the "Open File" button. Here, you can modify titles and remove individual columns you do not require, add rows and edit descriptions. After saving the file, the IEA displays the new titles that you must then assign.


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Finishing the Model Once you have assigned the import data to the model data, click the "Finish" button. You then have a model available with an assignment to a column of the import file for each selected I/O and each selected message; in other words every column of the import file has been used (1:1 assignment). With messages, not all lines of the model data must be supplied with data from the input file; in other words the number of messages in the import file can be less than those in the model (here the 1:1 assignment does not apply). The hierarchy folder is displayed as a model in the SIMATIC Manager.

Modifying a Model Models that do not yet have replicas can be modified at any time (menu command: Options > Models > Create/Modify Model...). If you modify models that already have replicas, a message is displayed since the import data no longer match the model data. If you modify the flagged I/Os (IEA flags) of a model that already has replicas, a message is displayed and the dialog is extended by an additional step. All the modifications that have been made are logged in this additional dialog box. The modifications are then made in all replicas; in other words: •

If IEA flags are missing in the replicas, they are set.

•

If there are more IEA flags set in the replicas than in the model, these are removed from the replicas.

Note In an existing model or in replicas of a model, the names of the blocks must not be modified. Import/export would otherwise be impossible.

With the IEA, you can assign parameters to block I/Os and chart I/Os and interconnect them; you can also rename chart I/Os.

Note Remember that it may be necessary to adapt the IEA file as well.

Further information

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•

Section "How to Work with Models in the SIMATIC Manager"


Configuring PCS 7

7.11.7.2

Textual Interconnections and Models Using a textual interconnection, inputs and outputs of blocks or nested charts can be interconnected during import. This applies both within a chart or cross-chart.

Requirement The interconnection partners are in the same chart folder.

Syntax The interconnection has the following syntax: cfc\block.io

or

cfc\chart.io

If folders of the PH are included in the name, the path of the plant hierarchy can also precede the name (th\th\cfc\chart.block] but this is ignored.

Textual Interconnections Textual interconnections are possible only for I/Os defined as parameters. Textual interconnections can start both at outputs and imports if these are defined as parameters. Multiple interconnections are possible only at the outputs of the CFC. Only single interconnections are possible at the inputs. When creating the IEA file, the textual interconnection option must be activated in the "Parameters" tab.

Multiple Interconnections Multiple interconnections are interconnections that lead from one output to several inputs. Multiple interconnections can be entered in the import file for parameters or signal outputs. The I/O names are separated in the column by double quotes ("). •

If you want to retain an existing single interconnection and add a new interconnection, enter the delimiter " (double quote) after the text for the interconnection. Without this delimiter, the old interconnection would be replaced by the new one.

•

If a multiple interconnection already exists, the interconnection is always created during import in addition to the existing and connections regardless of whether the delimiter exists or not.

During export, the existing multiple interconnections are also indicated by the " delimiter.


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Rules Note • When you create a model/process tag, the "Create Template File" function enters the interconnection partner according to the interconnection in the model for the textual interconnection in the "TextRef" column. During import, this would lead to an interconnection in the model and therefore change the model. This column must therefore be corrected. To prevent accidental changes to the model, the interconnection partner has a preceding question mark ("?") in the "TextRef" column that would cause an error during import. When correcting, you can then search for "?" with the IEA file editor and modify these cells accordingly.

7.11.7.3

•

Textual interconnections should, whenever possible, only originate at inputs. For this reason, no "TextRef" columns are created for outputs when the file template is generated even if the "Textual Interconnection" option was marked in the selection dialog. If required, you must create these extra with the "Expand Column Group" function of the IEA editor.

•

Textual interconnections are set up at parameter flagged I/Os, interconnections to shared addresses at signal flagged I/Os.

Generating Replicas from Models

Generating Replicas Using the Assistant for models, you import the data of the model. The model is copied from the master data library to the specified target project as a replica and the data is then imported. According to the entry in the import file, you can create any number of replicas. When you import, you can decide whether or not the imported signals will be entered in the symbol table (option: "Include signals in the symbol table"). With PCS 7, we recommend that you do not use the option because these entries are made when you configure the hardware with HW Config.

Requirement To generate replicas from models, the corresponding import file must exist.

Further Reading You will find a detailed description of the settings of the import files with the IEA file editor in the section "Importing/Exporting Process Tags/Models". Below, you will find a description of the basic procedure for existing import files.

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Procedure 1. Select the required model in the master data library. 2. Select the menu command Options > Models > Import... Result: After starting the function, the assistant searches for the models and corresponding import files (in all hierarchy subfolders as well) and displays them. The import function will include all listed import files. 3. If you do not want to import certain files, you can select them and remove them from the list with the "Remove" button. With the "Other File" button, you can browse for a different import file and select it instead of the selected file. 4. Start the actual import with the "Finish" button. Result: Depending on the options selected, the complete list of import activities or only the errors that occurred are displayed in the log window. The log is saved in a log file and the name and path of the file are displayed below the log window. You can modify this setting with the "Other File" button.

Further information

7.11.7.4

•


•

Section "How to Import Process Tag Types and Models"

How to Work with Models in the SIMATIC Manager

Copying Models Note In a multiproject, a model must not exist more than once and must be located in the master data library.

Copy a model in the SIMATIC Manager ... •

within the same multiproject or from the multiproject to another multiproject - this copy is then a replica with identical content.

•

from the master data library to a project - this produces a replica.

•

from the master data library to another master data library (other multiproject) - it remains a model.

•

from the master data library to another library - it remains a model. This allows you to create a backup of the model. During import, the backup is ignored.


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Copying Replicas of the Model If you copy a replica of the model in the SIMATIC Manager within the same multiproject, the new hierarchy folder is also assigned to the original of the model; in other words, the copy is just like all other replicas created with the IEA and does not have its own assignment to the import file; in other words, it behaves just like a replica created by importing with the IEA. If you copy a replica to a different multiproject, it has no assignment there as long as there is no copy of the corresponding model in the master data library. The replica receives its assignment again if it is copied back to the original project (for example when branching and merging project data).

Procedure - Removing Models You do not want a model to be available any longer for import/export; in other words, you want the model to become a normal hierarchy folder again. 1. Select the hierarchy folder. 2. Select the menu command Edit > Object Properties. 3. Change the property in the "Models" tab using the "Clear" button. Result: The assignment to the import file is deleted. This also means that all existing replicas of the model are changed to normal hierarchy folders.

Procedure - Removing Replicas The replicas of a model can be removed in the same way as models; in other words, you can make them normal hierarchy folders, 1. Select one of the replicas 2. Select the menu command Edit > Object Properties. 3. Select the replicas in the "Models" tab and click the "Clear" button.

Deleting Models with Replicas If you delete a model of which replicas already exist, all the replicas are retained unchanged but they lose their assignment to the model. If you then replace the deleted model with a model of the same type (for example by branching and merging projects), the assignment of the replicas is established again. If you do not want to retain them as replicas, but want to change them back to normal hierarchy folders, use the procedure described above ("Procedure Removing Replicas").

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7.11.7.5

How to Assign Replicas to a Model Later With the IEA, you can make replicas or neutral hierarchy folders with CFC charts that do not belong to a model into replicas of an existing model if the structure of the replica matches that of the model completely. The following applications are conceivable: •

You imported into a project and then adapted the replicas locally. A handling error (for example in distributed engineering the model was forgotten after branching and merging) replicas exist but the corresponding model is missing.

•

You want to continue working with the IEA in a project after several charts have already been created and adapted locally. You want to assign the hierarchy folders with these charts to a model as replica.

The procedure for the situations outlined above is described below.

Procedure - Recreating a Lost Model If replicas no longer have a model, a suitable model can be created for them. 1. Select the replica. 2. Select the menu command Options > Models > Create/Modify Model. 3. In the next dialog steps, select the previous import file and assign this import data to the model data: Refer to the section "How to Create a Model". 4. Start the export with the menu command Options > Import/Export Assistant > Export to obtain an IEA file with the current data of all existing replicas.

7.11.8

Editing Mass Data in the Process Object View With the process object view all the data of the basic control throughout a project can be displayed in a process control-oriented view. Project-wide means that the data of all projects in a multiproject is acquired.

Working with the Process Object View In the tree structure, you can create new objects, copy, move and delete objects. The properties of the hierarchy folders for batch and continuous plants can also be edited here. All the essential aspects of the objects can be documented and edited in the table directly (content window) without the user needing to change to the tools editing the objects. Not all the attributes can be edited directly. This information is then grayed. There are however shortcuts to the necessary configuration tools.


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Shortcuts out of the Process Object View You can edit aspects of an object (process tag, CFC, SFC, picture) in the appropriate configuration tool if they cannot be edited in the process object view. To allow this, there are shortcuts to the selected object in the process object view that you can activate with the menu command Edit > Open Object (Open object / Open chart / Open picture). This applies regardless of the selected tab. Examples (General tab): Object

Establishes ...

Opens ...

Picture

The connection between a process tag, a The WinCC Graphics Designer with the CFC or an SFC and their picture picture defined by the currently selected interconnections. cell/row.

Archive

The connection between a process tag, a WinCC Tag Logging with the archive defined CFC or an SFC and their archive tags. by the currently selected cell/row.

Chart

The connection to the CFC/SFC chart.

Module

The connection between a process tag or HW Config with the object properties of the a CFC and the corresponding modules. module.

Message

The connection to the block message.

The dialog box for configuring messages with block messages defined by the currently selected cell/row.

Symbol Table

The connection to the symbol table.

The symbol table of the S7 program defined by the currently selected cell/row.

The CFC/SFC Editor with the relevant chart defined by the currently selected cell/row.

Overview Editing mass data in the process object view involves the following topics:

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How to Display the General Data

•

How to Edit Parameters

•

How to Edit Signals

•

How to Edit Messages

•

How to Edit Picture Objects

•

How to Edit Measured Value Archives

•

How to Test in the Process Object View


Configuring PCS 7

7.11.9

Working in the Process Object View

7.11.9.1

Filtering and Sorting

Filtering In the process object view, you can limit the objects displayed using a filter. The default is: ). In the "Filter by column:" combo box, select the column in which you want to select the objects to be displayed in the table using the filter text ("Display:" input field). Examples: •

You want to display all CFC charts in the table. In "Filter by column:", select the type and enter cf in the "Display:" input field. Result: All object types are displayed that start with the letters cf, for example all CFC charts.

•

You want to display all objects from a particular area. In the "Filter by column:" combo box, select the path and enter "tank" in the "Display:" input field. Result: All objects containing the string "tank" in their paths are displayed.

There are special filter entries for the "Simulate outputs" column.

Note The filter settings you make in the "General" tab also apply to the other tabs. The filter settings in these tabs further restrict the selection.

Sorting The data in the process object view can be sorted in ascending or descending order (alphanumerically). Simply click on the column header of the column according to which you want to sort. A small arrow indicates the ascending or descending order.




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7.11.9.2

Setting, Showing/Hiding, Resorting and Defining Columns

Width of the Columns You can set the width of the columns directly in the table (as in Excel). These settings are retained even when you close the process object view or the SIMATIC Manager and open them again.

Splitting the Table You can also split the window into two halves (left and right) with each pane having its own scroll bar. This is a function familiar from programs such as Excel.

Showing and Hiding Columns With the menu command Options > Settings, you can hide the displayed columns in the "Columns" tab, show previously hidden columns and change the order of the columns.

Defining Your Own Columns With the menu command View > Defined Columns, you can add or remove your own columns. In these columns, you can enter project-specific data, for example a waiting time. This information is stored with the corresponding process object and is copied when you copy the object.

Importing and Exporting Using import and export functions, you can also exchange this data with other tools. Refer to the section "Adopting the Data from the Plant Engineering"

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7.11.9.3

Copying, Moving, and Deleting

Rules In the process object you, you can also copy, move, and delete objects in the same way as in the plant view. The following restrictions apply however: •

It is only possible to copy from the content window (right-hand window) to the tree structure (left-handle window) or to a different view in the "General" tab.

•

Copying and moving from the tree window or from another view to the content window is not possible.

•

Deleting objects is possible only in the tree window or in the "General" tab.

Blocks of Information You can select, copy blocks of information in the table and paste the information elsewhere. This function is available not only within the table but also between the table and, for example, office applications such as Excel and Access. This allows you to copy data quickly and simply from existing lists into PCS 7. If an error occurs when doing this, you can correct the error using the "Undo" function implemented in the table (right-click for context-sensitive menu).




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7.11.9.4

Search and Replace

Search and Replace In the tabs of the process object view, you can search and replace text: right-click and select menu command. The search begins at the cell selected or in which the write cursor is positioned. Depending on the area you have selected to search, the entire table is searched (All), or from left to right (By rows), or from top to bottom (By columns). The search makes a "round trip"; in other words, at the end of a line or column the search continues at the beginning until it reaches the cell where the search began. The search stops at the first text found. If you click "Find", the search is continued without replacing the text. If you click "Replace", only the text in this cell is replaced; if you click "Replace All", all occurrences of the text are replaced.

Note • You do not need to specify an entire text but simply enough of the text to make it identifiable. •

If you click the "Replace"/"Replace All" button and have not entered any text in the "Replace with": box, the found text is deleted.


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7.11.9.5

How to Edit the General Data

General In this tab, all the underlying ES objects (objects of the PH) for the part of the plant selected in the hierarchy window are displayed along with their general information. If the selection is changed, the relevant objects are read in again.

Columns in the Table If you have selected the icon for a multiproject in the hierarchy window, only the columns relevant to the objects of the multiproject are displayed. The "Hierarchy" column changes to "Path" and displays the storage location of the projects / libraries. Column

Meaning

Hierarchy / Path

Displays the technological path of the object (or the storage location of the projects / libraries).

Name

Displays the icon of the object and the object name. You can modify the object name here.

Comment

Shows the comment on the object. You can change the comment.

Type

Displays the object type, for example, process tag, CFC, SFC, picture, report, or additional document.

Process tag type

Displays the name of the process tag type from which the process tag was derived.

FID

Text box for the function identifier. The text modified here is entered in the CFC/SFC in the labeling field, "Part 3" tab, "Name:".

LID

Text box for the location identifier. The text modified here is entered in the CFC/SFC in the labeling field, "Part 3" tab, "Designation block according to place:".

Status

This column is visible only in the online view. A status message is displayed here if the check box is set in the the"Watch" column. In terms of color and text, the status display is analogous to CFC.

Watch

This column is visible only in the online view. Here, you can register the process tag or the chart for test mode. If the watch is activated, the columns "Activated", "Simulate inputs", and "Simulate outputs" are displayed dynamically.

Activated

With this option, you can activate or deactivate charts in the run sequence. The check box can be set offline and online.

Simulate inputs

With this option, the input signals of the sensor are changed to the simulation values of the driver blocks (CH_AI, CH_DI, CH_U_AI, CH_U_DI, CH_CNT, PA_AI, PA_DI, PA_TOT). The check box can be set offline and online. Exception: If all SIM_ON I/Os are interconnected, the check box is disabled. If only some of the SIM_ON I/Os are interconnected, the check box is enabled, the setting, however, applies only to the SIM_ON I/Os that are not interconnected.


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Column

Meaning

Simulate outputs

With this option, the output of signals to the actuators in the automation system is changed from the calculated value to the simulation value of the driver blocks (CH_AO, CH_DO, CH_U_AO, CH_U_DO, PA_AO, PA_DO). The check box can be set offline and online. Exception: If all SIM_ON I/Os are interconnected, the check box is disabled. If only some of the SIM_ON I/Os are interconnected, the check box is enabled, the setting, however, applies only to the SIM_ON I/Os that are not interconnected.

CPU

Displays the component path to the S7 program containing the process tag or the CFC/SFC chart. By clicking in the box, you can display a drop-down list box. If the project contains several S7 programs, these are displayed in the drop-down list box. If you select a different S7 program, you can move the chart.

OS

Displays the component path of the OS containing the picture or report. By clicking in the box, you can display a drop-down list box. If the project contains several operator stations, these are displayed in the drop-down list box. By selecting a different OS, you can move the object.

Block Icons

In this column you can see the pictures for which block icons will be automatically generated (in the PH or when the OS is compiled). You can set or reset the attribute "Derive block icons from the plant hierarchy" for each of the collected pictures without needing to open the object properties of the individual pictures.

Author

Text field for the name of the author.

Version

Displays the version number of the CFC and SFC charts that you can change here.

Size

Shows the size of the object in bytes as far as is practically possible.

Last modified

Displays the date of the last modification to the object.


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7.11.9.6

How to Edit Parameters

Parameters This tab displays the flagged I/Os for all the process tags and CFC charts displayed in the "General" tab that were selected explicitly for parameter assignment or interconnections between the process tags or CFC charts. I/Os can be selected for the "Parameters" tab •

in the SIMATIC Manager using the menu command Options > Process Objects > Select I/Os... (display of the objects selected in the tree structure)

•

in CFC in the "Properties – I/O" dialog (of a block)

•

in the block type system attribute S7_edit = para

•

in the process tag type in the "Create/Change Process Tag Type" dialog box

Processing You can enter the value, unit, identifier, operate texts for binary states and comments for the I/Os visible here. As an alternative to the value, you can also insert block interconnections. Each cell displayed in the table with a white background can be edited directly in the process object view. You can open the corresponding CFC chart in the context-sensitive menu. The relevant I/O of the block is selected. You can limit the selection of objects displayed using a filter (refer to the section "Filtering and Sorting").

Columns in the Table Column

Meaning

Hierarchy

Shows the technological path of the process tag or CFC (cannot be changed).

Chart

Shows the name of the process tag or CFC (cannot be changed).

Comment

Shows the comment on the object (cannot be changed).

Block

Shows the block name (cannot be changed).

Block comment

Show the comment on the block. You can change the comment.

I/O

Shows the name of the block I/O (cannot be changed).

I/O comment

Text field for the comment on the block I/O. You can change the comment.

Process tag connector Shows the name of the flagged I/O as specified for the process tag type (cannot be changed). Category

Shows the category of the flagged I/O as specified for the process tag type (cannot be changed).

Status

This column is visible only in the online view. The status message is displayed here if the option is set in the the"Watch" column. In terms of color and text, the column is analogous to CFC.

Watch

This column is visible only in the online view. Here, the I/O can be registered or deregistered for the test mode. If monitoring is activated, the columns "Status" and "Value" are displayed dynamically.


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Column

Meaning

Value

Text field for the value of the I/O according to the data type and permitted range of values. You cannot edit the value if it involves a interconnected I/O of the type IN or IN_OUT. If this is the value of an enumeration, if it exists, the text for the enumeration value can be selected from a drop-down list box. The enumerations and their values are declared and managed on the ES. If "Watch" is active in test mode, the column is displayed dynamically.

Unit

Text field for the unit of the value. Apart from entering texts, you can also select common units (kg, m, s, min, ...) from the drop-down list box (I/O with system attribute "S7_unit"). See also Entering Units.

Interconnection

Text field for interconnecting the I/O. Apart from entering text, you can also start the interconnection dialog from the context-sensitive menu "Insert Interconnection". A textual interconnection is displayed on a yellow background. See also: Rules for Displays and Entries in the "Interconnection" Column.

OCM possible

Check box with which you can display whether the I/O can be controlled and monitored by the operator (I/O with system attribute "S7_m_c"; the attribute cannot be changed).

Identifier

Text field for the shortcut of the I/O (I/O with system attribute "S7_shortcut").

Text 0

Text field for a text describing the state "0". The text is only displayed and can only be edited when the I/O is of the data type "BOOL" and has the system attribute "S7_string_0".

Text 1


Watched

Check box that decides whether the I/O is registered in test mode (I/O with system attribute "S7_dynamic"). You can modify the option.

Archiving

In this column, you can see whether or not the block I/Os that can be controlled and monitored by the operator are intended for archiving (I/O with system attribute "S7_archive"). You can change this entry. If you click in the text box, a drop-down list box is displayed. The following can be selected: •

No archiving

•

Archiving

•

Long-term archiving

Can be read back

Indicates whether or not the I/O is marked as being capable of being read back (I/O with system attribute "S7_read_back"). You cannot modify the option.

MES-relevant

Option with which you can decide whether the information of this I/O can be transferred to the management levels MIS/MES in response to a request. The option can only be selected when the "Operator C and M possible" check box is set. Note: In the default setting, the column is hidden since this information is not normally used in PCS 7. If you want the column to be displayed in your process object view, you can select this with Options > Settings > Columns.

Enumeration

For I/Os with the system attribute "S7_enum", the object name of the enumeration assigned to the I/O is listed here. You can change the name. If you click in the text box, a drop-down list box opens from which you can select the required name of the enumeration. The enumerations and their values are declared and managed on the ES.

Data type

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Shows the data type of the I/O (cannot be changed).


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Column

Meaning

I/O

Shows the I/O type (IN = input, OUT = output, IN_OUT = in/out parameter) and cannot be changed.

Block type

Shows the name of the block type from which the block originates (cannot be changed).

Chart type

Here, you can see whether the flagged I/O belongs to a CFC or SFC chart.

Process tag type

Shows the name of the process tag type from which the process tag is derived (cannot be changed).




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7.11.9.7

How to Edit Signals

Signals This tab displays the flag I/Os for all the process tags and CFC charts displayed in the "General" tab that were selected explicitly for signal interconnections. As default, these are all the VALUE inputs and outputs of the PCS 7 channel driver blocks. I/Os can be selected for the "Signals" tab •

in the SIMATIC Manager with the menu command: Options > Process Objects > Select I/Os...

•

in CFC in the "Properties – I/O" dialog box

•

in the block type: system attribute S7_edit = signal.

Processing You can enter symbolic names for the interconnection with the I/O as well as text attributes and comments. As an alternative to textual entry of the interconnection symbol, signals can also be selected in a dialog if they have already been specified by the hardware configuration. In the context-sensitive menu, you can open either the relevant CFC chart or the hardware configuration (HW Config) or the symbol table. You can limit the selection of objects displayed using a filter (refer to the section "Filtering and Sorting"). Each cell displayed in the table with a white background can be edited directly in the process object view.


Meaning

Hierarchy


Chart


Comment


Block


Block comment


I/O


I/O comment


Process tag connector Shows the name of the flagged I/O as specified for the process tag type (cannot be changed). Category

Shows the category of the flagged I/O as specified for the process tag type (cannot be changed).

Status

This column is visible only in the online view. A status message is displayed here if the option is set in the the"Watch" column. In terms of color and text, the status display is analogous to CFC.

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Column

Meaning

Watch

This column is visible only in the online view. Here, you can register or deregister the I/O for test mode. If monitoring is activated, the columns "Status" and "Value" are displayed dynamically.

Value

Text field for the value of the I/O according to the data type and permitted range of values. You cannot edit the value if it involves a interconnected I/O of the type IN or IN_OUT. If this is the value of an enumeration, if it exists, you can select the text for the enumeration value from a drop-down list box. The enumerations and their values are declared and managed on the ES. If "Watch" is activated in test mode, the column is displayed dynamically (on a yellow background). If I/Os are interconnected, the value to be monitored is displayed on a grayish yellow background (cannot be edited). A red background indicates a problem in transmission (value failed).

Unit

Text field for the unit of the value. From a drop-down list box, you can select the most common units (kg, m, s, min, ...) for this I/O (with system attribute "S7_unit"). Note: The list of units is generated from the basic set of CFC. This basic set can be managed and changed in the ES.

Signal

Text field for the name of the interconnected signal. You can also enter an absolute address. If a symbol exists for the absolute address you enter, this is displayed; if not the absolute address is displayed preceded by '%'. Apart from entering text, you can also start the interconnection dialog from the contextsensitive menu "Insert Signal".

Signal comment

Text field for the signal comment read from the symbol table (cannot be changed).

Absolute address

Absolute address of the signal (for example QW 12 or I3.1) read from the symbol table or originating from the "Signal" input field if the absolute address was entered there (cannot be modified).

Hardware address

Hardware address of the signal. Read from HW Config (cannot be changed).

Measurement type

Measuring type of the signal for input modules; output type of the signal for output modules. Read from HW Config (cannot be changed).

Measuring range

Measuring range of the signal for input modules; output range of the signal for output modules. Read from HW Config (cannot be changed).

CPU

Component path to the S7 program containing the process tag or the CFC chart (cannot be modified).

OCM possible

Check box with which you can display whether the I/O can be controlled and monitored by the operator (I/O with system attribute "S7_m_c"; the attribute cannot be changed).

Identifier

Text field for the shortcut of the I/O (I/O with system attribute "S7_shortcut").

Text 0


Text 1


Watched

Check box that decides whether the I/O is registered in test mode (I/O with system attribute "S7_dynamic"). You can modify the option.

Can be read back

Indicates whether or not the I/O is marked as being capable of being read back (I/O with system attribute "S7_read_back"). You cannot modify the option.


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Column

Meaning

Enumeration

For I/Os with the system attribute "S7_enum", the object name of the enumeration assigned to the I/O is listed here. You can change the name. If you click in the text box, a drop-down list box opens from which you can select the required name of the enumeration. The enumerations and their values are declared and managed on the ES. You can also enter a name in the text box for which no enumeration has yet been defined.

Data type

Shows the data type of the I/O (cannot be changed).

I/O

Shows the I/O type (IN = input, OUT = output, IN_OUT = in/out parameter) and cannot be changed.

Block type


Chart type


Process tag type



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7.11.9.8

How to Edit Messages

Messages This displays the message texts of the signaling blocks belonging to the process tags and CFC/SFC charts displayed in the "General" tab.

Processing The relevant charge can be opened from the context-sensitive menu. You can limit the selection of objects displayed using a filter (refer to the section "Filtering and Sorting"). Each cell displayed in the table with a white background can be edited directly in the process object view.


Meaning

Hierarchy


Chart


Comment


Block


Block comment


I/O


I/O comment


Sub number

Sub number of the message (cannot be changed).

Class

Message class as specified for the block type. You can select from a drop-down list box. You cannot change the message class if it is locked in the block type message.

Priority

Message priority. You can select from a drop-down list box. You cannot change the priority

Origin

•

if it is locked in the block type message.

•

if the message was configured according to the old message concept ("message numbers assigned uniquely throughout the project").

Origin of the block. In PCS 7, the keyword $$HID$$ is used. You cannot change the text if it is locked in the block type message.

OS area

OS area text according to which the message list can be filtered online. In PCS 7, the keyword $$AREA$$ is used. You cannot change the text if it is locked in the block type message.

Event

Text field for the event text (for example "$$BlockComment$$ too high). You cannot change the text if it is locked in the block type message.

Batch ID

BATCH message text. You cannot change the text if it is locked in the block type message.


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Column

Meaning

Info text

You cannot change the text if it is locked in the block type message. Note: Apart from the "Info text" column, the tab also includes the "Free text 1" .... "Free text 5" and "Operator input" columns. In the default setting, the columns are hidden since these texts are not normally used in PCS 7. If you want the columns to be displayed in your process object view, you can set this with Options > Settings > Columns.

Block type


Chart type


Process tag type



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7.11.9.9

How to Edit Picture Objects

Picture Objects This displays all the blocks of the CFC charts that can potentially be controlled and monitored by the operator for the process tags and CFC charts displayed in the "General" tab, along with any existing picture interconnections and picture assignments. All the SFC charts and any existing picture and connections and picture assignments are also displayed. For each block, you can see the location at which they are used (in which OS, in which picture, interconnected with which picture object). With block icons, you can select the appearance of the icon. If a row next to the block is empty, this means that the block is not controlled or monitored by the operator on any OS of the project.

Processing The displayed interconnections and assignments cannot be edited. The tab essentially has a cross-reference function, and is used to provide a fast overview of the existing or missing picture interconnections and assignments of one or more process tags. If you want to change something in a picture, you can open the selected picture WinCC Graphics Designer using the context-sensitive menu (you can also open the CFC chart in the context-sensitive menu). You can limit the selection of objects displayed using a filter (refer to the section "Filtering and Sorting"). Each cell displayed in the table with a white background can be edited directly in the process object view.


Meaning

Hierarchy


Chart


Comment


Block


Block comment


Create block icon

Check box with which you can decide whether or not a block icon is generated for this block. With SFC, this row is displayed empty. The option can only be selected when the "Operator C and M possible" check box is set. If you set the option, you can also edit the cell in the "Block icon" column.

Block icon

Name of the icon with which the block is displayed in the OS picture. The cell can only be edited if the check box in the "Create block icon" column is set. With SFC, this row is displayed empty. Here, you enter a name for this block instance if there is more than one variant of block icons for this block type. If no name is entered, the standard block icon is used.


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Column

Meaning

OCM possible

Check box with which you can decide whether the block can be controlled and monitored by the operator (system attribute "S7_m_c") or whether the SFC chart is transferred to the OS for visualization.

MES-relevant

Check box with which you can decide whether the information of the picture objects can be transferred to the management levels MIS/MES in response to a request. The option can only be selected when the "Operator C and M possible" check box is set. Note: In the default setting, the column is hidden since this information is not normally used in PCS 7. If you want the column to be displayed in your process object view, you can set this with Options > Settings > Columns.

I/O

Shows the name of the block I/O or SFC I/O (cannot be changed). This row is empty if a picture object is assigned to the block as a whole.

I/O comment

Text field for the comment on the I/O. You can change the comment. This row is empty if a picture object is assigned to the block as a whole.

Process tag connector Shows the name of the flagged I/O as specified for the process tag type (cannot be changed). This row is empty if a picture object is assigned to the block as a whole. OS

Displays the component path of the OS on which the picture is located. In a multiproject, the project name is also displayed in the path of an OS from a different project (cannot be modified).

Picture

Name of the OS picture (cannot be modified).

Picture object

Name of the picture object, for example faceplate, user object (cannot be modified).

Property

Name of the interconnected or assigned property of the picture object (cannot be modified).

Block type


Chart type

Here, you can see whether the picture is assigned to a CFC or SFC chart.

Process tag type


Further information

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7.11.9.10 How to Edit Measured Value Archives

Measured Value Archives Here, all the process tags, CFC charts, SFC charts and any existing interconnected WinCC archive tags displayed in the "General" tab are displayed along with their attributes. Each archive tag is visualized in a row. Not all the attributes defined in WinCC Tag Logging are displayed, only the set relevant to PCS 7.

Processing The archive tags must first be created in WinCC Tag Logging. The attributes of the archive tags can then be edited directly in the table (without opening WinCC Tag Logging). When necessary, you can open WinCC Tag Logging from the context-sensitive menu. You can limit the selection of objects displayed using a filter (refer to the section "Filtering and Sorting"). Each cell displayed in the table with a white background can be edited directly in the process object view.


Meaning

Hierarchy


Chart


Comment


Block


Block comment


I/O

Displays the name of the block I/Os or SFC I/O (cannot be modified). This sale is displayed empty if a picture object is assigned to the block as a whole.

I/O comment

Text field for the comment on the I/O. You can change the comment.

Process tag connector Shows the name of the flagged I/O as specified for the process tag type (cannot be changed). OS

Displays the component path of the OS containing the picture or report. In a multiproject, the project name is also displayed in the path of an OS from a different project (cannot be modified).

Archive name

Name of the measured value archive (cannot be modified).

Variable name

Text field for the name of the archive tag.

Variable comment

Text field for the comment of the archive tag.

Long-term archiving

Indicates whether or not the archive tag is intended for long-term or short-term archiving. A change made here, takes effect directly in the measured value archive of WinCC; in other words, the OS does not need to be recompiled. The changes also affect the "Parameters" tab and the relevant block I/Os in CFC.

Variable supply

Type of variable supply. You make the selection from a drop-down list box (system, manual input).


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Column

Meaning

Archiving

Here, you can specify whether archiving begins immediately at system startup. You make the selection from a drop-down list box (enabled, disabled).

Acquisition cycle

Cycle for acquiring data. You can make the selection from a drop-down list box.

Factor for archiving cycle

Here, you can specify the factor for the archiving cycle. The factor cannot be modified if the acquisition type is acyclic.

Archiving/display cycle Here, you can enter the cycle used for archiving and for displaying the data. You can make the selection from a drop-down list box. The cycle cannot be modified if the acquisition type is acyclic. Save on fault/error

Here, you enter the type of correction if faults or errors occur. You make the selection from a drop-down list box (last value, substitute value).

Archive if

Here, you specify the state change of the logical signal, the type of change, and the time at which the change is archived. You can make the selection from a drop-down list box. The entry is possible only for binary tags.

Unit

Unit from the ES data management. This is only displayed here and can be modified in the "Parameters" tab.

Data type

Displays the data type of the I/O.

I/O

Displays the I/O type (IN = input, OUT = output, IN_OUT = in/out parameter).

Block type

Displays the name of the block type from which the block originates.

Chart type

Here, you can see whether the archive tag belongs to a CFC or SFC chart.

Process tag type

Displays the name of the process tag type from which the process tag was derived.

Further information

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7.11.9.11 How to Test in the Process Object View

Test Mode in the Process Object View The process object view provides a test mode in which you can test and commission process tags and CFC charts online on the CPU. In test mode, the following columns are displayed dynamically in the process object view: Tab

Dynamic Column

Additional Column in Test Mode

General

Status

Watch

Activated Simulate inputs Simulate outputs Parameters

Status

Watch

Value Signals

Status

Watch

Value

The "Messages", "Picture Objects", and "Measured Value Archive" tabs cannot be selected in test mode.

Procedure You can set the selection of the test mode in the process object view with the "View" menu. Enabling and disabling only affects the active window of the process object view. •

Activating Test Mode: In the SIMATIC Manager, you can enable the test mode with the View > Online menu command. When you enable the test mode, no new window opens, the existing window is switched over.

•

Activating Test Mode: You can disable the test mode with the menu command View > Offline.

When you change to test mode, the online and offline data is checked to make sure it matches (similar to the test mode in CFC and SFC). If there are deviations, a message to this effect is displayed.


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Explanations of the Tabs Tab

Description

General

In this tab, it is not possible to delete, move, or copy objects. Apart from the "AS" column, all the columns remain editable if they can be modified in offline mode. Changes in the "Activated", "simulate inputs", and "Simulate outputs" columns are effective both online and offline. This also applies if the process tag or chart is not registered for the test.

Parameters" and In these tabs, the columns "Watch", "Value" and "Watched" can be edited. "Signal" Changes in the "Value" and "Watched" columns are effective both online and offline. This also applies when the I/O is not marked for testing. Dynamic values are shown on a different background according to their status as follows: •

yellow (dynamic, can be changed)

•

gray-yellow (dynamic, cannot be changed)

•

red (failed)

If you want to edit the value, the color changes from yellow to white when you click in the cell. The offline value is then shown.

Settings for Test Mode Analogous to CFC, the test mode can run in process or laboratory mode. You can set this in offline mode with the menu commands Options > Process Objects (Online) > Process Mode or > Laboratory Mode. With the menu command Options > Process Objects (Online) > Test Settings..., you open a dialog box in which you can set the watching cycle. The watching cycle has global effects on all process tags and CFC charts of the current window in the process object view (not CPU-specific as in CFC and SFC). The settings are stored for the user and are not dependent on the settings in CFC/SFC.

Logging the Changes in the Change Log In test mode, all actions that cause a change (value change) in the CPU are logged in the change log. This is only possible if the SIMATIC Logon Service is installed and the change log is activated for the current chart folder. If there is a change, the change log is opened and the reason for the change must be entered. When the user is not yet logged on in the SIMATIC manager, the SIMATIC Logon Service dialog opens before the change log opens. You will find the logged changes in Options > Charts > Logs in the "Change Log" tab.

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Printing the Displays in the Tabs Just as in offline mode, you can print out the values displayed in the current tab using the context-sensitive menu Print > Current Tab. With the menu command File > Print > Object List..., in contrast to offline mode, you can only print the current tab. This is already selected in the "Settings for printing the process object view" and cannot be modified.




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7.11.10


Copying and Pasting between PCS 7 and Excel In all the editors in PCS 7 and the process object view, you can select areas and transfer them to Excel by copying and pasting, edit them and then return them in the same way. You can also exchange data with Access in the same way.

Import/Export Functions All the essential applications of the PCS 7 engineering system have import/export interfaces. The use of these import/export interfaces has the following advantages: •

Data from the plant planning can be synchronized with the data of the control system engineering. This allows control system engineering and class engineering to be edited at the same time independent of each other.

•

Data from the engineering system can be exported as a template, reproduced in an external program (for example Excel), and then imported back into the engineering system. This allows the configuration of repeated or similar plant information to the optimized.

Overview of all Import/Export Functions Refer to the section "Import and Reuse of Plant Data"

Overview of All Importable/Exportable Data Formats Refer to the section "Which Data and Data Formats Can be Imported?"

Preview These sections describe the following import/export functions:

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7.11.11

Import/export of Process Tags/Models

7.11.11.1 Identifying Repeated Functions The starting point for mass data processing is to identify repeated functions.

Functional Units of a Plant Generally a plant is structured by dividing it into smaller functional units that can be classified, for example fixed setpoint controls, motor controllers etc. Instead of implementing new functional units each time they are required, you can create a pool of ready-made functional units that you then only need to copy and modify for the new situation. In keeping with the functional unit of the plant, the now familiar objects process tag types and models are configured in the ES. Using import/export functions, any numbers of process tags and replicas can be created from these objects.

Specifying Process Tag Types and Models Define the process tag types and models of your plant. Check which "off-the-peg" process tag types from the PCS 7 Library can be used in your project or create your own process tag types and models with CFC charts.


Section "How to Create a Process Tag Type from a CFC Chart"

•



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7.11.11.2 Working with the Import/Export Assistant

Note The Import/Export Assistant (IEA) is a separate optional package in PCS 7 and requires a separate authorization. The IEA is supplied on the PCS 7 Toolset CD along with the PH and the process object view and is installed along with them.

When do I work with the IEA? During the planning of a plant, a wide variety of data is created, often at a point in time at which no concrete decision has been made about the details of the control system. By using the import function, this data can be made available to the control system engineering. You use the IEA when you use several models or process tag types often in a project (processing mass data) and want to modify the parameter descriptions of the blocks.

Using the IEA The following graphic illustrates the function of the IEA based on the example of a model.

Define model

ES data management

Planning system

Assign import data IEA file

Copy and parameterize model

Function units I/O signals, ...... Interconnection and parameter description ......

Import/ export log

Update planning system

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7.11.11.3 Working with Process Tags and Models

Overview Working with process tag types and models involves the following topics: •

Requirements and Steps in Configuration

•

Functions for Working with Process Tags and Models

•

How to Create an Import File or Assign it to the Process Tag Type

•

What Happens during Import?

•

How to Import Process Tag Types and Models

•

What Happens during Export?

•

How to Export Process Tag Types and Models

•

Restrictions with the IEA

7.11.11.4 Requirements and Steps in Configuration

Requirements To work with the Import/Export Assistant, you must first create process tag types and/or models in the master data library.

Steps in Configuration Step

Activity

1

Create process tag type/model (Refer to the sections "How to Create a Process Tag Type" and "How to Create a Model")

2

Assign the import file to the process tag type/model - create the import file (Refer to the section "How to Create an Import File or Assign it to the Process Tag Type" and Section "How to Create a Model")

3

Edit the import file with the IEA file editor (Refer to the section "Creating/Editing Import Files with the IEA File Editor")

4

Import process tag types/models (Refer to the section "How to Import Process Tag Types and Models")

5

(Supply process tags and replicas with actual parameters. Only if the data was not already added with the IEA file editor.)


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How the IEA Works The following graphic illustrates the functions of the assistant based on the example of a "process tag type". The steps for a model are analogous and shown in gray.

Data from the plant engineering

Process tag type B Process tag type A Process tag type X

Wizard: Assign/create import file

Master data library

Model A

Assigned import file Data for process tag 1 Data for process tag 2 Data for process tag X

Assigned import file

Model B Model X

Assigned import file

Wizard: Import process tag Wizard: Export process tag Wizard: Synchronize process tag Assigned import file Data for process tag 1 Data for process tag 2 Data for process tag X

Wizard: Import model Wizard: Export model Assigned import file Data for process tag 1 Data for process tag 2 Data for process tag X

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Starting the IEA You start the Import/Export Assistant in the SIMATIC Manager either in the plant view or in the process object view with a hierarchy folder selected. (With process tag types, individual process tag types can also be selected.) In the "Options" menu, select the "Process Tags" or "Models" function and then the required function in the submenu.




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7.11.11.5 Functions for Working with Process Tags and Models With the Import/Export Assistant (IEA), you can work with process tag types and their process tags or models and their replicas. The IEA provides functions for reusing and adapting the process tag types/models.

Functions for Creating Assistant

Functions of the Assistant

Create/Change Process Tag Type

With the assistant, you can do the following:

Creating/Modifying Models

•

Create a process tag type from existing CFC charts and enter it in the master data library.

•

Modify an existing process tag type; in other words, add or remove I/Os or messages.

•

Check existing process tags for discrepancies compared with the process tag type and synchronize any differences.

With the assistant, you can do the following: •

Create a model from the existing PH objects with CFCs, SFC charts, pictures, reports etc. that will be stored in the master data library.

•

Modify an existing model; in other words, add or remove I/Os or messages.

•

Create and assign an import file.

•

Check the consistency of the model with the assigned import file.

•

Check replicas for changed IEA flags.

The selected I/Os and messages are all assigned to a column of the import file. If all the data is entered in the import file, the import can be started.

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Importing Data from the Plant Planning Each functional unit in the plant corresponds to a line in the import file. The IEA copies the suitable model (and generates replicas) or process tag type (and generates process tags) for each function unit and then modifies the interconnection and parameter description and message texts depending on the relevant row of the import file. When you import, you can decide whether or not the imported signals will be entered in the symbol table (option: "Include signals in the symbol table"). With PCS 7, we recommend that you do not use the option because these entries are made when you configure the hardware. Assistant


Importing process tags

With the assistant, you can create process tags from process tag types and import the data from the import file to the process tags. The process tag type is copied from the master data library to the relevant target projects. The data is then imported. The result is a process tag as a copy of the process tag type for each row of the import file. The data of the import file is written to the relevant I/Os or blocks of the process tag.

Importing Models

With the Assistant, you can create replicas of models and import the data from the import file to the replicas. In a multiproject, the model is copied from the master data library to the specified target projects as a replica. The data is then imported. The result is a replica of the model for every row of the import file. The data of the import file is written to the relevant I/Os or blocks of the replica.

Process tag: Assigning/creating the import file

With the assistant, you can do the following: •

Assign an import file to a process tag type.

•

Check the assignment of the import file to the process tag type.

•

Create a template for the import file for the process tag.


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Exporting Data for Plant Planning The replicas of the models or the process tags of process tag types are modified, for example, during testing and commissioning of the control system. This also involves data that was configured with other tools during plant planning and imported for the control system engineering. The following applications are possible: •

If you want to match the plant documentation to the current configured status, export the current data of the models created previously during import in the same form as when you imported them.

•

You can export the data of the plant configured with replicas of models or with process tags, edit the data again with the IEA file editor or with other tools (for example Excel or Access) and then import it again. You can make modifications to the project simply and quickly.

Assistant


Exporting process tags

You can export the data of the process tags with the assistant. In the multiproject, all available projects are included. The result is an export file for each process tag type and a row in the export file for each process tag of the process tag type. An import file must be assigned. The individual column groups are structured in exactly the same way as in the import file; in other words, the same number and names of the column titles.

Exporting models

With the assistant, you can export the data of the replicas of models. In the multiproject, all available projects are included. The result is an export file for each model and a row in the export file for each replica of the model. If a valid import file exists, the individual column groups are structured in the sector the same way as in the import file; in other words, the same number of column titles.

Note When working with the "import/export" functions of the Import/Export Assistant, further hierarchy folders may be contained in the model. If the picture hierarchy is based on the PH, there must only be one picture per hierarchy folder. If the model includes nested hierarchical folders, these must not be renamed.

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Further Functions Assistant


Process tags: Updating

The process tag type and the process tags can be synchronize using the assistant: •

Parameters/flagged signal I/Os and messages that do not exist in the process tag type are removed from the process tags, in other words, the relevant attributes are reset.

•

Parameters/flagged signal I/Os and messages that have been redefined in the process tag type are added to the process tags, in other words, the relevant attributes are set.

•

Categories changed in the process tag type are corrected in the process tags.

Inconsistencies between the process tag type and the process tag that could not be synchronized automatically are entered in the log.

Note To make the charts clearer to read, you can switch block I/Os of the blocks of the models that you do not require to invisible. If you edit later in the IEA, you will see the selections set in the CFC in the process object view and can if necessary correct them. The same applies to selections in models.


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7.11.11.6 What Happens during Import?

Example "Model" - As an Explanation of the Import Procedure The procedure for importing process tags is identical. After you have configured a model and have assigned an import file to it, you can start the import. If you do this directly with this model, the following steps are handled automatically. 1. The hierarchy path from the "Hierarchy" column of the first row of data in the import file is read and checked to see whether the path already exists. Result of the check: Yes: Check the hierarchy folder to see whether or not it is a suitable replica. If -

Yes: Replica is assigned parameters according to the import file

-

no: IEA queries all the I/Os and checks whether they match the model completely. If

-

yes: the hierarchy folder with its CFC chart is made into a replica of the model and assigned parameters according to the import file.

-

no: the hierarchy folder is not accepted as a replica of the model.

No: Create the hierarchy folders required for this hierarchy and copy the model to the appropriate position as a replica and then give it the required hierarchy name. 2. Function identifier (FID), location identifier (LID), CFC chart name and chart comment are inserted in the footer of the charts (optional, if the columns exist). 3. Texts and values of the parameter descriptions and the interconnection descriptions (signals) are written to the corresponding block or chart I/Os of the replicas.

Note An interconnection is deleted when the signal name (symbol or textual interconnection) consists of the codeword "---" (three dashes). An interconnection remains unchanged, if no interconnection name (symbol or textual interconnection) is specified.

4. Check out the data types of the I/Os for signals and assign them to the interconnections. The rule for interconnections with shared addresses is as follows: If the Option "Include signal in the symbol table" is set, look for the names in the symbol table of the resource of the model. For PCS 7, it is recommended not to set this option, since the entries are made in the symbol table when you assign the hardware addresses with HW Config. If the symbol name exists in the symbol table: -

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Symbol name exists: The data type must be the same, the symbol name must only exist once. The data type is set according to the block/chart I/O, the absolute address overwritten and the symbol comment (if it exists in the import file) is entered for the symbol. Only the information that has changed will be overwritten, existing attributes are retained. Process Control System PCS 7 - Engineering System A5E00346923-02

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-

If the symbol name does not exist: the interconnection is created and the data type set according to the I/O, the absolute address and symbol comment (if they exist in the import file) are created for the symbol.

5. The message text is imported for each message. 6. Points 1 to 5 are repeated for each line in the import file. If you have selected a hierarchy folder that contains more than one model, the input files appear in the list along with the model. You can still edit the list. Following this, the import is started for all models in the list as described above. You will receive error messages in the import log in the following situations : •

The hierarchy path contains a replica that does not belong to the model; in other words, input/output flags are missing or there are too many and/or the block is not or is incorrectly marked as a signaling block.

•

There is a model in the hierarchy path

•

The settings in the plant hierarchy do not match the imported hierarchy path

•

Signals in the symbol table are not unique or will be written with incorrect data types.


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7.11.11.7 How to Import Process Tag Types and Models

Overview Using the Assistant for process tags or models, you import the data •

of the process tag types. The process tag type is copied from the master data library to the specified target projects as a process tag and the data is then imported. According to the entry in the import file, you can create any number of process tags. When you import, you can decide whether or not the imported signals will be entered in the symbol table (option: "Include signals in the symbol table"). With PCS 7, we recommend that you do not use the option because these entries are made when you configure the hardware with HW Config. As a result of the import, a process tag of this process tag type is created in the target project for every row of the import file according to the specified hierarchy path.

•

of the model. The model is copied from the master data library to the specified target project as a replica and the data is then imported. According to the entry in the import file, you can create any number of replicas. When you import, you can decide whether or not the imported signals will be entered in the symbol table (option: "Include signals in the symbol table"). With PCS 7, we recommend that you do not use the option because these entries are made when you configure the hardware with HW Config.

Note Before importing, check the language set for display. If you created the model in German and if the current setting of the SIMATIC Manager is in "English", the German message texts will be written into the English text file.

Procedure - Starting the Import Dialog 1. Select the required hierarchy folder, project node or process tag library (hierarchy folder in the master data library) or the process tag type. 2. Select the menu command Options > Models > Import... or Options > Process Tags > Import. Result: The import dialog opens. After starting the function, the wizard searches for the models/process tag types and corresponding import files (in all hierarchy subfolders as well) and displays them. The import function will include all listed import files. 3. If you do not want to import certain files, you can select them and remove them from the list with the "Remove" button. With the "Other File" button, you can browse for a different import file and select it instead of the selected file. 4. Start the actual import with the "Next" button followed by "Finish". Result: Depending on the options selected, the complete list of import activities or only the errors that occurred are displayed in the log window. The log is saved in a log file and the name and path of the file are displayed below the log window. You can modify this setting with the "Other File" button.

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Variants of Process Tag Type/Model Import •

First Import of Process Tag Types/Models When you import a process tag type or a model for the first time, the process tags/replicas are created in the PH according to the entries in the import file and assigned parameters.

•

Importing Further Process Tag Types/Models If you import a process tag type or model again, the I/Os copied during the first import are overwritten by the parameters, signals and messages specified in the IEA file (import changes), and those that do not yet exist are created.

•

Deleting Replicas/Process Tag During Import You can decide whether existing replicas of a model or process tags of process tag type are deleted or overwritten during import. Using the import mode "delete" (in the "ImportMode" column of the import file), you can delete the replica/process tag. message displayed after import indicates whether or not the deletion was successful.

Note When you import, all the rows with the "delete" keyword are processed first and the subjects deleted. Only then are new objects created. If you have already created interconnections to the replicas, these are lost.

•

Reimporting a Process Tag Type/Model If you import again without modifying the model or the process tag type, the I/Os copied during the previous import are overwritten by the parameters, signals and messages specified in the IEA file (import changes).


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Reassigning CFC Charts without an Assignment to the Process Tag Type (Adopting) If you have CFC charts in your projects that are no longer process tags (for example because the assignment to the process tags type was canceled) or charts that are not yet process tags but have the conditions for process tags, you can assign these charts to the process tags type as process tags. Refer to the section "How to Adopt Process Tags". The same principles apply to adopting models.

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7.11.11.8 What Happens during Export?

Example "Model" - As an Explanation of the Export Procedure The procedure for exporting process tags is identical. Once you have created replicas of the models by importing or copying in the SIMATIC Manager and, for example, have edited various values of the parameters and signals during test and startup, you can export the current data in the same form as they were imported. If you start the export function for a model or a replica directly, the following steps are run through automatically: 1. All the replicas of this model are identified. A data line is created in the export file for each replica found. 2. The identifiers LID, FID and the chart names are entered in the export file. 3. The parameter descriptions and interconnection descriptions (per model found) are written to the corresponding cells of the file. For interconnections with shared addresses, this means finding interconnection descriptions based on the interconnection names (symbol names) in the symbol tables of the replicas and writing them to the corresponding cells in the file. 4. The messages of the blocks are identified and written to the appropriate cells of the file. If you have selected a hierarchy folder containing more than one model, the export files with the model found are displayed in the list. If required, you can still edit the list. Finally, the export is started (as described above) for all models in the list. You will see error messages in the export log if flagged I/Os are missing or if there are too many in the replica.


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7.11.11.9 How to Export Process Tag Types and Models Using the Assistant, you can export data for models or process tags. The following options are available: •

Select a model/process tag type to export this alone.

•

You can select a top hierarchy folder or the project node to select and export all nested models (replicas) or process tags.

As a result, there is a row in the relevant export file for every replica of a model or process tag of a process tag type found. The structure of the export file corresponds to that of the import file.

Procedure 1. Select the required hierarchy folder, project node or process tag library (hierarchy folder in the master data library) or the process tag type.

Note If you have selected a replica, a prompt is displayed, and you change to the corresponding model in the master data library.

2. Select the menu command Options > Models > Export... or Options > Process Tags > Export.... Result: The export dialog opens. The models/process tags are now searched for and listed. 3. In the next step in the dialog, you can assign the export files to the displayed models/process tags or modify an existing assignment. You can change the names of the assigned files in a dialog box displayed with the "Other File..." button in which you can select a different file or enter a new file name. 4. In the final step of the dialog, you can select the log file, activate or deactivate the filter so that you only log error messages and the finished message. 5. Start the export with the "Finish" button.

Note The selected export files are completely overwritten during the export or are newly created if they do not yet exist.

Multiple Export By exporting the model(s)/process tags more than once, you can create several export files (copies). Each time you export, you must modify the file name of the assigned export file (see above). If you do not change the file names, the export file is overwritten.

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7.11.11.10 Restrictions with the IEA The following modifications must not be made to charts/chart I/Os with IEA attributes in CFC since these would prevent import or export. In the following situations, the log contains appropriate error messages: •

Renaming nested charts (charts with chart I/Os included in the chart of a model).

•

Deleting nested charts.

•

Modifying the data type of a chart I/O.

•

Modifying the relative order of chart I/Os with IEA flags (or flagged I/Os of a process tag), for example by inserting or deleting chart I/Os (without IEA flag).

•

If the model contains nested hierarchy folders, the names of the nested folders must not be modified.


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7.11.11.11 Data of the IEA File in the ES

Preview The following sections explain how to create and edit the import/export files (IEA file) with the IEA file editor. This involves the following topics: •

Creating/Editing Import Files with the IEA File Editor

•

How to Exchange Data with Excel/Access

•

Structure of the IEA File

IEA File in the Engineering System The figure shows an example of the relationships between the objects of the project and the data of the import file. Project V12 RA1

Replica1 CFC1

Replica 2

Symbols

Messages

Valve open Interrupt 1

CFC2

Heating on

Interrupt 2

Plant hierarchy

Import file Hierarchy Parameter H\: V12\RA1\P01 V12\RA1\T01

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PI:

Parameter interconn. SI: V12\RA1\P01.V

Signal

Message

SI: Valve open Heating on

MI Interrupt 1 Interrupt 2


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7.11.11.12 Creating/Editing Import Files with the IEA File Editor IEA File Editor The Import/Export Assistant (IEA) works with import/export files with a fixed format. A plant planning tool such as SIGRAPH EMR supports this format. To be able to create or edit import files even if you do not have a plant planning tool available, an IEA data editor is installed with Import/Export Assistant, that keeps exactly to the rules governing the structure of the import file. The IEA Editor "s7jieaEx.exe" is a separate application, in other words it can also be used outside the PCS 7 installation. It can be copied and made available to plant planners.

Situations for using the Editor (based on the example of a "process tag" / "model") The IEA File Editor is intended for the following situations: •

You have created a process tag type/model and created the import file with the IEA. With this import file, you want to create replicas of the model or process tags. The number of rows in the import file must be increased according to the number of replicas/process tags you want to create (for example by copying and editing).

•

You have created a process tag type/model and created the import file with the IEA. You want to change this model, for example by including further I/Os and need to extend the import file by adding these columns.

•

You do not have a tool for creating an import file and want to use the IEA File Editor as a planning tool to structure the columns, column groups and rows of the import file and the corresponding values.

•

You want to compare an import file with an export file (or vice versa). By opening two windows and arranging them in the IEA File Editor window, you will have no difficulty in making the required comparison.


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Appearance of the IEA Editor The IEA Editor is displayed as a table with columns and column titles. Certain columns are put together to form column groups, for example, column group for the chart with the words of the columns: "ChName" and "ChComment". You can change the name of the column group to correspond to the column title of the import file. If you only want to use part of the full range of import options, you can also delete columns within a column group. If you remove all the columns of a column group, this flagged I/O is lost; in other words, the IEA file no longer matches the model. The row headers contain the number of the row. If you select a row header, the entire row is selected (for example so that it can be copied). The IEA File Editor also provides all the normal functions of an editor (copy, paste, save etc.). To allow you to insert column groups, all the column group types (general, chart, parameter, signal, message) are defined in a submenu and are also available as buttons in the toolbar. You can also add new columns to the column groups "general", "chart", "parameter", "signal" and "messages". In the expansion dialog, you can only select the column titles that do not yet exist in the relevant column group. You can select all the possible functions using the menu commands in the menu bar or the buttons in the toolbar. Otherwise, the structure of the editor corresponds to the structure of the import/export file (IEA file).

How to Start the IEA File Editor You start the editor by opening an IEA file.

Working in the Table of the IEA Editor With the IEA file editor, you work in the same way as with other Windows applications (for example Excel). The following functions are available: •

You can navigate through the file using the arrow keys and TAB key.

•

You complete an entry and change to the next row using the ENTER key.

•

You can select entire columns and rows.

•

You can modify or optimize the column width.

•

With the Cut, Copy, Paste functions, you can paste the cell contents of the table from the clipboard to selected cells (several at one time is also possible).

•

You can use the Find/Replace functions.


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7.11.11.13 How to Exchange Data with Excel/Access Introduction The import/export data (IEA file) is available as text files in the CSV format. The CSV format is supported by many applications (Excel, Access, ...) and is therefore suitable as a general data interface between any planning tool and the ES. In the IEA, these files are expected with the extension ".IEA"; in other words, you may need to modify this extension. CSV stands for "Comma Separated Value" and is an ASCII text format in which tabular data are saved. The separator of the cells is a semicolon, a new row is created by pressing the Enter key. You can create and edit a CSV file with table programs (for example Excel) or as an export file from a database (dBase, Access, ...). You can also edit the file (with the extension .IEA) conveniently using the IEA File Editor.

Procedure - Editing the File with Excel 1. Change the exception of the file from *.IEA to *.CSV. 2. Start Excel. 3. Select the menu command file > Open and open the *.CSV file. Result: The file is opened; the file content is displayed in much the same way as it is in the IEA file editor. Note If you open a CSV file by double-clicking it, the content of the file is not shown in table form in Excel. All cells should be formatted as "Text", otherwise the displayed information may be incorrect. Example: The numeric string "1.23" could be displayed as "23. Jan.". 4. Edit the file and save it. 5. Change the extension of the file from *. CSV to *.IEA. 6. Make any other changes you require in the IEA file editor and/or run the import with the IEA.

Procedure - Data Exchange with Excel You can edit the file (with the extension .IEA) conveniently using the IEA File Editor. You can use functions such as Cut, Copy and Paste or Find and Replace. Excel, however, provides further functions. If you require these, follow the steps outlined below: 1. Start the IEA file editor and open the required file. 2. Start Excel and create a new file. 3. Select, for example, an area of the table in the IEA file editor and copy it. 4. Insert the copied area into the empty Excel file. 5. Edit the data in Excel. 6. Select and copy the data in Excel. 7. Paste the copied data in the IEA file editor to the IEA file. Process Control System PCS 7 - Engineering System A5E00346923-02

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7.11.11.14 Structure of the IEA File

Import/Export File (IEA File) You can edit the import file (with the extension .IEA) conveniently using the IEA File Editor. The import file is a CSV file that you can create and edit with table programs (for example Excel) or as an export file from a database (dBase, Access, ...). To edit with a table or database program, you must be familiar with the file structure described below.

File Structure There must be a column group for each I/O and message. Rows

Meaning

0

There can be a comment line before the first header row (starting with "#" or "//") containing for example the version number and the date created.

1

The first header row contains the titles of the column groups.

2

The second header line contains the column identifiers. This information tells the Import/Export Assistant how to interpret the columns. These identifiers are the same in all language versions.

3

The third header row contains the keywords for the relevant flagged I/O. This decides which data will be imported for this I/O. It is not necessary to enter all keywords, only the first one is obligatory.

4-x

The next rows contain the data. There is one row for replica or process tag. During import, each row generates a replica of the model in the specified hierarchy folder. With process tags, the process tag is created in the hierarchy folder.

Example: Measured Value Acquisition In the following example, the IEA file is shown as a table to make it easier to read and the text in the three header rows is shown in "bold" print. The quotation marks are also missing at the start and end of each column entry. You can only edit the area with the data and not the header lines. Since this is pure ASCII text, you must not format an original file (for example, insert blanks or tabs or use bold print etc.).

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The IEA file can be displayed and edited as a table formatted with the IEA File Editor. #Version = 6.1 --- Import-Export-Assistent Tue Mar 19 18:13:10 2003 --Hierarchy;

FID;

LID;

Chart;

Upper limit;

Measured value

Alarm upper

H\;

F;

O.;

C|;

P|;

S|;

M|

;

;

;

ChName| ChComment;

Value| ConComment| S7_shortcut| S7_unit;

SymbolName| SymbolComment| ConComment| S7_shortcut| S7_unit;

Event|

V12\RA1\P01; ;

;

P01|Internal pressure;

90|Com.| UL|mbar;

Tpress|ComS.| ComA.|PT|mbar;

Int. pressure too high

V12\RA1\P02; ;

;

P02|External pressure;

8.5|Com.| UL|bar;

Epress|ComS.| ComA.|PA|bar;

Ext. pressure too high

V12\RA2\T01;

;

;

T01|Temp contr

80|Com.| UL|degC;

Mtemp.|ComS.| ComA.|MT|degC;

Temperature exceeded

V12\RA2\T02;

Delete

Explanations of the Column Groups •

Hierarchy The "Hierarchy" column group contains the complete hierarchy path even if individual hierarchy folders do not contribute to the name. During import, the hierarchy folders (replicas of the models or process tags) are created from this and the content of the model/process tag (charts etc.) is copied into this new Hierarchy folder if it does not yet exist. During export, all existing replicas of the model are entered. With process tags, the process tags are created from the process tags type and created in the hierarchy folder. There can be several process tags in the same hierarchy folder. The hierarchy levels are separated by "\", and the IEA is informed of this in the second row. Here, "\" must be used as the separator.

•

FID and LID The "FID" and "LID" column groups belong to the "general column groups" and are optional. The FID and LID are entered in the text boxes of all top charts of the replicas. The "FID" column group contains the function identifier. The "LID" : group contains the location identifier. The data of the FIDs and LIDs are missing in the example. The ";" must nevertheless be included so that the number of column groups remains the same. The text is entered in the text box in the "Part 3" tab, "Description:" or "Code field according to location:".


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•

Chart The "Chart" column group is optional for models, but if used it always follows the "Hierarchy" column group, or, if they exist, after the general column groups. Any name can be used for the title. The column group contains the name and comment of the CFC or SFC chart. The name of the chart in the replica of the model is changed with the keyword ChName. The chart comment is changed with the keyword ChComment.

•

Other Column Groups The following column groups identify the I/Os to be imported. Each of these I/Os is described by a text string (in quotation marks) separated by ";" (semicolon) from the next I/O. Within the text string, the data is separated by "|" (pipe character).


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7.11.12


Introduction You can work on station configurations not only within the entire project (for example saving or opening), but also independent of the project by exporting it to a text file (ASCII file, CFG file), editing it, and then importing it again. The symbolic names of the inputs and outputs are also exported or imported (as long as you have not changed the default setting).

Applications •

Data import from hardware planning tools

•

Can be distributed using electronic media (for example E-mail)

•

An export file can be printed out with word processing systems or can be edited for documentation purposes.

A further important application of the import of a station configuration is when you have identical or almost identical configurations in different parts of the plant. Using the import function, you can create the required plant configuration quickly.

What is Exported/Imported? When you configure the hardware, the data necessary for the configuration and parameter assignment of modules is exported/imported. The following are not included: •

Data managed by other applications (for example programs, connections, shared data)

•

A selected CPU password

•

Cross-station data (for example the linking of intelligent DP slaves or configurations for direct data exchange)

Note If your configuration contains modules from older optional packages, it is possible that not all the data of the module will be included with the "Export Station" function. In this case, check whether the module data are complete following import.


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Setting - What Will Be Imported? You can select what is included in the exported text file and in what form it is stored when you export (menu command Station > Export): •

Legible or compact form -

In the legible format, the identifiers, for example of parameters, are entered in the export file as strings.

-

In the compact format, identifiers are entered in the export file in hexadecimal format.

Caution When you export the station configuration, to read it in using other PCS 7 versions, select the "Compact" option.

!

•

Name of the file (*.cfg) freely selectable

•

with or without symbols You can decide whether or not symbols you specified for the inputs and outputs are also included in the export file.

•

with or without subnets You can decide whether or not subnets are exported. If you select this option, the network data for the interfaces of the station is also exported (assignment to subnets, subnet parameters).

•

Default values for module parameters can be omitted as an option (PCS 7 knows the default values and supplies them internally when you import).

Caution If you export a station configuration with symbols, you can no longer import the file with earlier PCS 7 versions.

7.11.12.1 How to Export a Station Configuration Procedure 1. Select the required station in the component view. 2. Select the menu command Edit> Open Object. Result: The station configuration is opened in HW Config. 3. Select the menu command Station > Export. 4. Enter the path and name of the export file, formats and other options in the dialog (refer to the section "Importing/Exporting the Hardware Configuration"). 5. Confirm your settings with "OK". Result: The station configuration is exported and stored in the selected path in the form of a CFG file.


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7.11.12.2 Structure and Content of the CFG File CFG File The export of a station configuration as described in "How to Export a Station Configuration" produces an ASCII file that you can read and edit with an editor such as "Notepad" or "WordPad". This file (CFG file) contains all the data of the hardware configuration including the parameter assignments from the dialogs of the HW Config graphic user interface and the corresponding symbols (if these were exported). Based on the introductory text in the individual fields, the sections are easy to identify. You will find a section from a possible CFG file structure in the following example.

Example Section of the CFG File

Information/Object Properties for

FILEVERSION "3.0" #STEP7_VERSION V5.2 Addon #CREATED "Thursday, 18. April 2003 17:21:09" STATION S7400 , "SIMATIC 400(1)" BEGIN REPORT_SYSTEM_ERRORS "0" OBJECT_REMOVEABLE "1" POS_X "0" POS_Y "0" SIZE_X "0" SIZE_Y "0" OBJECT_COPYABLE "1" CREATOR "" COMMENT "" END SUBNET INDUSTRIAL_ETHERNET , "Ethernet(1)" BEGIN COMMENT "" NET_ID_2 "00 31 00 00 00 13" NET_ID "003100000013" END SUBNET MPI , "MPI(1)" BEGIN MPI_HSA "31" MPI_BAUDRATE "187.5_KBPS" MPI_GAP "5" MPI_READY "20" MPI_RETRIES "2" MPI_IDLE1 "60" MPI_IDLE2 "400" MPI_TQUI "0" MPI_TSL "415" MPI_TTR "9984" COMMENT "" NET_ID_2 "00 31 00 00 00 01" NET_ID "003100000001" END

File


STATION

Subnet (Ethernet)

Subnet (MPI)

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Section of the CFG File

Information/Object Properties for

SUBNET PROFIBUS , "PROFIBUS(1)" BEGIN PROFIBUS_HSA "126" PROFIBUS_BAUDRATE "1.5_MBPS" PROFIBUS_RETRIES "1" PROFIBUS_GAP "10" PROFIBUS_READY "11" PROFILE_SELECTION "DP" NETCONFIG_ENABLE "0" NETCONFIG_ACTIVE "1" NETCONFIG_PASSIVE "2" : : : : RACK 0, SLOT 7, "6ES7 421-1BL01-0AA0", "DI32xDC 24V" BEGIN IPACTIVE "0" CPU_NO "1" ALARM_OB_NO "40" OBJECT_REMOVEABLE "1" POS_X "0" POS_Y "0" REDUNDANCY BEGIN END SIZE_X "0" MODULE_ADD_FLAGS "0" SIZE_Y "0" OBJECT_COPYABLE "1" CREATOR "" COMMENT "" LOCAL_IN_ADDRESSES ADDRESS 0, 0, 4, 0, 0, 0 SYMBOL I , 0, "I0.0", "" SYMBOL I , 1, "I0.1", "" SYMBOL I , 2, "I0.2", "" SYMBOL I , 3, "I0.3", "" : : : SYMBOL I , 30, "I3.6", "" SYMBOL I , 31, "I3.7", "" END : :

Subnet (PROFIBUS)

Digital input including symbols

Modules (PS, CPU, CP, DI, DO, AI, AO etc.)

: :


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7.11.12.3 Expanding CFG Files

Expansion CFG files should always be created based on an existing, exported station configuration (refer to the section "How to Export a Station Configuration"). The CFG file should already contain all the objects (passages of the file) required for station expansion. This allows you to make the required expansions simply by copying and pasting. Keep the configuration consistent, the copied objects must be suitably adapted (for example rack assignment, addresses, symbols). For an explanation of the structure and content of the CFG file, refer to the section "Structure and Content of the CFG File". With this as a basis, you can edit the individual sections of the file to suit your purposes (copy, paste, edit). Caution You should be familiar with the content of the sections of the CFG file in detail since editing is not supported by the system. Any errors made will only be detected during the subsequent import. This can lead to inconsistent data that you would then have to re-edit in HW Config.


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Procedure - Example You want to add a further digital input module to an ET 200M and change the existing slot assignments. 1. Identifying the Area Section of the CFG File DPSUBSYSTEM 1, DPADRESS 7, SLOT 6, "6ES7 321-FH00-0AA0", "DI16xAC120/230V" BEGIN PROFIBUSADDRESS "0" CPU_NO "1" ALARM_OB_NO "40" OBJECT_REMOVEABLE "1" POS_X "0" POS_Y "0" REDUNDANCY BEGIN END SIZE_X "0" SIZE_Y "0" OBJECT_COPYABLE "1" CREATOR "" COMMENT "" LOCAL_IN_ADDRESSES ADDRESS 0, 0, 2, 0, 1, 0 SYMBOL I , 0, "I0.0", "" SYMBOL I , 1, "I0.1", "" SYMBOL I , 2, "I0.2", "" SYMBOL I , 3, "I0.3", "" : : : SYMBOL I , 30, "I3.6", "" SYMBOL I , 31, "I3.7", "" END

Information/Object Properties for Digital input including symbols

2. Select and copy the required area. 3. Paste the copied area at the required location. 4. Adapt the inserted area (DP address, slot number, symbols etc.) 5. If necessary, adapt the already configured modules. 6. Follow the same procedure if you want to add further components. 7. Save the file. 8. Start HW Config.

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9. Select the menu command Station > Import. 10. Select the appropriate CFG file and click the "Open" button. During import, you may be prompted to confirm overwriting of existing data. Result: The modified station configuration is imported into the open station. A log is created and any error messages output. 11. Select "Save" in this dialog box to save the error messages in a text file. Select the path and enter the name of the text file and confirm with "Save" followed by "Close".



7.11.12.4 How to Import a Station Configuration (First Import of an Entire Station)

Procedure Recommendation: do not import an exported station configuration from the same project. In this case, PCS 7 cannot handle the network assignment. Select a different or new project for the import. 1. With an empty station configuration open (in HW Config), select the menu command Station > Import. If no station configuration is open, a dialog box opens in which you select a project. In this case, navigate to the project into which you want to import the station configuration. 2. In the dialog, navigate to the CFG file you want to import. 3. Confirm your settings with "OK". Result: The station configuration is imported. During import, the imported file is checked for errors and conflicts and messages are displayed.

Note If you also want to import DP master systems during import, these must not have the same names as DP master systems that already exist in the project.




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7.11.12.5 How to Import an Expanded Import File (Extra Remote I/O, Field Device, Module)

Importing to an Existing Station You can also import a station into an open station configuration (menu command Station > Import). During the import PCS 7 asks whether you want modules/interface modules that have already been configured to be overwritten. For each component, you can decide whether you want to retain it or overwrite it. If a component is overwritten, all the settings (parameters) contained in the import file become valid. Settings that are not included in the import file are retained in the station configuration.

Procedure - Inserting a Digital Input Module You want to add a further digital input module and change the existing slot assignments. 1. Open the required CFG file with an editor (for example WordPad). 2. Identify the area that describes the digital input module, then select and copy it. 3. Paste the copied passage directly after the digital input module you copied. 4. Adapt the slot number, address, symbols and any other relevant data and save the file. 5. Open the station for which you made the changes in HW Config. 6. Select the menu command Station > Import and import the required CFG file. Result: A dialog is opened in which you can decide whether to overwrite the entire configuration or only the modified parts. A error log is also created during import. 7. Save the imported data. 8. Check the data consistency with the menu command Station > Check Consistency and eliminated any inconsistencies.


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7.11.12.6 How to Update an Imported Station Configuration (Change Attributes, Signal Assignments of Modules)

Importing to an Existing Station If you have already modified configured modules/interface modules in the CFG file, you can update an existing station configuration by importing into the station. During the import PCS 7 asks whether you want modules/interface modules that have already been configured to be overwritten. For each component, you can decide whether you want to retain it or overwrite it. If a component is overwritten, all the settings (parameters) contained in the import file become valid. Settings that are not included in the import file are retained in the station configuration.

Procedure – Parameter Modifications You have modified an existing station configuration, however only the settings (parameters). 1. Select the menu command Station > Import with the station configuration open and import the required CFG file. Result: A dialog opens in which you can decide whether the entire configuration ("All" button or only the modified parts ("Yes" and "No" buttons) should be overwritten. A error log is also created during import.

Note If you only overwrite the changed parts, the import is much quicker.

2. If errors are reported, save the error log. You can then eliminate any errors based on the log. 3. Then confirm saving of the imported data with "Yes". If you select "No" here, the import is aborted. The station configuration then remains unchanged.




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7.11.12.7 Exporting to Synchronize with Planning Tools You have configured the station according to the planning data of the plant engineering and made changes or corrections in the detailed hardware configuration. You can return these changes to the data of the plant engineering using the export file. •

How to export a station configuration was explained in the section "How to Export a Station Configuration".

•

The structure of the CFG file is explained in the section "Structure and Content of the CFG File".

Prepare the content of the CFG file as you require it for import into the planning tool (plant engineering) and then run the import.

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7.12

Configuring OS Functions

Introduction Configuring the operator station involves several steps. Here you make the settings using several PCS 7 tools: •

In the SIMATIC Manager

•

In the WinCC Explorer

The entire configuration of the PCS 7 OS is done in the engineering system so that all the configuration data can be managed centrally. Depending on the requirements of your project, some of the steps in configuration are mandatory and others optional. For a completed description of configuring the OS functions, refer to the Configuration Manual Process Control System PCS 7; Operator Station. Below you will find preliminary information in the form of a table listing all the configuration steps. From the table, you can see which configuration steps are necessary and which are options.

SIMATIC Manager Configuration Activities

must

Inserting and configuring a PCS 7 OS

can X When additional operator stations are required. The PCS 7 Wizard creates a PCS 7 OS automatically

Configuration of network connections for a PCS 7 OS

X

Inserting pictures in the plant hierarchy

X

AS-OS assignment

X

Creating block icons

X

Changing units and operator texts

X

Configuring Messages

X If you want to define messages that differ from the defaults

Selecting the message number range

X

Specifying message priority

X Important for messages in the message line in the overview area

Definition of the plant identifier

X

Specifying the OS area identifier

X

X

Plant hierarchy

Control and monitoring attributes

Specifying picture names and the picture hierarchy


X If you want to define picture names that differ from the defaults

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Configuring PCS 7

Configuration Activities

must

can

Settings for updates: •

Updating the AS-OS connections

•

Updating the OS area identifier

X

Compiling the OS

X

Downloading the OS

X

Compiling the OS You run the "Compile OS" function once you have completed ES configuration of all data in the SIMATIC Manager and before you start to configure the OS data in the WinCC Explorer. (You must also "Compile OS" if you have made subsequent changes in the ES configuration.) All the data from the SIMATIC Manager, such as variables, messages, texts and the hardware and connection configuration is "made known" to the OS for further configuration.

WinCC Explorer Configuration Activities

must

can

Setting the object properties

X

Setting the computer properties

X

Settings in the OS Project Editor

X If you want to define settings that differ from the defaults

Setting up user permissions Visualization of a plant – basics: •

Inserting dynamic objects

•

Using a status display

•

Using an expanded status display

•

Inserting an I/O field

•

Configuring a group display

X X Using the required objects

X

Visualization of a plant – advanced: •

Using faceplates and block icons

•

Creating user objects

•

Creating user object templates

•

Using picture windows

•

Using the process object view and cross-reference lists

Calculating the group display hierarchy

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These options support you effectively when making settings for process pictures

X


Configuring PCS 7

Configuration Activities

must

X

Settings for the alarm system: •

Definitions in the Project Editor

•

Settings in Alarm Logging

•

Configuring the message lists

•

Configuring the acoustic signaling device

Configuring archives and logs

X

Setting

X

•


•

Sign-of-life monitoring

Directly on the OS servers/OS clients after downloading the project: •

can

X

Activating the project




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7.12.1

Setting the AS/OS Lifebeat Monitoring

Introduction With the OS function "Lifebeat monitoring", it is possible to monitor the functions of the CPUs and operator stations connected to the plant bus in the SIMATIC PCS 7 control system. This means that you always have an up-to-date overview of the state of your plant. The monitoring function is executed by the operator station declared as the lifebeat monitor.

Lifebeat Monitor The lifebeat monitor monitors all OS servers, OS clients and all automation systems. Requirements: All the components to be monitored are connected to a continuous network and assigned to the lifebeat monitor. The monitoring is performed in a cycle that you can specify when configuring lifebeat monitoring. New edit lifebeat monitoring in the WinCC "Lifebeat Monitoring" editor.

Monitoring an Automation System On an automation system, a process control message is generated in two situations:

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•

The life beat monitoring reads the current operating state from the automation systems. If a mode change is detected, for example from RUN to STOP, a control system message is generated by the lifebeat monitor.

•

Lifebeat monitoring sends monitoring requests to an AS. As soon as, for example, the power or the device fails, or a wire break is detected, the AS can no longer react and a process control message is generated.


Configuring PCS 7

Lifebeat Monitoring in Process Mode Lifebeat monitoring is activated automatically when the OS starts up and is performed on the OS in cycles between 5 seconds and 1 minute. An error message appears as follows: •

As soon as lifebeat monitoring recognizes that a component has failed, a process control message is generated automatically.

•

The state of all monitored components is also displayed in a separate picture that the operator can display using a button in the button set. In this picture, the failed component is indicated by being "scored through". An additional text, such as "fault", "server failed", "server set up" is also displayed in this picture.

The elimination of a problem is also indicated by a process control message.


You will find step-by step instructions on configuring the AS/OS lifebeat monitoring in the configuration manual Process Control System PCS 7; Operator Station


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7.13

Configuring BATCH Functions

Introduction SIMATIC BATCH is a SIMATIC PCS 7 program package with which discontinuous processes, known as batch processes, can be configured, planned, controlled and logged. Simple batch processes with configurable sequential control systems are automated with the CFC and SFC tools included in the PCS 7 Engineering System. In more demanding systems with recipe procedures, SIMATIC BATCH is used. With SIMATIC BATCH, recipe structures are designed, modified, and started graphically on an operator station or on a separate PC. Configuration involves the following: •

Engineering

•

Permission management

•

Recipe creation (offline)

•

Process mode

Engineering Configuration of the batch process cell takes place along with the basic engineering of the S7-400 on the engineering station in the SIMATIC Manager (for example phase and operation types, unit classes, user data types, units of measure etc.). Configuration Activities

must

Batch plant configuration in the engineering system (ES)

X

Compiling Batch process cell data

X

Downloading Batch process cell data to target systems (BATCH servers, BATCH clients)

X

Reading in Batch process cell data on the BATCH clients

X

can

Permission Management SIMATIC BATCH uses the central user management of PCS 7. Configuration Activities Specifying the user permissions for SIMATIC BATCH

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must

can

X


Configuring PCS 7

Recipe Creation (Offline) Reading in the Batch process cell data (engineering data) on any BATCH client with BatchCC allows the creation of offline data. You create the materials, formula categories, and formulas with BatchCC. You create libraries and master recipes with the BATCH Recipe Editor. Releasing master recipes, library elements and formulas allows their subsequent use in process mode. Configuration Activities

must

Editing materials

X

Creating and editing master recipes

X

can

Creating and editing library operations

X When working with libraries

Validating recipes

X

Releasing recipes for production

X

Creating a new formula category (only with external formula)

X

Creating formulas (only with external formula)

X

Interconnecting parameters between master recipe and formula (only with external formula)

X

Process Mode The first phase of process mode is batch planning. The production orders are created here. These are divided into batch orders that can then be released and started. The actual Batch processing programs (equipment phases) run on the automation system and are coordinated by the batch control. The batch data management makes use of individual WinCC components. The values for the required measured value sequences for a batch report are obtained from the measured value archive and all Batch-relevant messages are filtered from the message archive and displayed within BatchCC. Configuration Activities

must

Creating the production orders

X

Creating and editing batches

X

Releasing batches

X

Starting production of a batch

X

Operator control during production of a batch

X

Batch reports

X

Archiving batches

X

can


Online help on SIMATIC BATCH

•



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7.14

Configuring the Interface to the Management Level (@PCS 7 and SIAMTIC IT)

7.14.1

Configuring the Interface to the Management Level

Introduction @PCS 7 is software based on @aGlance used to access the process data acquired by PCS 7. @PCS 7 has access to the following PCS 7 data: •

WinCC archives (message, measured value and user archives)

•

WinCC data management

Each @aGlance-compliant client application of MIS/MES is therefore capable of accessing the data of PCS 7.

Configuration Configuration involves the system settings and the server configuration of the @PCS 7 system. Once the @PCS 7 system has been configured, you can start, stop or restart it. The system messages of the @PCS 7 environment since the last cold start are also displayed. Configuration Activities Setting the language for the @PCS 7 user interface

must

can

X

Setting the system parameters

X

Configuring the @PCS 7 server

X

Configuring the @PCS 7 server-server configuration

X When connecting other @aGlance servers to your @PCS 7 server

Specifying the user permissions for @PCS 7

X


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Manual @PCS 7; Interface to the Management Level


Configuring PCS 7

7.15

Merging Projects after Distributed Editing (Multiproject Engineering)

Overview Merging projects of a multiproject following distributed editing involves the following topics:

7.15.1

•

How to Move Projects Edited on Distributed Stations to the Central Engineering Station

•

How to Merge Subnets from Different Projects into a Multiproject

•


•

How to Configure New Cross-Project Connections between AS and OS

How to Move Projects Edited on Distributed Stations to the Central Engineering Station

Requirements •

The project is physically located on a distributed engineering station and is included in the multiproject.

•

The distributed engineering station is obtainable over the network.

Procedure 1. If necessary: Delete the existing project of the same name (version prior to moving to distributed engineering station) on the central engineering station (backup copy). 2. Open the project on the distributed engineering station from the central engineering station with the menu command File > Open in the SIMATIC Manager and click the "Browse" button. 3. In the "Browse" menu in the "Find in directory" field, enter the path of the project you want to move in UNC notation and select "Start Search". Result: the project is displayed in the "User projects" tab. 4. Select the required project in this tab and confirm with "OK". Result: The project is opened. 5. Select the menu command File > Save As ... Make the following settings: -

Disable the "With Reorganization (slow)" option.

-

Enable the "Insert in multiproject" option.

-

Select "Current multiproject" in the drop-down list box.

-

Enable the "Replace current project" option.

6. Confirm the dialog box with OK. Result: An identical copy of the project of the distributed engineering station is Process Control System PCS 7 - Engineering System A5E00346923-02

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created on the central engineering station in the multiproject. The original is retained on the distributed engineering station and can remain there as a backup or be deleted.

Note Before the copied project can be copied back to its old location (same folder name), this backup must be deleted or renamed (refer to the section "How to Move Projects to the Distributed Engineering Stations").

Note You can also move a project back to the central engineering station after it was moved out with the "Remove to edit..." function and if it is obtainable over the same path as when it was removed: 1. Select the "project removed for editing" on the central engineering station (grayed out). 2. Select the File > Multiproject > Reapply after editing... menu command Result: The project is reinserted from the distributed engineering station into the multiproject on the central engineering station.


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Section "How to Move Projects to Distributed Engineering Stations"


Configuring PCS 7

7.15.2

How to Merge Subnets from Different Projects into a Multiproject If you use cross-project networks in the multiproject, the networks in the projects must still be merged in the multiproject.

Requirement To be able to merge subnets, you must have write access to the projects involved and their subnets.

Procedure 1. Select the required multiproject in the SIMATIC Manager 2. Select the menu command File > Multiproject > Synchronize Projects Result: The "Compare and Match up Projects in Multiproject" dialog opens. 3. In the left-hand window, select the Ethernet networks you want to connect up and click "Execute". Result: The dialog for merging or branching subnets is opened. 4. In the left-hand field, select the subnet and click the "->" button. Result: The selected subnet is merged in the selected entire networ. 5. Change the default name of the cross-project network according to the requirements of your project (click on the name twice). 6. Follow the same procedure for all the subnets you want to merge. 7. Click the "Apply" button followed by "Close" to exit the dialog. In the same dialog, you can separate networks again that have already been merged. In this dialog, you can also create new cross-project subnets ("New" button).

Note After merging the subnets and prior to downloading, you should use NetPro to check that there is consistency throughout the multiproject (menu command Network -> Check Interproject Consistency).


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7.15.3


Procedure Cross-project connections can be merged •

During the synchronization of projects in a multiproject in the SIMATIC Manager with the menu command: File > Multiproject > Adjust Projects.

•

In NetPro with the menu command Edit > Merge Connections

Functionality There are differences in the functionality as explained below: SIMATIC Manager:

NetPro:

•

In the SIMATIC Manager, the only connections • that are merged are those in the projects that were configured as "Connection partner in other project" with identical connection names (reference).

In NetPro, you can also match up connections that have similar or different connection names.

•

When merging in the SIMATIC Manager, it is • not possible to foresee which connection partner retains the connection properties and which connection partner adapts its connection properties (for example active connection establishment).

When you merge in NetPro, the partner always adapts its connection properties to those of the local module. Apart from this, it is also possible to change the properties of connections in the dialog for merging connections in NetPro.

•

In the SIMATIC Manager, S7 connections to an unspecified partner are ignored.

•

S7 connections to an unspecified partner can be merged to a cross-project S7 connection in NetPro.

Further information

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•


•

Section "How to Merge Cross-Project Connections".


Configuring PCS 7

7.15.4

How to Configure New Cross-Project Connections between AS and OS

Introduction Cross-project connections between AS and OS components are configured in the same way as cross-project connections between AS components.

Requirements •

The networks involved are merged and the multiproject level: Refer to the section "How to Merge Subnets from Different Projects into a Multiproject"

•

The AS/OS assignment is fixed: Refer to the section "How to Specify the AS/OS Assignment"

Procedure When creating cross-project connections between AS and OS components, in contrast to the procedure described in the section "Cross-Project Connections in a Multiproject", you select a connection partner in a different project.


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8


Introduction The functions for compiling and downloading are available in the following editors: •

HW Config Compiling and downloading the hardware configuration (refer to the section "Configuring the Hardware")

•

NetPro Compiling and downloading the network and connection configuration and the hardware configuration (refer to the section "Creating Network Connections")

•

CFC Compiling and downloading the CFC configuration (refer to the section "Creating CFC Charts")

•

SFC Compiling and downloading the SFC configuration (refer to the section "Creating SFC Charts")

•

SIMATIC Manager Compiling and downloading individual or all objects of a multiproject

Actions after Merging Projects Edited on Distributed Stations The following tasks must be performed for multiproject engineering once the distributed projects have been assembled: •

Compiling the OS server with assigned AS components

•

Only when downloading the first time: Downloading the OS server data to the OS clients

•

Downloading to all CPUs (AS, OS server, OS clients, BATCH server, BATCH clients etc.)


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Note Downloading the OS server data to the OS clients only needs to be performed once after the first download. Each time an OS client is restarted in process mode or when downloading changes to the OS server, the OS server data is automatically updated. Note on updating server data: The server data includes the computer name of the engineering station from which the data was first downloaded. If you change engineering stations or change the storage location of the project/multiproject on the engineering station, make sure that the OS is recompliled and remember that the server data must be downloaded once from the new computer (computer name) or storage location. The compilation and downloading of the OS and the updating of the OS server data on the OS clients is described in detail in the Configuration Manual Process Control System PCS 7; Operator Station and is therefore not dealt with in detail here.

To test the program, in other words, the CFC and SFC configuration, initially you only need to compile and download the AS data.

Overview

8-2

•

Compiling and downloading for PCS 7 includes the following topics:

•

Requirements for Compiling and Downloading

•

Downloading to All CPUs

•

Options for Compiling and Downloading

•

Change Log



8.1

Requirements for Compiling and Downloading

One-time Download of the OS Server Data fter downloading the OS server data to the OS server, this data must be updated once on the OS clients. Each time an OS client is restarted in process mode or when downloading changes to the OS server, the OS server data is automatically updated.

Procedure 1. Select the OS client in the SIMATIC Manager. 2. Select the menu command Options > Assign OS/OS Server. Result: The OS server data is downloaded to the OS client. The OS client then knows the assigned OS servers.



Downloading Entire Programs To be able to use the "Compile and download objects..." function for the automation systems, the hardware configuration and the network configuration of every SIMATIC 400 station must first be downloaded once (from within NetPro).


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8.2

Downloading to All CPUs

Introduction A project is downloaded in the SIMATIC Manager with the central menu command "Compile and Download Objects". PCS 7 provides the "Compile and Download Objects" dialog for this task. The display of the objects in this dialog corresponds to the component view in the SIMATIC Manager, i.e. you are shown all automation systems, operator stations and SIMATIC PC stations that you have created in the SIMATIC Manager. The required settings for compiling and downloading are made in this dialog. In this dialog, you can also specify whether you want to compile and download the entire project or, for example only individual operator stations.

"Compile and Download Objects" dialog In the display menu you will find all objects relevant to downloading, their status and operating mode. The "Compile and Download Objects" dialog box is used to prepare the selected objects of your project or multiproject for downloading to the CPU and then download them to the CPU. The dialog can be used for objects in a station, a project or a multiproject. PCS 7 coordinates compiling and downloading, i.e. you do not need to pay attention to the order of the tasks.

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Requirements •

The PC station and AS station are configured and have been downloaded to (from NetPro so that the connections are also loaded)

•

The CFC and SFC configuration is completed.

•

You have selected one of the following objects in the SIMATIC Manager: -

Multiproject

-

Project

-

STATION

Rules •

When downloading the entire program of an AS, in contrast to downloading from one of the editors (for example CFC), the CPU always changes to STOP.

•

Downloading the entire program to an OS is possible only when the OS servers have been shut down (are not in process mode).

•

Downloading changes to an OS is possible only if the OS is in process mode.

Procedure Note You should also refer to the section "Options for Compiling and Downloading" 1. In the SIMATIC Manager selects the object that you want to compile or compile and download. 2. Select the SIMATIC Manager menu command PLC > Compile and Download Objects. Result: the "Compile and Download Objects" dialog opens. 3. Open the tree and activate the corresponding check boxes in the "Compile" or "Download" columns for all objects that you wish to compile or download. 4. Select the objects you want to compile/download in the "Compile" and "Download" columns. Your selections are indicated by a check mark. 5. With the "Status" and "Operating Mode" buttons you can check the statuses (changed, compiled, downloaded ...) and modes of your objects (RUN, activated, ...), so that you can make the correct settings for compiling and downloading. 6. Select the object you want to compile and/or download and click the "Edit" button. Make the settings for the compilation and/or download (for example compiling and downloading the entire program or changes only). Note When you have completed the settings for compiling an operator station, it takes some time for the compilation settings to be saved and for the download dialog to be opened! The target path of the OS should already be entered here, otherwise you should enter this in your station.


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7. Click the "Check" button. Result: The validity of the settings is checked. If settings are not valid, the download is not performed. 8. Make the required settings for the individual objects. Click on the "Help" button in the dialog for detailed information about the settings. 9. Activate the option "Compile only" if you only want to check the blocks and not download them to the CPU. 10. Activate the option "Do not load if compilation error is detected" if you want to prevent downloading corrupt blocks to the CPU. 11. Select the "Start" button to begin compiling/downloading. 12. Follow the instructions on the screen. 13. If you wish to see a log once the compiling/downloading is completed, click on the following buttons in the "Open Log" area: -

"Single Object" – This displays the detailed compilation and download log of the selected AS or the compilation log of the selected OS.

-

"All Objects" – This displays the results of all compilation and download actions (without details).

Note Do not use the "Compile and Download Objects" function for PLCSIM downloading.

Changes during the commissioning Settings you made for operator control and monitoring during the test should be read back into the project. Parameter settings, for example controller parameters, must also have the required values in the offline program (CFC) as they were set during commissioning. In CFC, it is possible to read back the CFC charts which also triggers an automatic compilation of the entire program. You should only read back CFC charts when your plant is in a defined and safe status. After reading back the charts, the changes must be downloaded so that the offline and online program match. Following this, a check is still possible in the "PLC Comparison" dialog. The time stamps "last offline program change" and "last online program change" must match.

8-6



Reading Back the Parameter Settings of the CPU 1. Open the multiproject in the SIMATIC Manager and select your project. 2. Start the CFC editor by double-clicking on a CFC chart of the modified program. 3. Select the menu command Chart > Read Back. 4. In the "Read Back" dialog, select "Program on the CPU" and "OCM-capable parameters" or "Designated parameters".

Note If the "Marked parameters" option is selected, only the block I/Os with the "Can be read back" attribute (S7_read_back = true) are read Back. This setting must first be made at the I/Os of the block type. The attribute cannot be modified in the block instances.

5. Confirm with "OK". Result: When you read back the charts, there is automatically a full compilation of the charts.


Online help on the "Compile and Download Objects" dialog box

•

Section "Options for Compiling and Downloading"


8-7


8.3

Options for Compiling and Downloading

Central settings for compiling and downloading In the "Compile and Download Objects" dialog box, make the required settings for compiling and downloading separately for each object. In the "Compile" and "Download" columns, you specify if you want to compile and download the entire project or individual components. Compiling the charts generates an executable program that can run on the CPU. The consistency of the blocks and interconnections are also checked.

Options in the "Compile and Download Objects" Dialog Box Option Settings for Compilation/Download "Edit" button "Check" button

Update "Status" button

"Operating Mode" button Status on opening

Select Objects Select All Deselect All

Compile only

8-8

Description Opens a dialog in which the compiling and downloading settings can be changed for objects selected in the "Objects" column. Checks the compiling and downloading properties of objects selected for compiling and downloading in the "Objects" column. This button is not active for block folders. The button is only active when the objects support this function. The following is checked for a "hardware" object: • Are the modules in the STOP mode (not with modules that automatically stop and can be started again, for example CPs)? • Is a password required (i.e. is a password assigned) and has a password been entered? The password is entered after pressing the "Edit" button for a selected block folder CPU. Click the "Status" button to update the objects in the selection table. With the "Hardware" object, "undefined" is displayed after a status update if the station contains a cross-station PROFIBUS subnet. In this case, the editing of the other station that is also connected to this PROFIBUS subnet can have effects on the currently displayed station. Click on the "Operating Mode" button to update any changed operating modes in the display. When the option is deactivated (default), the "Compile and Download Objects" dialog opens immediately with the menu command CPU > Compile and Download Objects. "undefined" is however entered everywhere in the "Status" column. To update for the first time, click the "Status" button. When the option is activated, expect a long delay before the dialog opens regardless of the number of objects. With this button, you can select or deselect all objects in the "Compile" and "Download" columns. If the "Compile Only" check box is selected, the button only affects the "Compile" column. If the "Compile Only" check box is cleared, the "Select All " and "Deselect All" buttons select or deselect all objects in both columns. Activate this option if you only want to compile the selected objects. The objects will not be downloaded to the CPU and the "Download" column is hidden.



Option

Description

Do not load if compilation error is detected

If the option is activated, a compilation error (for example a time stamp conflict) means that no object is downloaded. If the option is not activated, all objects are downloaded that were compiled without error. Objects that caused an error during compilation are not downloaded. Take connections into consideration Activate this option if you want to compile or download configured connections of the project or multiproject. This option can only be activated when a project or multiproject is the initial object selected. A multiproject is especially suited as an initial object because all partners in cross-project connections can be automatically downloaded from this object. When this check box is activated, displayed "hardware" and "connection" objects are automatically activated for compiling (setting cannot be altered). When the "Compile only" check box is deactivated as well, all "hardware" and "connection" objects are also automatically activated for downloading (setting cannot be altered). Note: Because the hardware configuration is always loaded as well through this dialog, you can only perform a download when the CPU is in STOP mode. Individual connections can be downloaded using NetPro.

Settings for Downloading Hardware Objects The download procedure will not be interrupted by acknowledgment prompts when the following settings are made for downloading multiple objects. When several CPUs are installed in a station, the settings must be made for every CPU. •

Stop CPU before download A hardware configuration can only be downloaded when the CPU is in the STOP mode.

•

CPU password Enter a password here if the CPU is password protected. If you do not enter a password, the download process will be interrupted later by a prompt for the password.

Special considerations downloading hardware objects for fault-tolerant CPUs •

Stop H system before download The identical hardware configuration is in both CPUs following the download.

•

Downloading to a CPU 4xx H Before beginning to download, you must make sure that the selected CPU(s) are actually in the STOP mode. If they are not, to download if canceled with an error message. This prevents inadvertent stopping of the entire H system. If only one CPU is activated for downloading and only this CPU is in the STOP mode, you can start this CPU with "Switchover with modified configuration" following the download. This avoids stopping the H system.


Online help for "Compile and Download Objects" (Station properties)


8-9


8.4

Change Log The change log enables you to document the user, time, changes made, the affected CPU and the reason for the changes.

Requirement •

The SIMATIC Logon Service is installed.

•

The change log is activated for the currently selected chart folder.

Activating the change logs for the chart folder The change log must be activated for the currently selected chart folder in the Object Properties dialog. 1. In the component view of the SIMATIC Manager, select the chart folder for which the change log should be activated. 2. Select the menu command Edit > Object Properties... Result: The Properties dialog of the chart folder opens. 3. Go to the "Change log" tab and activate the option "Change log active". 4. Confirm with "OK". Result: The "SIMATIC Logon Service - Sign Action" dialog is displayed if you are not already globally logged on in SIMATIC Manager. If you are logged on, the change log opens immediately and you can enter the reason for the activation. If you do not want to log the protected actions, for example during an early phase of the configuration, you can deactivate the change log by resetting the "Change log active" check box (without check).

Rules •

Note that an activated change log can only be deactivated on the computer on which SIMATIC Logon Service is installed. Reason: The deactivation and activation tasks themselves must be recorded in the change log.

•

Before the download is performed to each individual CPU with the "Compile and Download Objects" function in the SIMATIC Manager, there is a pause in the operation brought about by the opening of the change log if it is activated for the currently selected chart folder.

Note If you copy the program or chart folder with an activated change log to a computer on which the SIMATIC Logon Service is not installed, you receive an error message when you attempt to download or switch to test mode and the action is not carried out. You cannot deactivate the change log in this situation because there is no "Change log" tab in the Object Properties dialog of the chart folder. You can only activate and deactivate the log in this dialog.

8-10



Opening the change log The change log is opened when you start a protected action requiring logging (select the chart folder and the menu command Options > Charts > Logs). Protected actions for logging are: •

Download to CPU (Entire program)

•

Download to CPU (Changes)

•

Test mode

Logon is performed in the SIMATIC Logon Service dialog. If a user is already globally logged on, the change log for this user is opened immediately when a protected action is started. The user name can be changed for pending actions - and only for pending actions. The setting of the global user remains unchanged. When no user is logged on, the SIMATIC Logon Service dialog opens before the change log opens.

Logging Logging is performed in the "Logs" dialog area in the "Change log" tab: •

Every action is registered in chronological order (last action in the top line) in a main line followed by a line giving the reason and perhaps a log of the action itself (a download, for example).

•

For the action "Download entire program", the change log is deleted from the log but archived as a file with a date identifier at the same time. The archiving action and the file name used (including the path) is recorded in the log.

•

For the action "Start test mode", all subsequent actions resulting in a change (of value) in the CPU are logged. The logging includes the value and how it changed (address, old value, new value). Specifically, these are: In CFC:

In SFC:

•

Configuration of the connections

•

Activation/deactivation of sequence groups

•

Configuration of constants in steps

•

Configuration of constants in transitions

•

Configuration of constants in sequence properties


8-11


8-12


9

Testing

Test Options The process object view provides a test mode, with which you can test and commission process tags and CFC charts online on the CPU: Refer to the section: "How to Test in the Process Object View" You can document changes made in test mode with the change log dokumentieren (which user, when, on which CPU, what change was made ...). This is only possible if the SIMATIC Logon Service is installed and the change log for the current chart folder is activated: Refer to the section "Change Log". You will also find the essential test functions in the editors with which you configured the programs. With these functions, you can test the configuration. The following editors provide test functions: •

CFC Testing the CFC configuration: Refer to the section "How to Test CFC Charts"

•

SFC Testing the SFC configuration: Refer to the section "How to Test the SFC Program"

Overview The following procedures should be distinguished for testing: •

How to Test a Plant During Operation

•

How to Test S7-PLCSIM

•

How to Test Field Devices


Manual Process Control System PCS 7; Getting Started – Parts 1 and 2


9-1

Testing

9.1

How to Test with S7-PLCSIM

Introduction S7-PLCSIM is an optional software package for simulation of an AS. It is included in the installation of PCS 7 and can be started from the SIMATIC Manager. S7-PLCSIM allows you to edit and test your program on a simulated programmable controller installed on your computer or programming device. Since the simulation is implemented completely by the PCS 7 software, you do not require any S7 hardware (CPU or signal modules). You can test programs 47-400 CPUs using a simulated automation system. This allows you to test operator control and monitoring of the simulated CPU (OS runtime) on the engineering station. S7-PLCSIM provides a simple user interface for monitoring and modifying the various parameters that are used in your program (for example, for switching inputs on and off). You can also use the various applications in the PCS 7 software while the simulated CPU is processing your program. For example, you can monitor and modify variables with the variable table.

Note • S7-PLCSIM operates with an MPI connection in contrast to the usual network configuration for PCS 7 over Industrial Ethernet. •

The simulation of I/O modules is not performed with S7-PLCSIM; it is carried out by the blocks CH_DI, CH_AI etc. within the CFC charts.

•

S7-PLCSIM is not suitable for the simulation of large-scale configurations in the PCS 7 environment.

Installing PLCSIM PLCSIM is not installed automatically when PCS 7 is installed. You will find the software on the 3rd CD. To run the software, you require a separate authorization.

Requirements for working with S7-PLCSIM The following requirements must be fulfilled in order to use S7-PLCSIM:

9-2

•

The driver for an MPI card must be installed.

•

During the simulation, there should be no connections to actual automation systems.

•

All network cards in the configuration console must be set to the "PG operation" mode.

•

If you wish to test the display and behavior of faceplates in process mode, the OS must be configured as a PC station.


Testing

Principle Procedure The simulation can be started from the SIMATIC Manager when there are no connections to actual automation systems. 1. Start the SIMATIC Manager. 2. Select the menu command Options > Simulate Modules. Result: S7-PLCSIM is started and a "CPU" subwindow is opened (with the preset MPI address). 3. Select the object "Charts" in the tree. 4. Download all of the required data to the simulated AS (for example, hardware configuration, blocks) with the menu command PLC > Download. 5. Configure S7-PLCSIM for the test (for example, create subwindows for monitoring the AS) and ensure that the program can be executed. 6. Set the simulated CPU to RUN and test your program. 7. Open the SFC and CFC charts and select the menu command Test > Test Mode. 8. Test the program exactly like you would with a real CPU.


9.2

!

Online help for S7-PLCSIM

How to Test a Plant During Operation Warning Testing a program while a process is running can lead to serious damage to property or persons if errors occur in the function or in the program! Ensure that no dangerous situations can occur before you execute this function!

Testing an operating plant is not fundamentally different from the test described in the section "How to Test with S7 PLCSIM" or the test with a test setup with an AS. The number of obtainable automation systems and operator stations is, however, normally far larger than possible with a test setup. There are higher requirements for safety during ongoing operation and the number of persons involved is greater. The warning above should make this clear. Another concern is that the test should limit any disruption or interruption in the operation of the plant to a necessary minimum. The plant operator should be usually consulted beforehand.


9-3

Testing

9.3

How to Test Field Devices The options for parameter configuration and diagnostics using SIMATIC PDM are not described in this manual.

Further information

9-4

•


•

For more detailed information, refer to the documentation for SIMATIC PDM. Start > SIMATIC > Documentation > English


10


Introduction The Version Cross Checker is a separate application you can order as an option. The Version Cross Checker (VXC) allows you to quickly and reliably compare two S7 programs in order to find differences relevant to downloading. This feature allows you to recognize any changes in the S7 program.

Requirements Archived configuration versions must be compared to determine any changes since the last supply and acceptance, for example after it was delivered to the customer or after certification by Technical Inspectorate or FDA authorities. This information is important, for example in the following areas of application: •

A previously accepted project status is to be approved after changes were made and expansions were added. You therefore need to know the status of changes since the last acceptance.

•

The contractual and accepted project status has been expanded due to subsequent changes in requirements and the expansions are to be verified.

•

In parallel to the commissioning of a project status at a plant, the status was expanded at an engineering office. The expansions are to be identified in order to add them to the current project status.

•

The documentation of an already completely documented project status is to be updated. It is to be determined which object documentation requires revision due to changes.


10-1


10.1

Using the Version Cross Checker (VXC)

Introduction Automation solutions are configured PCS 7 engineering system in the form of CFC and SFC charts using blocks. The project version is compiled as a program and downloaded to the AS. This version can be saved by archiving the project (for example, after the customer, Technical Inspectorate or FDA representative accept the project). This project will be changed over time, errors will be corrected and additions will be made, for example. If acceptance has to be performed again, the Version Cross Checker (VXC) can be used as proof of everything that has changed. One S7 program (current program) and a second S7 program (for comparison) are selected in the VXC. The comparison is started automatically by selecting the object for the comparison.

What is compared? The VXC compares objects (including all objects contained within) and their attributes and displays the differences in graphical form. This requires that the objects being compared have already been structured hierarchically or at least can be displayed in the form of a tree. The object trees that are compared are processed simultaneously, each object pair is compared attribute for attribute and assembled in a "results tree" in RAM. The results tree of the comparison is similar to superimposing two transparencies. The common comparison results tree is assembled according to the following rules: •

All objects with the same identity are collected in a node in the comparison results tree.

•

In the comparison results tree, all additional existing objects contained in the first or second object tree are handled as separate nodes.

A state is displayed in color for each node of the comparison results tree. The following information can be derived from this color coding by comparing the object attributes:

10-2

•

The object is in the first and second object tree (identity) / only in the first or only in the second object tree.

•

Both objects (with the same identity) are identical / different.

•

The objects contained within the two objects (with the same identity) are identical / different.



The results of the comparison are documented - example.

Display of Change States Version changes are indicated by the five following representations: Color of the object Symbol for the status Meaning name of the change Black on yellow

Both objects are identical and underlying objects are different

White on red

Both objects are identical and underlying objects are identical

Yellow or read

Both objects are different and underlying objects are different

White on blue

Object also exists in first object tree

White on green

Object also exists in second object tree


10-3


Identity of the objects The VXC defines the identity of two objects as follows: •

Two objects can only have the same identity when they have the same object type (basic requirement).

•

Underlying objects can only have the same identity when they have the same parent (hierarchical addressing).

•

Objects that have the same name have the same identity (unnamed objects are therefore not recognized!). The term 'name' here generally represents any string of characters.

•

For objects with no names, the identity is determined based on similarity when in doubt, only the object type is considered.

•

For object lists based on ordering, the relative position determines the identity (smallest difference method).


10-4

Online help for VXC



10.2

How to Compare Project Versions

Procedure 1. Select the menu command Start > SIMATIC > STEP 7 > VXC – Compare Versions. Result: The SIMATIC Version Cross Checker is started. 2. Select the menu command File > Open.... 3. Select the desired object type in the "Open" dialog. 4. Click on the "Browse..." button and open the original project. 5. Select the desired object. The VXC reads the selected object including all of the objects within and displays it. 6. Select the menu command File > Compare with... 7. Open the changed project and select the desired object. The VXC reads the second selected object including all of the objects within and compares it to the first selected object. The two objects are superimposed in a comparison tree. The deviations are displayed with color coding. 8. Navigate in the hierarchy or detail window to the objects for which you require detailed change information. 9. If you only wish to see specific objects, select the menu command Options > Filter and set the filter as needed. 10. Select the menu command View > Filter on/off. This activates the filter. 11. Print and/or export the comparison results.

Update If the project data has been changed in the meantime with a PCS 7 application, you can update the comparison data. To do this press the function key "F5" or select the menu command View > Update. The VXC then deletes the internal management structures and reads both objects again - including all of the objects contained within - and performs a full comparison of the objects one more time.

Export the results You can export the data or comparison results to a text file (menu command: File > Export...). The file is created in the format (.csv, .txt, etc.) that you specified under "Customize Export". •

All of the data is exported if the current window is alone, i.e. no comparison has been performed.

•

Only the comparison data is exported if the current window is a comparison window, i.e. the comparison has been performed.


10-5


Printing You can print the differences found in the comparison (menu command: File > Print Differences...). •

All objects also contained in a project are printed on one sheet.

•

All differences between objects are printed on another sheet.


10-6

Online help for VXC


11

Archiving and Documenting SIMATIC PCS 7 provides a variety of functions for archiving and documenting configuration data and archiving process values. •

•

Archiving PCS 7 provides two basic functions for logging: -

Archiving of process values (such as measured values, messages) The operator station saves measured values and messages in archives so that the data can be called up over a longer period of time. Refer to the configuration manual Process Control System PCS 7; Operator Station for more information.

-

Archiving of projects The multiproject is archived with all projects and the master data library. Refer to the section "How to Archive a Multiproject and the Project Master Data" and "How to Retrieve a Multiproject and the Project Master Data"

Documenting with DOCPRO (optional package) -

Creating and managing plant documentation.

-

Centralized control of printing (project segments or entire project).

-

Custom layout (e.g. DIN 6771).

For more detailed information, refer to the manual for the DOCPRO optional package.

Caution Be sure to make a backup copy of your project. You should keep at least five older backup copies of the project. If there is a network failure, hard disk crash or network disruption, you can always revert to a backup of your project.


11-1


11.1

Archiving/Retrieving Multiprojects and Project Master Data

11.1.1

How to Archive a Multiproject and the Project Master Data You can save a multiproject in compressed form in an archive file just like projects or libraries. The compressed files are saved to a hard disk or transportable data media (such as a Zip disk). If parts of the multiproject are stored on network drives, you can use the following file compression tools to create an archive for multiproject data: •

PKZip

•

ARJ32

•

JAR

Prerequisite for archiving: Since the archiving function affects all projects of the multiproject, the relevant projects must not be accessed by any other processes. A UNC path can be entered in the project management. There must also be a drive assignment for the path \\Computer\Share\.. to the projects or libraries.

Procedure: 1. Select the multiproject in the SIMATIC Manager. 2. Select the SIMATIC Manager menu command File > Archive. 3. Confirm the selected multiproject in the subsequent dialog and click "OK". 4. In the next dialog, select the name and path of the archive and the archiving program (for example, PKZip) 5. Confirm the dialog with "Save".

Further information

11-2

•

Online help for SIMATIC Manager

•




11.1.2

How to Retrieve a Multiproject and the Project Master Data

Procedure 1. Select the SIMATIC Manager menu command File > Retrieve. 2. In the next dialog, select the multiproject archive. 3. Confirm the dialog with "Open". 4. In the "Select destination directory" dialog that appears, select the target directory for unpacking the archive files. 5. Confirm the dialog with "OK". Result: A new directory is created in the selected directory and the complete project directory structure of the unpacked multiproject now appears on the same level below this directory.

Note All directories are located on the same level below the destination directory following retrieval.

Further Information

11.1.3

•

Section "Requirements for Compiling and Downloading"

•

Online help for SIMATIC Manager

•


Data Security and Backup

Recommendation Save various project states. You should always perform a backup: •

After changing the configuration

•

Before and after upgrading system components

•

Before and after upgrading configuration software

Further information You will find a step-by-step description of saving and backing up ES and OS project data in the manual Process Control System PCS 7; Service Support and Diagnostics.


11-3


11.2

Documentation

11.2.1

Creating Project Documentation

Overview Once you have created a project, the entire mass of project data must be documented clearly to allow an overview of the whole system. Clearly structured documentation makes both future development of the project and service and maintenance much easier. DOCPRO is an application that can be used for effective creation and management of plant documentation. It allows the project data to be structured flexibly in standardized technical documentation that can then be printed in a uniform format.

Further information For more information, refer to the manual DOCPRO; Creating Documentation and the DOCPRO online help.

11.2.2

How to Convert Documentation to a PDF File

Introduction DOCPRO can generate documentation to an electronic manual (PDF format). There is no automatic conversion function in PCS 7!

Requirement To perform this task, you require a full license for the Adobe Acrobat program from Adobe Systems Incorporated.

11-4



Procedure 1. Create the documentation for a project in DOCPRO, for example with the aid of the DOCPRO wizard. 2. Print the documentation from DOCPRO to a file using the print to file option in the Windows Print dialog. 3. Open the Acrobat Distiller and drag all the files created by DOCPRO from the Explorer to the Distiller. The Distiller then creates a PDF file for each individual file.

Note Siemens accepts no liability for the programs offered by Adobe Systems Incorporated. For detailed information on using the Acrobat Reader, refer to the Acrobat Online manual that can be started with the Help menu command.


Manual DOCPRO; Creating Documentation

•

Online help for DOCPRO


11-5


11-6


12

Service

12.1

Diagnostics with a Maintenance Station

Maintenance Station With the maintenance station, PCS 7 allows you to call up information on the status of all PCS 7 components in hierarchically structured diagnostic pictures. The data of a component is analyzed with the existing online functions of the corresponding tool. From within the diagnostic pictures, it is possible to access the ES data (can be controlled by protection mechanisms). Pictures for process control diagnostics can be generated automatically for the entire plant and made available graphically on the maintenance station. The highest level is a picture with an overview of the entire plant.

Requirements •

The cross-project consistency check was successful (for example names of the S7 programs unique throughout the multiproject)

•

Block from a PCS 7 library V6.1 or higher were used.

•

The module drivers were generated and interconnected with the signalprocessing blocks in the CFC charts.

•

The diagnostic blocks were set to "OCM possible".

•

In the settings in the PH; the option "Derive diagnostic pictures from the plant hierarchy" was activated.


12-1

Service

Diagnostic Options Area

Components

PC stations

Operator stations Archive server WinAC slot Industrial PC Standard PC

Automation Systems

CPU External I/Os, such as ET 200M, ET 200S, input and output modules HART Modules Third-party components

Network

Ethernet components such as ESM, OSM

PROFIBUS components

DP interfaces

Redundancy

Master standby configurations

Additional information

I&M information, such as MLFB, name, identification number

Further information

12-2

•

The Configuration manual Process Control System PCS 7; Operator Station contains a description of how the maintenance station is configured.

•

You will find a description of working with the maintenance station in process mode in the manual Process Control System PCS 7; Operator Station Process Control.


Service

12.2

Teleservice with PC Anywhere PC Anywhere enables you to communicate directly with the operator station via modem in order to check, change or remote control the station (remote access). The schematic below illustrates the principle: ss

Customer Support Service Personal

Plant

Modem

Modem

Further information For more detailed information on working with PC-Anywhere, refer to the manual Process Control System PCS 7; Service Support and Diagnostics.

12.3

Further Service Support and Diagnostics

Further information In the Manual Process Control System PCS 7; Service Support and Diagnostics, you will find a detailed description of the further diagnostic options available with PCS 7 and what to do if service becomes necessary. This manual contains information that supports in the following situations: •

When taking measures to ensure the availability of a PCS 7 plant.

•

When checking the requirements for effective diagnostics of your PCS 7 plant.

•

Understanding the alarm concept of a PCS 7 plant

•

Using the right procedure if a problem occurs and providing detailed information about the state of the PCS 7 plant for service experts

•

Selecting the correct diagnostic tool so that you can run diagnostics on your PCS 7 plant with the specified aids.


12-3

Service

12-4


13

Appendix

Overview This appendix contains information about the following topics:

13.1

•

Installation Guidelines for PCS 7

•

Lightning Protection

•

Electrical Installation

•

Basics of EMC-Compliant Installation of PCS 7

•

Degrees of Protection (Housing Protection)

Installation Guidelines for PCS 7

Introduction The installation guidelines must be followed to ensure correct operation of a PCS 7 system. This appendix contains additional information about lightning protection, grounding and EMC-compliant installation. The basic installation guidelines can be found in the installation manuals of the components (for example. Installation Manual Programmable Controllers S7-400; Hardware and Installation).

Introduction The configuration method is largely determined by the components used in SIMATIC PCS 7: •

Operator stations

•

SIMATIC NET (Fast Ethernet, Industrial Ethernet and PROFIBUS)

•

S7-400/S7-400H/FH

•

Distributed I/O (ET 200M, ET 200S, ET 200iSP, and field devices)

Each component has numerous configuration variations that can be adapted to meet the requirements of a particular application. There is also the option of installing programmable controllers and the distributed I/O systems in cabinets. For more detailed information about the installation of an entire plant (lightning protection, grounding, etc.) refer to the relevant sections below. The options available for connecting process signals to the CPUs are described in detail in the section Installation of the I/O. Note ET 200M is used as an example of distributed I/O in the following. Refer to the relevant product manuals for more information about installing other ET models.


13-1

Appendix

Rack or Wall Mounting The PCS 7 system can be mounted in racks or on a wall if the system is being operated in an environment with low noise levels in which the permitted environmental conditions can be maintained. To discharge voltages coupled in on large metal surfaces, you should install rails, shields and the lightning conductive bar on reference potential surfaces made of sheet steel.

Cabinet installation S7-400 programmable controllers and ET 200M modules can be installed in cabinets for the SIMATIC PCS 7 process control system. The following illustration shows the S7-400 programmable controller and distributed I/O system ET 200 M installed in a cabinet. The different racks can be combined as necessary to allow you, for example, to install the distributed I/Os in separate closets (electronics closets, wiring closets).

1 AS and 5 ET 200M 2 AS and 2 ET 200M 3 AS

5 ET 200M

The cabinets made up of system and I/O units and modules that do not belong to the system (basic cabinets, supply units and optional packages) provide reliable protection against unauthorized manipulation, mechanical influences, contamination and corrosion. Due to the modularity and associated variability, the cabinets can be adapted to different types of system and different sizes of system.

13-2


Appendix

EMC Compliance The SIMATIC PCS 7 system and its components comply with the EMC requirements of European standards. These standards require that EMC-compliant devices have sufficient immunity to noise during operation when correctly installed, suitably maintained, and be used for correct purposes in a normal EMC environment. The emission of noise is limited to guarantee normal operation of radio and telecommunication devices. The cabinets of the SIMATIC PCS 7 system consisting of the system units, I/O units, basic cabinets, power supply units and optional packages are CE compliant. This means that the cabinets and the SIMATIC PCS 7 system comply with the EMC regulations such as: •

Electromagnetic compatibility(89/336/EEC; 92/31/EEC)

•

Low voltage directive (73/23/EEC; 93/68/EEC)

•

Hazardous areas directive (94/9/EEC)


13-3

Appendix

13.2

Lightning Protection

Introduction Industrial plants and power stations must be equipped with lightning protection to protect people, buildings and equipment from damage resulting from lightning strikes. Process control systems with extensive cabling networks are often at risk since high voltages can occur between points at great distances from each other. The destruction of electronic components due to lightning can lead to plant failure with extremely expensive consequences. The risk of damage by lightning can result from •

a building being struck directly

•

a lightning strike in the immediate vicinity of the system

•

a remote strike (in a free line)

•

cloud to cloud discharge

Originating in the lightning channel, the lightning creates a cylinder-shaped electromagnetic wave that penetrates into the building and induces voltages in cable loops. The closer the lightning strike, the more powerful the fields created. Both with lightning from cloud to cloud or from cloud to earth, the charges induced in free lines (high and low power and telecommunication lines) change. These changed charges then flow as traveling waves along the cable. If these traveling waves reach equipment at the end of the cable they can also enter a plant or system. Normally, however, only signal and bus cables in the vicinity of transformers and signal and telecommunication lines are at risk. The lightning protection for a process control system can be roughly divided into external and internal lightning protection.

Exterior lightning protection Exterior lightning protection includes all the equipment used outside a building for discharging lightning to earth.

Interior lightning protection Interior lightning protection includes the measures taken to counteract lightning and the effects of its electrical and electromagnetic fields on metallic installations and electrical systems within the building.

13-4


Appendix

Lightning protection zone concept The principle of a lightning protection zones requires that facilities to be protected from overvoltages, such as a section of a factory, should be divided into lightning protection zones based on EMC considerations. The division of the lightning protection zones is made according to the distance from a point liable to lightning strikes and the resulting high-energy electromagnetic fields. Lightning protection zones are as follows: Exterior lightning protection of the building (field side)

Lightning protection zone 0

The shielding of - Buildings


- Rooms and/or


- Devices


Further information The rules for bridging the interfaces between the lightning protection zones and a sample circuit for networked SIMATIC 400 stations are explained in "S7-400 Programmable Controllers; Hardware and Installation".


13-5

Appendix

13.3

Electrical Installation

Introduction To operate correctly, PCS 7 components depend to a large extent on adherence to certain rules regarding electrical installation. This involves the following aspects: •

Equipotential bonding (VDE 0100)

•

Grounding

•

Overvoltage protection

•

Shielding

•

Cabling

Equipotential bonding According to VDE 0100, all electrically conductive metal parts of a system (cabinet panels, racks etc.) must be interconnected. This ensures that any potential differences are reduced to such an extent that there is no danger for either human beings or equipment.

Grounding Low-resistance ground connections reduce the risk of electrical interference in case of short circuits or faults in the system. By using low-impedance connections for grounding and shielding cables and devices, the effects of noise on the system and the emission of noise from the system can be reduced. The SIMATIC S7-400 programmable controller and the distributed I/O system ET 200M allow both grounded and ungrounded operation.

Grounded reference potential or ungrounded design The modules used in the S7-400 are always grounded via the backplane bus of the rack. This strategy is usually used in machines or in industrial plants and interference currents are discharged to local earth. In the chemical industry or in power stations, it may be necessary to operate systems with an ungrounded reference potential due to the ground-fault detectors. In this case, a jumper on the rack can be removed so that the reference potential is connected to local earth via an integrated RC network.

Overvoltage protection Overvoltages can occur at module outputs when inductors are turned off (at relays, for example). The digital modules of the SIMATIC S7 400 have integrated overvoltage protection. In certain situations (for example, when there is an additional contact between the module output and inductor), an external overvoltage suppressor must be installed directly on the inductor.

13-6


Appendix

Balanced signal circuits In balanced signal circuits, all the signal routes have the same impedance. This means that if there is interference, the induced longitudinal voltages in the signal cables are of the same magnitude and no interfering current can flow. A balanced signal circuit is typically used for highly sensitive measurement circuits and for systems operating at high frequencies. Balanced measuring circuits have a high degree of immunity to noise but are extremely complicated and hardly found in process control systems. In process control systems, shielding of cables is preferred.

Shielding Cables are shielded to reduce the effects of magnetic, electrical, and electromagnetic disturbances on the cables. The interference currents induced in the shields are discharged direct to ground via low-impedance connections. Braided shields are preferred to foil shields since foil shields can be damaged easily, reducing the efficiency of the shield. Grounding shields via long, thin wires also makes the shield ineffective. Due to the high inductance, interference currents cannot flow to ground. If the shielding effect of the cable shield is inadequate, the cables should be pulled into metallic conduits that are grounded at both ends. With high-frequency disturbances, it is advisable to contact the shield at both ends of the cable, whereas for low-frequency interference, the shield should be contacted at the start or end of the cable. The effectiveness of the shield with lowfrequencies is determined by the ohmic resistance (shield cross section), while with high frequencies the inductance and therefore the structure of the sheath (closed conduit better than braid etc.) decides the effectiveness. To prevent coupling in magnetic fields, shields should, whenever possible, be connected to an equipotential bonding system at both ends. Indoors, this is often not done due to fears of violating specifications for the current load on the foil shields that can be caused by power-frequency interference currents. Grounding both ends of a shield is not permitted when strong magnetic inference fields are present (generators, conductor bars). Connecting the shields at both ends would form a loop into which power-frequency interference voltages could be coupled. To avoid the effects of induced voltages resulting from magnetic fields, signal cables are twisted. The twisting results in a positive induces voltage in one half of the twist and a negative voltage in the other. These voltages cancel each other out over the length of the full twist.


13-7

Appendix

The following schematics illustrate possible shielding configurations. Receiver

Transmitter

L+ usually impermissible

Signal cable

LEquipotential bonding system Receiver

Transmitter

L+ Signal cable

permissble L-

Equipotential bonding system

Shield

Transmitter

Receiver L+

Signal cable

better L-

Equipotential bonding system Shield

Transmitter

Receiver L+ good

Signal cable

LEquipotential bonding system 2nd Shield

Transmitter

Receiver L+ very good

Signal cable

LEquipotential bonding system

13-8


Appendix

Contacting the cable shield at the cabinet inlet Care must be taken that interference running along the cable shield is not allowed to enter electronics cabinets. If the cable shields are grounded inside the cabinet or casing, the field generated in the shield grounding cables by the shield current is coupled not only into the unshielded signal cables but also into the loops on the modules behind the inlet protection circuits and generates interference voltages. You should also make sure that the shields make large-area contact on the grounding bar. Long thin wires between the shield and ground bar have high inductance and are therefore unsuitable for discharging interference currents with high frequencies. Note the following points: •

Use short wire lengths (if possible do not use wires at all but make direct largearea contact)

•

Choose a suitable route for the shield grounding wires (do not lead them close to sensitive electronics)

•

Use a short, thick cable from the shield bar to the equipotential bonding system

If cabinets or casings are included to shield the control system, remember the following points: •

Cabinet panels such as side panels, back panels, ceilings and floors should be contacted at adequate intervals when cascaded.

•

Doors should have extra contacts to the cabinet chassis.

•

Cables leaving the shielding cabinet should either be shielded or fed via filters.

•

If there are sources of strong interference in the cabinet (transformers, cables to motors etc.), they must be separated from sensitive electronics by partitions. The partitions should be connected with low impedance to the equipotential bonding system via the cabinet.

All housings, cabinets etc. should be connected to the equipotential bonding system over the shortest route possible. Often, an independent equipotential bonding system is created. This is connected to the equipotential bonding system of the remaining plant by a single cable. It is a mistake to connect the PCS 7 process control system to a ground point outside the plant. The magnetic fields generated by the interference currents flowing in the equipotential bonding system induce voltages in the additional surface between the equipotential bonding conductors and the connection to ground.


13-9

Appendix

Cabling The aim of cabling is to reduce the field of interference current between the culprit and the signal cable to a minimum by laying the cable directly on the conductor carrying the interference current. Signal and bus cables should be laid next to cables with a large diameter since the field strength is lower here than with cables with a smaller diameter. If the conductor carrying the interference current is a plate (for example belonging to the building structure) lay the signal cable in the middle of the plate where the field strength is at its lowest. The cable should be fixed to the side of the plate with the least noise. This also applies to angles and girders.

Field lines

Cable Field lines

Cable

The lines of a signal or bus connection should be in one cable and be surrounded by a common shield. The cable should be laid as close as possible to the exciting cable to keep the insulation stress to a minimum. The cable carriers (for example, cable racks) should be connected to the equipotential bonding system if there no interference carrying part of the equipotential bonding system is within proximity. The cable shield can then be contacted at both ends with the casings of the electronic equipment and in turn connected to the equipotential bonding system.

Further information For more detailed information on the electrical installation, refer to the installation manual S7-400 Programmable Controllers; Installation and Hardware.

13-10


Appendix

13.4

Basics of EMC-Compliant Installation of PCS 7

Introduction Measures to counteract noise are usually only taken when the system is already in operation and problems are encountered receiving signals. Although the SIMATIC PCS 7 system and its components were designed for use in an industrial environment and meet strict EMC requirements, an EMC assessment should be performed prior to installation and possible sources of noise identified.

Possible sources of noise Electromagnetic interference can affect automation systems in a variety of ways. •

Electromagnetic fields can affect the system directly.

•

Interference can be transported by bus cables.

•

Interference can be transferred via the signal wiring.

•

Interference can reach the system via the power supply or the protective earth.

Mechanisms Interference arising from various coupling mechanisms can affect the PCS 7 system. The type of coupling mechanism depends on the distance between the source of the interference and the PCS 7 system and the transmission medium. Coupling mechanisms

Cause

Sources of interference

Galvanic coupling

Occurs when two circuits share a common line

Switched mode devices; motors starting; static discharge

Capacitive coupling

Occurs between two cables at different potential

Crosstalk between parallel signal cables; contactors; static discharge from operator

Inductive coupling

Occurs between two cables carrying current. The magnetic fields of voltages induced by currents.

Transformers; motors; parallel power cables; cables with switched currents; high-frequency signal cables

Radiated coupling

Occurs when an electromagnetic Adjacent transmitters (walkie-talkie); wave meets a cable. Voltages radio links and currents are induced.


13-11

Appendix

Rules for maintaining electromagnetic compatibility Adherence to the following rules is normally adequate to guarantee electromagnetic compatibility: •

Protect the programmable controller from external noise by installing it in cabinet or casing. Include the cabinet or casing in the chassis connections.

•

Shield against the magnetic fields of inductors (transformers, motors, contactor coils) using partitions (steel, highly permeable material) from the programmable controller.

•

With shielded signal and bus cables use metallic connector casings (not metalized plastics)

•

Connect all inactive metal parts together wit low impedance and making largearea contact and also to local ground.

•

Create a central connection between the inactive metal parts and ground point.

•

The shield bar should be connected to chassis with low impedance and making large-area contact.

•

Divide cables into cable groups and lay them separately.

•

Lay power cables, signal cables and bus cables in separate channels or bundles.

•

Lay Ex (hazardous area) and normal signal cables in separate channels.

•

Only feed cables into a cabinet from one side.

•

Lay signal and bus cables as close as possible to chassis surfaces (such as support struts)

•

Use twisted cables.

•

Contact the shields of signal cables at both ends.

•

Lay analog cable with double shields. The inner shield must be contacted at one end and the outer shield at both ends.

•

Contact cable shields with the shield bar over a large area immediately where they enter a cabinet and secure with clamps.

•

Continue the contacted shield to the module without interrupting it.

•

The cable shield must not be interrupted between the function units and must be contacted at both ends.

•

Do not interconnect cable shields.

•

Use only network filters with metal casings.

•

Connect the filter casing over a large area; in other words with low impedance to cabinet chassis.

•

Never secure filter casings to painted surfaces (remove paint!).

•

Install filters at the point where the cable enters the cabinet.

•

Do not lay unfiltered cables in cabinets.

Further information For further information about plant installation, refer to the manual S7-400 Programmable Controllers; Installation and Hardware.

13-12


Appendix

13.5

Degrees of Protection (Housing Protection) In Europe housing protection is stipulated in standard EN 60529 by the IP codes IPxx with 2 numbers. The following table explains the IP norms conforming to EN 60529/IEC529:

First number 0 1 2 3 4 5 6

Contact and solid body protection

Remarks

No protection Protection against solid objects up to 50 mm Protection against solid objects up to 12.5 mm Protection against solid objects beyond 2.5 mm Protection against solid objects beyond 1 mm Protection against dust, limited penetration allowed Completely dust proof

e.g. inadvertent hand contact e.g. fingers e.g. tools and small wires e.g. tools and small wires No damaging deposits

Second number Degree of protection against water

Remarks

0 No protection 1 Protection against dripping water

Vertically falling drops of water

2

Protection against dripping water

Direct dripping inclined at 15° vertical angle

3 4

Protection against spraying water Protection against spraying water

5

Protection against water jets

6

Protection against high pressure water jets

7

Intermittent immersion at specified pressure for specified time should not result in damage Protection against permanent immersion at specified pressure for specified time as agreed by the manufacturer and user. However, the conditions must be more severe than those stipulated under Number 7.

8

Water spray from any direction should not result in damage Low pressure water jets from any direction should not result in damage Water jets from any direction should not result in damage

The casings of most SIMATIC components have ventilation openings. To allow more effective cooling of the electronics components, ambient air can flow through the casing. The maximum operating temperatures quoted in the technical specifications apply only when there is unrestricted flow of air through the ventilation openings. Depending on the size of the ventilation openings, such modules comply with the degrees of protection IP 20, IP 30 to IP 40. You will find the actual degree of protection of a SIMATIC component in its documentation. Components with the degrees of protection mentioned above do not provide protection against dust and water! If the installation site requires such protection, the components must be installed in an additional enclosure such as a switching enclosure that provides the higher degree of protection (for example IP 65/ IP 67).


13-13

Appendix

Installation in additional enclosures If you install these components in an additional enclosure, make sure that the conditions required for operation are maintained!

Note Make sure that the temperature inside the additional enclosure does not exceed the permitted ambient temperature for the installed components. Select an enclosure with adequate dimensions or use heat exchangers.

13-14


Index @ @PCS 7 3-62, 3-64 interfacing to the IT world 3-62

A Access to the PCS 7 OS over Web Client 3-65 Acknowledgment concept 5-26 Acknowledgment-triggered reporting (ATM) 5-29 Acknowledgment-triggered reporting (ATR) 7-125 Acoustic signaling 5-30 acoustic signaling device 5-30 Additional PH Functions in a Multiproject 7-34 Adopting the data from the plant engineering 7-266 Advantages and uses of SFC charts and SFC types/SFC instances 7-209 Archiving 11-1 archiving/documenting 11-1 AS 3-71, 3-78, 3-79, 3-80, 3-81, 3-85, 4-12, 7-10, 7-87, 7-185, 7-186 components 3-71 configring SIMATIC stations 7-10 configuration 4-12 configuration of fail-safe systems 7-87 configuration of fault-tolerant systems 7-87 configuring runtime measurement 7-185 fail-safe components 3-79 fault-tolerant components 3-77 possible uses in H systems and F systems 3-85 AS functions 7-153, 7-157 configuring 7-157 configuring cross-AS functions 7-153 ASI-BUS 3-56 interface into PROFIBUS DP 3-56 Assembly instructions 4-16 special features differences 4-16 Assigning objects in the PH 7-31 Assignment 7-27 ATR 7-125


B Backup 11-3 Balanced signal circuits 13-7 Basic Concepts of Engineering 5-1 Basic configuration 4-1, 7-11 configuring hardware 7-11 in PCS 7 process cells 4-1 Basics 7-104 BATCH stations 7-15, 7-16 configuring 7-15 inserting 7-15 Block 7-48 setting the language 7-48 Block icons 5-23, 7-49 creating/updating automatically for OS pictures 7-49 generating block icons and operator texts 5-23 Block type 5-11, 5-12 Blocks 7-45, 7-165, 7-166 inserting in CFC charts 7-165 project-specific adaptation 7-45 Blocks for 7-188 different connection types 7-188 FDL ISO/TCP connections 7-188 FMS connections 7-188 S7 connections 7-188 Braided shields 13-7 Branching and merging charts of a project 5-8

C Cable laying 13-6 Cable shielding 13-6 Cable shielding at cabinet inlet 13-6 Catalog profile 7-66, 7-67 defining for specific projects 7-66 Central plantwide engineering 5-1 CFC charts 7-179, 7-181, 7-183 compiling 7-180 download to the CPU 7-181 testing 7-183

Index-1

Index

Changes 7-116, 7-127, 8-10 change log 8-10, 8-11 configuration in RUN 7-127 undoing 7-116 Changing parameter settings of existing modules in ET 200M stations 7-117 Changing signal assignments of modules 7-299 CiR 4-17, 7-104, 7-105, 7-106, 7-107, 7-108, 7-109, 7-110, 7-111, 7-112, 7-113, 7-114, 7-115, 7-116 CiR elements 7-104 CiR modules 7-104 CiR objects 7-104, 7-105, 7-106 configuration rules 4-17 defining CiR elements 7-109 deleting CiR elements 7-113 introduction 7-107 recommendations 7-108 using CiR elements in RUN 7-114 Commission 1-7 Communication 4-9, 4-10, 7-142, 7-143, 7-146 communication partners 7-142 configuring between SIMATIC stations 7-144 data exchange over terminal bus and plant bus 4-9 on terminal bus and plant bus 4-10 Communication connection 3-32, 7-142 connection types and connection partners 7-142 with SIMATIC NET 3-32 communications processor 7-76 Communications processor 7-12 inserting 7-76 inserting in the stations 7-12 Comparing 10-5 project versions 10-5 Comparing project versions 10-1 Version Cross Checker 10-1 Compiling 7-50, 7-179, 7-229, 7-230, 7-231 CFC charts 7-179 charts and types 7-229 compiling and editing operator-relevant texts 7-50 Compiling and downloading 8-1, 8-2, 8-3, 8-8 AS data 8-2 options 8-8 OS server data 8-1, 8-2 requirements for OS 8-3 Component view 6-3, 6-4 AS configuration 6-3 hardware configuration 6-3 important functions 6-3 multiproject engineering 6-3

Index-2

OS configuration 6-3 Components 3-71 of an AS 3-71 configuration CiR 7-107 Configuration 3-71, 3-88, 4-2, 4-12, 5-9, 7-10, 7-65, 7-68, 7-72, 7-87, 7-107, 7-126, 7-127, 7-128, 7-142, 7-155, 7-157, 7-158, 7-185, 7-211, 7-301, 7-302, 7-303, 7-308 AS functions 7-157 AS runtime measurement 7-185 basic configuration in PCS 7 4-1 changes to distributed I/O 3-88 concept 7-68 configuration of textual interconnections by several users 7-158 configuring hardware 7-11 creating a SIMATIC station 7-72 cross-AS functions 7-153 downloading changes in RUN 7-127 downloading to the CPU 7-126 expanding CFG files 7-295 fail-safe systems 7-87 fault-tolerant systems 7-87 hardware 7-65 in run - CiR 7-107 interface to the management level 7-308 of a SIMATIC station 7-68 of an AS 3-71 of automation systems 4-12 of the AS and PC stations 7-10 OS functions 7-301 sequential control systems 7-211 structure and content of the CFG file 7-293 Structure of a PCS 7 plant 2-1 Configuration rules 4-17 plant modifications during operation CiR 4-17 Configuring 7-313 connections 7-142 cross-project connections AS - OS 7-313 in a network 5-9 Configuring and triggering the message 5-26 Configuring connections 7-142 Configuring Redundant Connections 7-156 Connection types and connection partners 7-142 Connections 7-155 merging cross-network 7-155 Consistency 7-32, 7-33, 7-93, 7-138, 7-139 checking the network 7-138 checking the PH 7-32 errors 7-93


Index

Copying 7-31, 7-32, 7-241, 7-247 charts 7-31, 7-32 replicas of the model 7-242 copying and moving within the PH 7-29 Copying and moving 7-29 Coupling 13-11 mechanisms 13-11 CP 443-1 7-76 CP 443-5 Extended 7-76 CPU 7-78, 7-79, 7-80, 7-81 setting properties 7-78 Creating 7-21, 7-196, 7-225, 7-227 an SFC type 7-225, 7-226 plant hierarchy 7-21 process tags from process tag types 7-196 SFC instance 7-227 Creating CFC charts 7-161 Creating network connections 7-133 Creating sequential control systems 7-208 Creating the chart topology 7-213 Cross-network connections 7-155 merging connections 7-155 Cross-project connections 7-312 merging 7-312 Cross-project networks 7-311 merging in the multiproject 7-311 Cross-project S7 connections 7-313 between AS and OS components 7-313 Cross-View Functions and How to Use Them 6-9

D Data 7-284, 7-287 exchange with Excel/Access 7-287 IEA file in the ES 7-284 Data exchange 4-9, 7-287 communication over terminal bus and plant bus 4-9 with Excel/Access 7-287 Data security and backup 11-3 Default parameter values for the CPUs 7-87 Default parameters of CPUs for PCS 7 projects 3-76 Defaults 7-3, 7-4 how to set 7-4 in the SIMATIC Manager 7-3 Degrees of housing protection 13-13 Deleting 7-279 replicas 7-278, 7-279 Diagnostic repeater 3-54, 7-96 configuring 7-96 use in PROFIBUS 3-54


Diagnostic Repeater configuring 7-96 Diagnostics 7-96, 7-103 configuration diagnostic repeater 7-96, 7-97 using SIMATIC PDM 7-103 Diagnostics and service 1-7 Diagnostics with a maintenance station 12-1 Distributed editing of the projects 7-57 multiproject engineering 7-57 Distributed engineering 5-5, 5-6, 5-7, 5-8, 5-9 branch and merge 5-8 configuring in a network 5-9 multiproject 5-5, 5-6, 5-7 Distributed I/O 3-85, 3-87, 3-88, 7-93, 7-94 changing the configuration 3-88 configuring ET 200M 7-91 interfacing HART devices 3-87 overview 3-85 which components to use? 3-84 Documentation 1-1, 1-2, 11-4, 11-5 converting to PDF file 11-4 for planning and configuring - access options 1-1 of the project 11-4 Download 7-181, 7-182, 7-232, 7-233 CFC charts to the CPU 7-181 downloading programs 7-232 Download changes 7-233 Downloading 7-126, 8-4, 8-5, 8-6 configuration to the 7-126 downloading to all target systems 8-4 Downloading changes 7-170, 7-181, 7-228, 8-5 DP master 7-72 DP slave 7-91 Driver blocks 7-191, 7-195 creating your own 7-195

E Effects on the process 7-128 Efficient engineering 3-91, 3-92 Electrical installation 13-6, 13-10 Electromagnetic compatibility 13-11 EMC planning 13-11 EMC requirements 13-11 EMC-compatible installation of PCS 7 13-11 Engineering 5-5, 7-300 distributed 5-5 synchronizing the engineering data 7-300

Index-3

Index

Engineering station 4-3, 4-4, 7-16 inserting configuring 7-16 structure 4-3 Engineering system 4-3 Equipotential bonding 13-6, 13-7, 13-9, 13-10 ET 200 3-86 module properties 3-86 ET 200M 7-91, 7-92, 7-93, 7-94 ET 200M Modules that allow new parameter settings and their reactions 7-120 Ethernet 3-43 structure of redundant networks 3-42 Export 7-68, 7-282, 7-300 hardware configuration 7-68 synchronizing with plant engineering 7-300 Exterior lightning protection 13-4, 13-5

F F systems 7-87 configuration 7-87 Fail-safe automation system safety concept of PCS 7 3-28 Fail-safe automation systems 3-28, 3-29, 3-31, 3-74, 3-79, 3-85, 7-87 configuring 7-87 possible uses 3-85 recommended use 3-31 using 3-74, 3-79 Fault-tolerant automation system 3-77, 3-78 Fault-tolerant automation systems 3-73, 3-85, 7-87 configuration 7-87 possible uses 3-85 technical specifications 3-73 using 3-77 Fault-tolerant components 3-25, 3-31 recommended use 3-31 Field device 9-4 testing 9-4 Fields of application and parameters 3-34 Filtering and Sorting 7-245 Function identifier 7-276 Function units 7-268 Functions of the IEA 7-272 Further service support and diagnostics 12-3

G General information on the Import/Export Assistant (IEA) 7-268 Generating 7-240 replicas of models 7-240

Index-4

Grounding 13-6, 13-7, 13-9

H H systems 7-87 configuration 7-87 Hardware catalog 7-72 Hardware configuration 5-18, 5-19, 7-65, 7-68, 7-72, 7-291 10 ms time stamps 7-124 Creating a SIMATIC station 7-72 exporting/importing 7-68 import/export 7-291 project-specific catalog profile 5-18 HART devices 3-87, 7-99 configuriing with SIMATIC PDM 7-101 Interfacing to distributed I/O 3-87 Help on installing the PCS 7 plant 4-13 Hierarchy folder 7-27, 7-31 copying 7-27 deleting 7-27 moving 7-27 How automation system CPUs are needed? 3-21 How can a plant be designed? 3-15 How can acoustic or optical signals be used? 3-69 How can project data be archived and compared? 3-13 How can SIMATIC PCS 7 be used? 3-18 How Can the Plant be Protected Against Unauthorized Access? 3-9 How can the process management be verified? 3-11 How many devices sensors and actuators can be integrated? 3-22 How many operator stations are required? 3-23 How many process tag types are in the project? 3-94 How should the plant be operated? 3-7 How to 7-11, 8-4 download to all target systems 8-4 steps in configuration the most important steps 7-164 the basic configuration of the hardware 7-11 How to activate acknowledgment-triggered reporting (ATR) 7-125 How to Adapt the Operating Parameters and Runtime Properties 7-220 How to adapt the runtime properties 7-173 How to add projects to the multiproject 7-7 How to Adopt Process Tags 7-203 How to archive a multiproject 11-2


Index

How to assign an import file to the process tag type (create an import file) 7-200 How to Assign Parameters and Interconnect the Blocks 7-167 How to assign symbols to input and output addresses 7-77 How to change 7-122 parameter settings of a channel 7-122 How to check 7-32, 7-138 consistency of the network 7-138 consistency of the PH 7-32 How to compile 7-179 CFC charts 7-179, 7-181 How to configure 7-95, 7-96, 7-101, 7-144, 7-215, 7-216, 7-218 communication between two SIMATIC stations 7-144 diagnostic repeater 7-96 HART devices with SIMATIC PDM 7-101 PA devices 7-95 sequencer properties 7-215 SFC steps 7-216 transitions 7-218 How to configure and download the PC stations 7-18 How to create 7-195 your own driver blocks 7-195 How to create a master data library 7-41 How to Create a New SFC Chart 7-212 How to create and assign parameters 7-135 a network attachment 7-135 new subnet 7-134 How to create and assigned parameters 7-134 How to create your own blocks 7-49 How to Define CFC Chart I/Os 7-177 How to display 7-133 networked stations 7-133 non-networked stations 7-133 How to document library objects 7-56 How to download 7-126, 7-127, 7-181 CFC charts to the CPU 7-181 configuration changes in CPU-RUN 7-127 configuration to the CPU 7-126 How to edit 7-64, 7-251, 7-254, 7-257, 7-259, 7-261 measured value archives 7-261 messages 7-257 parameters 7-251 picture objects 7-260 projects on distributed stations 7-64 signals 7-254 How to Edit the General Data 7-249 How to Expand a Project by Adding Further Components 7-8 Process Control System PCS 7 - Engineering System A5E00346923-02

How to Export a Station Configuration 7-292 How to find 3-3 systems to use 3-3 How to Generate Module Drivers 7-193 How to Import an Expanded Import File (Extra Remote I/O Field Device Module) 7-298 How to insert 7-7, 7-10, 7-12, 7-28, 7-74, 7-75, 7-165 blocks in a CFC chart 7-165 communications processors in the stations 7-12 first import of an entire station 7-297 modules in a SIMATIC station 7-73 objects in a hierarchy folder 7-28 project in a multiproject 7-7 SIMATIC stations in the projects of the multiproject 7-10 How to lock 7-47 message attributes against changes in the block instance 7-47 How to make the settings for the PH 7-25 How to merge 7-155, 7-311, 7-312 cross-network connections 7-155 cross-project connections 7-312 cross-project networks in a multiproject 7-311 How to modify 7-45, 7-136, 7-198, 7-228 a process tag type 7-198 attributes of the block I/Os 7-45 SFC types centrally 7-228 the node address 7-136 How to move 7-63, 7-310 projects edited on distributed stations to the central engineering station 7-309 projects to distributed engineering stations 7-62 How to program the SIMATIC connections 7-189 How to remove a project from the multiproject 7-8 How to retrieve a multiproject 11-3 How to save 7-137 network configuration 7-137 How to set 7-4, 7-90 defaults 7-4 time-of-day synchronization on the AS 7-90 How to specify the AS-OS assignment 7-30 How to store shared declarations 7-9 How to Store the Projects of the Multiproject 7-61 How to test 7-56, 7-183, 7-234 CFC charts 7-183

Index-5

Index

library objects 7-56 SFC program 7-234 How to Test in the Process Object View 7-263 How to translate 7-48 message texts 7-48 How to Update an Imported Station Configuration 7-299 attributes 7-299 How to Use the Trend Display in Test Mode 7-184 How to Work with the Connection Table 7-152 HW Config 7-65, 7-291 HW Config incl. CiR 7-65 import/export 7-291

I I/O 3-86, 7-191 interface to driver blocks 7-191 overview distributed and central 3-86 Identifying repeated functions 7-267 IEA 7-268, 7-269, 7-270, 7-271, 7-283 restrictions 7-283 Working with process tags/models 7-269 IEA file 7-268, 7-284, 7-285, 7-286, 7-288 data in the ES 7-284 stiucture 7-288 working with 7-285 IM 153-2 7-91 Import 7-68 hardware configuration 7-68 Import file 7-201 assigning a process tag type 7-201 creating 7-201 Import/export 7-291 hardware configuration 7-291 Important features of the message system 5-27 Importing 7-278, 7-279 Inserting a station 7-72 Inserting and configuring 7-13 operator stations 7-13, 7-14 Inserting configuration engineering station 7-16 Inserting configuring 7-16 Inserting hardware components 7-72 instabus EIB 3-58 interfacing to PROFIBUS DP 3-58 Installation 13-10 Installation Guidelines for PCS 7 13-1 Interaction between hardware and software 5-21 Interfacing 3-40, 3-48, 3-52, 3-56, 3-58, 3-59, 3-60, 3-61, 3-62, 3-87, 7-191

Index-6

ASI-BUS to PROFIBUS DP 3-56 Ethernet 3-40, 3-41 HART devices to distributed I/O 3-87 instabus EIB to PROFIBUS DP 3-58 MODBUS to PROFIBUS DP 3-59 network nodes 3-40 operator control and monitoring systems over OPC 3-61 PROFIBUS PA to PROFIBUS DP 3-52 PROFIBUS-DP nodes 3-48 to the I/O driver blocks 7-191 to the IT world with @PCS 7 3-62 to the IT world with SIMATIC IT Framework 3-60 Interior lightning protection 13-4 Introduction 3-82, 5-5, 7-70, 7-107 CiR 7-107 configuration overview 7-70 configuring in run 7-107 multiproject 5-5

L Language 7-48 setting for blocks 7-48 setting for display devices 7-48 Languages 7-50 library 7-37, 7-38 Library 5-17, 7-42, 7-56 testing library objects 7-56 using the master data library/libraries 5-17 working with 7-42 Lifebeat monitoring 7-304, 7-305 Lifebeat monitoring 7-304, 7-305 Lightning protection 13-4, 13-5 Lightning protection zones 13-5 Limits of the CPUs for PCS 7 Projects 3-75 Link 3-52, 3-53, 3-56, 3-57, 3-58, 3-59, 3-61 ASI-BUS to PROFIBUS DP 3-56 instabus EIB to PROFIBUS DP 3-58 MODBUS to PROFIBUS DP 3-59 operator control and monitoring systems over OPC 3-61 PROFIBUS PA to PROFIBUS DP 3-52 List of Driver Blocks 7-192 Local ID 7-151 Local time conversion 5-26 Location identifier 7-276 Log 8-10, 8-11 changes 8-10 setting displaying/hiding resorting defining columns 7-246


Index

M Management level scheme with Ethernet 3-36 Mass data 7-243 editing in the process object view 7-243 Master data library 7-37, 7-41, 7-43 blocks 7-43 Master data library/libraries 5-17 working with 5-17 Maximum transmission rate 3-35 Measured value archives 7-261 editing 7-261 Menu command 7-191 merging cross-project networks in the multiproject 7-139 Merging projects after distributed editing 7-309 Message attributes 7-47 locking against change in block instances 7-47 Message system 5-24 basic concepts 5-24 Message texts 7-48 translating 7-48 Messages 5-26, 7-48, 7-224, 7-257 configuring in SFC 7-224 editing 7-257 message buffer 5-26 message lists 5-26 translating message texts 7-48 MIS/MES connection 3-60 MOD blocks 7-191 MODBUS 3-59 interfacing to PROFIBUS DP 3-59 Model 5-16, 7-55, 7-236, 7-237, 7-238, 7-240, 7-241, 7-242, 7-243, 7-268, 7-269, 7-270, 7-272, 7-273, 7-274, 7-278, 7-279 assigning replicas later 7-243 copying 7-241, 7-242 creating 7-236 creating for replica 7-243 deleting 7-242 generating from replicas 7-240 model in the SIMATIC Manager 7-241, 7-242 working with 7-55, 7-269 working with the IEA 7-269 Models removing 7-242 Modifications 4-17 configuration rules for CIR 4-17 during operation CiR 4-17 Module drivers 7-191 Module replacement in operation 7-91 Modules 7-92, 7-93, 7-94


Modules in SIMATIC station 7-73 inserting 7-73, 7-75 Monitoring 7-304 connected AS and OS 7-304 lifebeat 7-304, 7-305 MPI network 7-72 Multiple export 7-282 Multiproject 5-5, 7-7, 7-10, 7-57, 7-58, 7-59, 7-60, 7-139, 7-311 conditions for editing 7-59 inserting a project 7-7 inserting SIMATIC stations in the multiproject 7-10 introduction 5-5 merging cross-project networks 7-139, 7-311 overview of the steps 7-60 Multiproject engineering 7-57 distributed editing of the projects 7-57 Multiproject engineering - distributed editing of projects 7-57 Multiproject/single project 7-5

N Named connection 7-148 Network 3-40 PC stations - interfacing over 3-40 Network configuration 7-137 saving 7-137 Networks 7-135, 7-139, 7-140 configuration of redundant networks 7-140 creating and assign parameters for an attachment 7-135 merging in the multiproject 7-139 Node address 7-136 changing 7-136 Non-redundant PROFIBUS 3-50 connecting to redundant systems 3-50

O OB_BEGIN 7-191 OB_END 7-191 Objects 7-28 inserting in a hierarchy folder 7-28 Objects of the Master Data Library 7-39 OPC 3-61 interfacing operator control and monitoring systems 3-61 Operation 1-7 Operator stations 7-13 inserting and configuring 7-13

Index-7

Index

Operator texts 5-23, 7-50 compiling and editing operator-relevant texts 7-50 generating 5-23 Generating block icons and operator texts 5-23 Optical and electrical transmission media 3-40, 3-45, 3-46 Optimization of the Run Sequence 7-175 Options 8-8 compile and download 8-8, 8-9 OS areas 5-22 based on the PH 5-22 OS functions 7-301 configuring 7-301, 7-302, 7-303 OS pictures 7-49 creating/updating block icons 7-49 OS server data 8-3 one-time update 8-3 Overview 3-71, 3-86 AS components 3-71 I/O distributed and central 3-86 Overview of the Steps in Configuration 7-163 Overvoltage protection 13-6

P PA devices 7-95, 7-96 configuring 7-95 Parameters 7-251 editing 7-251 PC components 3-68 attachment 3-68 PC station 7-3 setting up the local 7-3 PC stations 3-40, 7-10 configuring PC stations 7-10 interfacing to Ethernet 3-40 PCS 7 Applications and their Uses 6-1, 6-10 PCS 7 engineering system 4-3 PCS 7 ES 4-3 structure 4-3 PCS 7 Library 5-12 PCS 7 operator station 4-5 PDM 7-98, 7-99, 7-100 Permitted configuration changes 7-108 PH 5-22, 7-21, 7-26, 7-29, 7-33 basis for picture hierarchy and OS areas 5-22 checking consistency 7-32 creating 7-21 notes on copying and moving 7-29 rules for naming 7-26 structure of the PH 7-21

Index-8

Picture hierarchy 5-22 based on the PH 5-22 Planning 3-1, 3-2 before beginning 3-1 Planning diagnostics for Ethernet 3-43 Planning phase 1-3, 1-8 Planning the field level with PROFIBUS 3-43 Plant 11-4 documentation 11-4 Plant hierarchy 5-22, 7-21, 7-22, 7-23, 7-27, 7-29, 7-31, 7-32, 7-33, 7-35 assign objects 7-31 basis for picture hierarchy and OS areas 5-22 canceling assignment 7-31 checking the consistency 7-32 creating 7-21, 7-23 expanding 7-27 notes on copying and moving 7-29 structure 7-21 Plant view 6-5, 6-6 important functions 6-5 master data library 6-5 structure 6-5 Plants 7-304 configuration picture 7-304 Point-to-point connections 7-188 Preconfigured PCS 7 system bundles 3-68 Preface iii Preparations 7-1 Principle of time-of-day synchronization 7-88 PRIVATE 7-188 Process object view 6-6, 6-7, 6-8, 7-203, 7-244 component view and plant hierarchy 6-6 editing mass data 7-244 editing tags 7-203 important functions 6-6 objects 6-6, 6-7, 6-8 structure 6-7 Process tag type 5-13, 5-14, 7-53, 7-54, 7-196, 7-197, 7-198, 7-199, 7-201, 7-207, 7-268, 7-272, 7-273, 7-274, 7-275, 7-278, 7-279, 7-280 assigning to the import file 7-201 creating 7-196 modifying 7-198 repairing an assignment 7-207 working with 7-53 Process tags 7-91, 7-196, 7-199, 7-202, 7-203, 7-205, 7-206, 7-269 creating automatically 7-202 creating from process tag types 7-196 editing 7-203 inserting in a project 7-199 Process Control System PCS 7 - Engineering System A5E00346923-02

Index

process tags list 7-91 updating 7-205 working with 7-269 working with the IEA 7-269 PROFIBUS 3-49, 3-50, 3-51, 7-72, 7-102 connecting non-redundant P. - to redundant systems 3-50 DP master 7-72 non-redundant PROFIBUS connected to redundant systems 7-102 structure of redundant networks 3-49 PROFIBUS DP 3-52, 3-53, 3-56, 3-57, 3-58, 3-59, 7-91 DP slave 7-91, 7-92 interfacing ASI-BUS 3-56 interfacing instabus EIB 3-58 interfacing MODBUS 3-59 interfacing PROFIBUS PA 3-52 PROFIBUS PA 3-52 PROFIBUS PA interfacing to PROFIBUS DP 3-52 PROFIBUS-DP 3-48 interfacing nodes 3-48 Profile in the hardware catalog 7-72 Programming SIMATIC connections 7-188 Programs 7-232 downloading 7-233 Project 7-37, 7-38, 7-62, 7-63 edited on distributed stations - moving to the central engineering station 7-309 library 7-37 moving to distributed engineering stations 7-62 Project library 7-37 Project versions 10-5 comparing 10-5 Project-specific 5-18, 7-45, 7-66, 7-67 adapting blocks 7-45 catalog profile for hardware configuration 5-18 defining a catalog profile 7-66

R Realization phase 1-4 Recommendation for 3-31, 7-108 CiR 7-108 use of fault-tolerant and fail-safe components 3-31 Redundancy 3-42, 3-49, 3-50 interfacing non-redundant PROFIBUS to redundant systems 3-50 structure of Ethernet networks 3-42 structure of PROFIBUS networks 3-49 Reference potential 13-6 Relationships between the views 6-9


Replica assigning to a model later 7-243 Replicas 7-243, 7-278 Restrictions with the IEA 7-283 Reusability and central modifiability 5-10 rules for naming in the PH 7-26 Runtime groups 7-170, 7-171 Runtime Groups and Runtime Properties 7-169 Runtime measurement 7-185 configuring AS runtime measurement 7-185 Runtime properties 7-170, 7-171, 7-172 of the blocks 7-170, 7-172

S S7-PLCSIM 9-2, 9-3 testing with 9-2 Search and Replace 7-248 Security 11-3 Sequential control system configuration 7-211 Sequential control systems 7-211 Service 1-7 Setting the process image 7-82 Setting up 7-3 local PC station 7-3 Setting up projects 5-3 PCS 7 Wizard - New Project 5-3 SFC 7-216, 7-217, 7-218, 7-219, 7-222, 7-223, 7-224, 7-227, 7-234, 7-235 configuring messages 7-224 configuring steps 7-216 configuring transitions 7-218 copying and moving SFC charts 7-222 creating an SFC instance 7-227 deleting SFC charts 7-223 setting up projects 5-3 testing the program 7-234 SFC type creating SFC types 7-225 SFC types 5-15, 7-225, 7-226, 7-228 modifying centrally 7-228 working with 5-15 Shield contacts 13-6 Shielding 13-6, 13-7, 13-8, 13-9 Should distributed or central I/O be used? 3-82 Signal module 5-26 Signals 7-254 editing 7-254 SIMATIC BATCH 4-7, 7-306 SIMATIC IT Framework 3-60, 3-61 interfacing 3-60 SIMATIC Process Device Manager (SIMATIC PDM) 7-98

Index-9

Index

SIMATIC station 7-68, 7-72 configuration 7-68, 7-69 creating 7-72 Special features and differences compared with assembly instructions of the products 4-16 Special features and differences 4-16 Special forms of communication 3-56 Standard automation systems for PCS 7 3-72 Steps in configuration 7-164 the most important steps 7-164 Steps in handling 7-60 multiproject 7-60 Structure 3-42, 3-49, 7-21, 7-288 IEA file 7-288, 7-289 plant hierarchy 7-21 redundant Ethernet networks 3-42 redundant PROFIBUS networks 3-49 Subnet 7-134 creating and assign parameters for a new subnet 7-134 Switch 3-38 Switching technology 3-38 Symbolic connection name 7-148 Symbolic names 7-94 Synchronization 7-90 time of day on the AS 7-90

T Teleservice 12-3 Testing 9-1, 9-2, 9-3, 9-4 during operation 9-3 field device 9-4 with S7-PLCSIM 9-2 Text lists 7-50 Texts 7-50, 7-51, 7-52, 7-53 exporting/importing 7-50 operator-relevant 7-50 Textual interconnections 7-239, 7-240 Time 7-90 Synchronization on the AS 7-90 Time of day 7-90 synchronisation on the AS 7-90 Time Stamp with 10 ms Accuracy 5-30 Time stamps 7-124 Time stamps (10 ms) 7-124 Time-of-day synchronization 7-90 setting on the AS 7-90 Tips on editing the network configuration 7-140 Transitions 7-218 configuring 7-218

Index-10

Translating 7-48 message texts 7-48

U Undo 7-116 Updating 8-3 OS server data 8-3 Updating block types 7-44

V Version Cross Checker 10-1, 10-2 comparing project versions 10-1 working with 10-2

W What are the expansion limits? 3-24 What are the possibilities for integration in hazardous zones? 3-89 What Happens during Export? 7-281 What happens during import 7-276 What is the maximum plant capacity in a project? 3-19 What support does SIEMENS offer for PCS 7? 3-17 Which automation system should be used? 3-70 Which data formats can be imported? 3-93 Which I/O components can be attached? 3-84 Which networks are used for communication? 3-33 Which PC systems to use? 3-66 Which systems guarantee safety and availability? 3-25 With which partners can PCS 7 communicate? 3-8 Working with 5-15, 5-17, 7-42, 7-53, 7-55, 7-285, 10-2 IEA files 7-285 master data library/libraries 5-17 models 7-55 process tag types 7-53 SFC types 5-15 Version Cross Checker VXC 10-2 Working with libraries 7-42

Y Y-Adapter 7-102 Y-Link and Y-Adapter 7-102


PCS 7 Engineering System

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