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SIMATIC PCS 7
SIMATIC PCS 7
Process Control System
Edition
Brochure 2017 siemens.com/simatic-pcs7
© Siemens AG 2018
Enterprise
Cloud / ERP
Industrial Services
MES
Operations, Engineering and Maintenance
Totally Integrated Automation
Automation
Process Control System
Field
Totally Integrated Automation: This, in turn, is the basis for real added value in all automa-
Start efficiently. Increase productivity. tion tasks, particularly:
◾ Integrated Engineering
In the light of the growing complexity of machines and ◾ Integrated Operation
plants along with rising engineering costs, efficient engi- ◾ Industrial Data Management
neering is a key factor for success in the manufacturing ◾ Industrial Communication
industry. ◾ Industrial Security
◾ Safety Integrated
Totally Integrated Automation, industrial automation
Totally Integrated Automation creates the perfect frame-
from Siemens, makes engineering efficient. The open
work for strategically harnessing optimization potential -
system architecture that covers the entire production
throughout the entire production process:
process ensures the efficient interaction of all automa-
◾ Time and cost savings from efficient engineering
tion components. This is guaranteed with consistent data
◾ Minimized downtime thanks to integrated diagnostic
management, global standards and uniform hardware and
functions
software interfaces. These common features minimize the
◾ Greater flexibility in production due to integrated com-
engineering overheads. This reduces costs, shortens the
munication
time to market and increases flexibility.
◾ Plant and network security provided by integrated
security functions
The holistic approach of Totally Integrated Automation paves
◾ Protection of personnel, machinery and the environ-
the way for better production: faster, more flexible and more
ment with seamlessly integrated safety technology
intelligent.
◾ Improved quality due to data consistency
◾ Simplified implementation of automation solutions with
global standards
◾ Better performance with the interaction of system-
tested components
Content
Scalability
Lifecycle
management Availability
SIMATIC PCS 7
Efficient
Industry focus
top-down engineering
Operator
Safety & security
ergonomics
Integrated
asset management
Scalability Availability
The constant change in the process industry also has an Plant availability over many years is a central requirement
impact on process plants. Plant expansion, the merging of the industry. That is why all SIMATIC PCS 7 components
of control rooms, etc. require the control system to be are not only carefully designed and manufactured for
flexible. rough industrial use, but also for redundant configura-
tions. This especially applies to safety applications.
Thanks to a unique scalable system architecture,
SIMATIC PCS 7 creates the ideal basis for cost-effective Thanks to the flexibly scalable fault tolerance of Safety
implementation of individual automation solutions and Integrated (Flexible Modular Redundancy, FMR), the
economic operation of process plants. When the plant degree of redundancy can be individually defined for each
grows, SIMATIC PCS 7 simply grows along with it – of the architecture levels, controller, fieldbus and I/O and
without the provision of expensive reserve capacities! adapted to the field instrumentation. This enables the
implementation of individual, fault-tolerant architectures
The scalability applies for all levels of the system. The which are precisely tailored to the individual tasks.
architecture of the SIMATIC PCS 7 process control system
is designed in such a manner that instrumentation and In addition, SIMATIC PCS 7 supports all the usual commu-
control can be configured in accordance with customer nication protocols, most of which have their own redun-
requirements and optimally matched to the dimensions dancy designs, such as FOUNDATION Fieldbus, PROFIBUS
of the plant. The control system can be subsequently or PROFINET.
expanded or reconfigured at any time if there is an
increase in capacity or a technological modification. At the
control level alone there are several functionally-compati-
ble automation systems with graduated price/performance
ratios that are available to the user. The automation per-
formance can be optimally matched to the requirements of
the plant/unit.
G_PCS7_XX_00202
Laboratory/Test center Production plant Connected facilities at one production site
Every industry follows its own market laws, challenges and To keep the process control system up-to-date with the
opportunities. Siemens has integrated the industry-specific latest technology, Siemens provides a Software Update
process know-how of its employees in the development Service (SUS) for SIMATIC PCS 7.
of the universal SIMATIC PCS. 7 The comprehensive port-
folio of SIMATIC products and systems is thus enriched by The SIMATIC PCS 7 Management Console supports inven-
many years of experience and expertise from all process tory listing of the SIMATIC PCS 7 hardware and software
industries. components as well as centralized management of soft-
ware revision levels for all stations of the SIMATIC PCS 7
With technology libraries and optional functions for system. This enables fast analysis and targeted replace-
batch processing, process analysis, energy management, ment and update actions.
telecontrol and switchgear equipment, laboratories,
breweries, mining and cement plants etc., SIMATIC PCS 7 The supportive SIMATIC PCS 7 Lifecycle Services ensure the
has proven itself in numerous process industries. operation and serviceability of the control system over the
entire lifecycle of the plant while protecting investments.
They enable predictable maintenance costs and cost-effec-
tive modernization.
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Engineering System
System-wide engineering
SIMATIC S7
HW WinCC SIMATIC SIMATIC
Libraries CFC/SFC Route F Systems
Config Explorer BATCH PDM
Control
SIMATIC Manager /
uniform database
G_PCS7_XX_00114
Engineering for network/ OS Parameterization
communication/hardware engineering Route control of field devices
Engineering System 11
© Siemens AG 2018
Engineering System
Project management with the SIMATIC Manager
The SIMATIC Manager is the integration platform for the
engineering toolset as well as the project manager for all
engineering tasks of the SIMATIC PCS 7 process control
system. It is used to manage the SIMATIC PCS 7 project for
archiving and documentation. The engineering tools for
the application software, the hardware components and
the communications functions can be called directly from
the SIMATIC Manager.
Plant hierarchy
Creating hierarchy folders implements a project structure,
which is referred to as the plant hierarchy. By storing CFC
and SFC charts for automation systems and pictures and
reports for operator stations in a hierarchy folder along
with additional documentation, the configuring engineer
implicitly determines the hierarchical assignment.
12 Engineering System
© Siemens AG 2018
Engineering System 13
© Siemens AG 2018
Continuous function chart in the modernized design Sequential function chart in engineering
14 Engineering System
© Siemens AG 2018
Engineering System 15
© Siemens AG 2018
Faceplates of the Logic Matrix and the linked control module in the
Logic Matrix Viewer of the SIMATIC PCS 7 operator station Access and change verification
With the SIMATIC Logon user administration, an adminis-
SIMATIC PCS 7 Logic Matrix trator can create user groups with different access rights.
The SIMATIC PCS 7 Logic Matrix enables convenient Access rights for stations of the process control system
creation of the interlock logic between technological and operator privileges for blocks can both be set up.
functions (e.g. control modules or equipment modules) of Configurable modification protocols can record all access
the automation project using a cause&effect matrix. The operations to the engineering system as well as all online
matrix data can be integrated thereafter at the chart level changes. If you link the modification reports with the data
in the CFC project. There is no time-consuming configuring of SIMATIC Logon, it is possible to verify clearly who has
of the interlock logic in the CFC. made a particular change and when. Such verifications are
often the object of special sector-specific requirements,
In the Logic Matrix Editor, the project engineer links the formulated, for example, in FDA 21 CFR Part 11 or GAMP.
required input signals, for example, the APL-based tag
types, in the horizontal rows of a matrix table compara- Version Cross Manager
ble to a spreadsheet. Logic operations, timing response, The Version Cross Manager detects differences between
alarms etc. can be configured for each cause. The outputs different versions of a single or multi-project by tracing
can be linked to the effects in the vertical columns of the missing, additional or differing objects by comparing hard-
logic matrix in a similar manner. ware configuration, communication, plant hierarchy, CFCs/
SFCs, SFC details, block types, alarms, global variables, sig-
The causes and effects are then logically linked through nals and run sequences
the intersections of rows and columns, allowing various
reactions to be configured. The comparison results are displayed graphically in a com-
bination of tree and table. All differences are distinguished
The operator can operate and monitor the logic matrix by a color.
via the Logic Matrix Viewer on the SIMATIC PCS 7 operator
station. The logic matrix faceplate can be opened via the Version Trail
corresponding faceplate or via the technological blocks When used together with SIMATIC Logon, SIMATIC
concatenated in the causes and effects. Based on this Version Trail is responsible for version-specific archiving
causal chain, the operator can jump from the effect face- of libraries, projects and multiprojects, as well as retrieving
plate to the cause faceplate via the Safety Matrix faceplate. the version states from the archive. SIMATIC Logon orga-
nizes access protection for this. Archiving and retrieval
procedures can be automated on a time-driven basis.
16 Engineering System
© Siemens AG 2018
Engineering System 17
© Siemens AG 2018
◾ Central hardware and software configuration which ◾ Shared configuration tasks: Concurrent Engineering
is uniform throughout the system through use of one or Multiproject Engineering with Branch & Merge
engineering system
◾ Technological engineering with control module types
– Low-effort parameterization of communication
– Reduced testing effort through type-based testing
– Same configuration for redundant plants
– Faster, repeatable work through use of types
– Integrated configuration for field devices and
– Reduced maintenance effort for libraries
safety-related applications
– Parallel working reduces the project duration
◾ Technology-oriented configuration
◾ Configuration-dependent hiding of alarms for spe-
– Functional hierarchy organized according to plants,
cific operating states
units and technical equipment
– Hardware-independent engineering: AS assignment ◾ Special SFC functionalities:
and I/O modules can be subsequently selected – SFC type: sequential control for multiple use,
– Expandable on industry-specific basis using standard instances as block in the CFC
data exchange interfaces – SFC: sequential control for single use, also with
chart I/Os
◾ Integral user administration with access control
– Separate sequences for states such as HOLD,
◾ Libraries with sophisticated control functions: ABORT or SAFE STATE, conforming to ISA-88
– Advanced Process Library (APL)
◾ Lower engineering/validation overhead:
– Industry Library
– Libraries with functions and faceplates, icons and
– Condition Monitoring Library
process tag types
◾ Central dialog for compilation and loading of AS, OS – Type-instance concept with central modification
and SIMATIC BATCH changes option for all instances
– Central updating of all block types of a multiproject
◾ Selective compiling and downloading on the chart level
– Simple duplication of units by copying, renaming
◾ Process object view for display and processing of all and compilation
aspects of process tags/objects
◾ High-performance version management with version
– Convenient editing in tables
comparison and version history
– Process library with import/export functions
– Online mode for testing and commissioning ◾ Automatic generation of diagnostics displays for the
maintenance station on the basis of the project data
◾ Block type changes during ongoing operation with
AS 410 (TCiR)
18 Engineering System
© Siemens AG 2018
Integrated Engineering
Object,
e.g. motor
Logical diagram
Cabinet layout
G_PCS7_XX_00375
P&ID Electrical circuit Electrical single line Hardware configuration
diagram diagram
Synchronization of planning data, configurations, structures and function charts with the PAA
COMOS – One database for everything platform with efficient, wizard-guided support for creation
The basis for the Integrated Engineering is a data model of the topology diagram and automatically generated bills
in which there is exactly one instance of all engineering of materials from the hardware configuration.
information of a project. In addition, all data on the
engineering objects of the facilities is available directly, At the touch of a button, data such as the hardware con-
with consistent content and at all times, for example for figuration, interconnections, system structure and function
the plants, pipelines, EI&C systems, instrumentation and charts are generated from the engineering data in the con-
automation engineering. It is irrelevant whether facility trol system. This simplifies engineering of the automation
workers are located close together or are part of a global and enormously reduces time overheads. The bidirectional
project team from different countries: The database is synchronization enables changes in the automation to be
always the same – without exception. restored from SIMATIC PCS 7 to PAA during operation (e.g.
replacement of field devices). The database in the engi-
With COMOS, Siemens is the only provider to offer the neering tool is thus updated immediately, together with
process industry a software solution for the integrated the complete plant documentation.
management of a plant project and the management of
the entire plant documentation – from planning through The PAA uses the full basic scope of functions of the
operation and modernization up to decommissioning. COMOS platform with user administration, change
management with working layers and scalability. The
COMOS ensures that planners and operators can access all integration of the PAA as a module in COMOS provides
project-relevant data at any time, across all levels of corpo- holistic, seamless engineering across all planning phases
rate organization and all project phases. This has become of an industrial plant.
possible through the consistent object orientation.
In this way, integrated engineering provides the require-
Integrated engineering with the SIMATIC PCS 7 ments for more confident decision making and for more
Plant Automation Accelerator: the bridge between the efficient processes – thus making a contribution to sus-
COMOS and SIMATIC PCS 7 worlds tained improvements in competitiveness.
The Plant Automation Accelerator (PAA) tool bridges the
gap between plant planning and I&C from the quotation
phase to the operating phase. From quotation preparation
and planning to functional planning, the PAA provides a
Integrated Engineering 19
© Siemens AG 2018
Data
synchronization
Control Modules
Interlock Logic
Technological Hierarchy
Hardware Configuration
SIMATIC PCS 7 Plant Automation Accelerator (PAA) The planned project data is now synchronized with
With PAA, consulting engineers and planning offices as SIMATIC PCS 7 and then generates the PCS 7 engineering
well as end customers can significantly reduce their con- data. Changes can be made both in PCS 7 and with the
figuration and commissioning costs while simultaneously PAA. The bidirectional synchronization between PAA and
improving the engineering quality. SIMATIC PCS 7 with delta view ensures the controlled
editing of data. In this way a consistent database is
PAA acts as a link between standard engineering tools ensured from the planning phase to the operating phase.
from the SIMATIC PCS 7 Engineering Toolset (CFC,
HW Config, plant hierarchy) and tools for basic and The automatically generated As-Is documentation is
detailed planning. The open and system-neutral software based on this data. During commissioning, a software test
tool enables an integrated workflow across all engineering report can be automatically generated, for example. Even
phases during plant operation, current documentation containing
consistent PCS 7 and planning data is always available.
With its "Logical" and "EI&C" modules, PAA offers control PAA can be expanded up to and including the full version
cabinet engineering, circuit diagrams and interconnection of COMOS. Location-independent multi-user operation is
diagrams, EMR diagrams and detailed engineering and possible with corresponding licensing and management.
supports the hardware layout, including bundle and rack
configuration and I/O assignment. Mass data engineering
Plant Automation Accelerator is optimized for working
The PAA automatically creates quotation data such as bills with control module types (CMT) and provides an inte-
of materials from this planning configuration. A license grated CMT library.
overview, component overview and an article description,
including the article number, are also created. For auto- With system support, any user libraries with process tag
mation engineering, the control module types enable bulk types can be converted into control module types. Blocks,
processing of process tags, signals and parameters, which links, connections or messages can be added later to a
can be edited and changed in a controlled manner using a CMT or removed from it, even if instances (individual con-
delta view. Process tags (control modules) can be created trol modules (CMs)) already exist. In this way, versions of
with any PCS 7 project library. process tag types can be defined very easily for multiple
uses. The instances can be checked for deviations from
Inconsistencies can be detected quickly by means of plau- CMT and adapted if necessary.
sibility and data consistency checks, displayed in a log and
then eliminated in a targeted manner.
20 Integrated Engineering
© Siemens AG 2018
Operator System
Safe and convenient process control
Single-station system (OS single station)
In a single-user system architecture, all operator control
and monitoring functions for a complete project (plant/
unit) are concentrated in one station. A flat system con-
figuration with up to 8 OS single stations can be imple-
mented. In this case, two stations form a redundant pair of
OS single stations that can be further expanded. With such
a configuration, the engineering can be rationalized by
duplication of a basic project. The Process Historian is used
for long-term archiving.
.....
G_PCS7_XX_00343
the process sequence using various views and intervene as
necessary.
Process Historian S7-400H
The operator system architecture is extremely variable and
can be flexibly adapted to different plant configuration
Example of a flat system architecture
limits and customer requirements.
◾ Single-station system (OS single station) with up to
The OS single station can be connected to the Industrial
8 500 process objects
Ethernet plant bus in two ways:
◾ Flat system configurations based on a redundant
◾ CP 1623/CP 1628 communication module for commu-
OS single station pair, expandable with reference sta-
nication with a maximum of 64 automation systems of
tions to up to 8 OS single stations.
any type
◾ Client/server multiple station systems with up to
◾ Simple 10/100/1000 Mbps Ethernet network card and
18 OS servers/pairs of servers, each for 12 000 process
Basic Communication Ethernet for communication with
objects and up to 40 OS clients
up to 8 automation systems (single stations)
Operator stations
All operator stations are based on modern, high-perfor-
mance SIMATIC PCS 7 Industrial Workstations optimized
for use as OS single station, OS server or OS client. They
can operate in harsh industrial environments and offer
numerous standardized interfaces for options specific to
the system, customer or sector as well as expansions.
Operator System 21
© Siemens AG 2018
G_PCS7_XX_00342
Max. number of monitors per opera-
tor station with multi-channel opera- 4
tion
22 Operator System
© Siemens AG 2018
OS software
Operator System 23
© Siemens AG 2018
Trend controls for displaying tables and trends Parallel to the display, all messages recorded during
Using Trend Controls, operators can show archived values runtime and their changes in state can be documented in
of archive tags from the process value archive as well as chronological order in a message sequence log.
online values of process tags from the tag management
in relation to time (table/trend window) or in relation to By filtering, selecting or sorting the display according to
another value (function window). the contents of individual message blocks, e.g. chrono-
logically according to message priority or fault location,
During runtime, operators can individually adapt the the operator can individually adapt the message list during
TrendControls functions which have already been pre- runtime. It is also possible to integrate archive databases
defined during plant configuration and save the settings online. The settings can be saved globally or user-specific.
globally or user-specific. They are able to change the data
link during runtime, and to access other data, and inte- To reconstruct the state of the messages after a power
grate exported archive databases. failure, the most recent messages from the message
archive can be loaded back into the message window.
In the ruler window, additional information can be dis-
played for the time or time range selected in the trend/
table window with a ruler, for example, statistical infor-
mation such as minimum, maximum, average, standard
deviation, integral.
24 Operator System
© Siemens AG 2018
Time synchronization
Together with a SICLOCK time generator, the operator
system within SIMATIC PCS 7 can implement system-wide
time synchronization. This feature is especially beneficial
for widely distributed plants present in different time
zones, e.g. pipelines.
Operator System 25
© Siemens AG 2018
LAN LAN
INTERNET
Front
Firewall
Back
Firewall
Terminal bus
Mobile terminals with WinCC/WebUX
Plant bus Based on WinCC/WebUX, authorized personnel access
G_PCS7_XX_00116
26 Operator System
© Siemens AG 2018
◾ Flexible, modular architecture with scalable hardware ◾ Versatile, practical controls for alarms and trends
and software components for single-user and multiple
◾ Flexible online configuration of trend displays with
station systems
values of APL-based process tags
◾ Client-server multiple station systems, suitable for
◾ Variable, customer-oriented logging system
large plants with up 18 OS servers / server pairs and up
to 40 OS clients ◾ Highly effective alarm management provides support
for operating personnel
◾ High-performance, stress-resistant operator stations
– Assignment of priorities with up to 16 message
based on rugged industrial standard PC technology
priorities as additional attribute to the message
◾ OS single stations and OS servers that can be config- classes
ured as redundant pairs – Visual and audible hiding of messages which are
irrelevant depending on the operating state
◾ Optimized AS/OS communication
(dynamic or manual)
◾ Copying of modifications without interfering with – Suppression of sensor/actuator alarms during
ongoing operations startup or in event of malfunction
◾ Online test of changes by selective loading of redun- ◾ High-performance archiving system with circular
dant servers archives and integral archive backup, which can be
combined with the Process Historian for long-term
◾ Ergonomic graphical user interface for convenient
archiving
process control and high reliability
◾ Central user administration with access control
◾ Browser for stateful view, filters and sorting of
APL-based process tag ◾ System-wide time synchronization
Operator System 27
© Siemens AG 2018
Add-ins for
Microsoft Word and Excel
IS client
Terminal bus The Process Historian and Information Server do not need
a connection to the plant bus. They can be connected to
OS single the OS and batch stations of the SIMATIC PCS 7 system via
station
the terminal bus.
- OS server Process Historian
- Batch server
Archiving and visualization functions
◾ Real-time archiving of the process values and messages
Plant bus
of OS single stations und OS servers
G_PCS7_XX_00297
◾ Archiving the batch data of SIMATIC BATCH
◾ Support of multiple SIMATIC PCS 7 projects
Automation ◾ Scaling of performance and configuration limits for the
systems
basic hardware employed
◾ Data export to external storage media, e.g. a NAS drive
◾ Data import from external storage media
Information server ◾ Data visualization on the OS clients / OS single stations:
Visualization of the data from the Process Historian data- – Configuration of views (picture windows and masks)
base is supported by an additive reporting system, the including the selection criteria for displaying the data
Information Server. It provides the archived data in a Web – Visualizing of messages in table form dependent on
browser in the form of shift, daily, weekly or monthly logs. filter functions
Based on the Microsoft Reporting Services, the Informa- – Display of process values in table or graphic form
tion Server enables Web-based thin-clients to access to depending on filter functions
historical data. Add-ins for Microsoft Word und Excel offer – Batch overview (with a detailed log of a batch)
additional methods of accessing the Process Historian
Reporting functions
database. The number of clients that have access to the
◾ Set of conventional report templates for process values,
Information Server can be regulated with cumulative client
alarms and batches
access licenses.
◾ Free creation of any number of new report templates
◾ Storage of configured report templates for fast access
The Information Server is able to access one data source
◾ Report export in common document formats
or multiple data sources in parallel. In addition to the
◾ Subscriptions for cyclic report generation including
Process Historian, this might also include archive data from
e-mail service
operator stations. It can therefore also be used for plant
◾ Creation and storage of role-based dashboards
reporting independent of the Process Historian.
◾ Role management for Windows users
– Support for Active Directory and workgroups
If the Process Historian OPC UA Server is installed on the
– Project-specific assignment of access permissions
Process Historian, other applications can act as OPC UA
◾ Integration of reports as pictures into Word documents
clients and read the process values and messages archived
◾ Creation and storage of Excel report templates for
in the Process Historian.
historic process values and alarms
◾ Subscriptions for Excel report templates
Hardware and configuration
Depending on how important the availability of archive
data is for the plant operator, the Process Historian can be For additional information, see:
configured either as a single server or a redundant pair of www.siemens.com/simatic-pcs7/processhistorian
servers. For optimal, project-specific layout of the com-
puter hardware for the Process Historian, please use the
PH Hardware Advisor, available at
https://support.industry.siemens.com/cs/ww/en/
view/109740115
SIMATIC PDM (Process Device Manager) is an universal, Plant-wide access to the field devices with secure server-
multi-vendor tool for configuration, parameterization, client communications, significantly reduces the service
commissioning, diagnostics and servicing of intelligent and traveling times of the service personnel:
field devices (sensors and actuators) and field compo- ◾ Field device configuration on stationary and mobile
nents (remote I/Os, multiplexers, control room devices, workstations with standard browsers
compact controllers). It enables the handling of more than ◾ Connection of up to 30 clients to a SIMATIC PDM server
3 500 devices from Siemens and over 200 vendors world- without installing additional software
wide on one homogeneous GUI.
Variety of application options
From the viewpoint of device integration, SIMATIC PDM is ◾ Single point station for handling a single field device
the most powerful open device manager available in the ◾ Local service and configuration station for handling
world. Devices which previously were not supported can multiple field devices on the fieldbus segment or
be integrated in SIMATIC PDM by importing their device remote I/O station
description files (Electronic Device Description, DD/EDD ◾ HART service and parameter assignment station for
technology) or device description packages (Field Device processing HART field devices
Integration, FDI technology). ◾ Central service and configuration station for processing
field devices of a production plant
Advantages with operational processes ◾ Configuration tool in the engineering station for han-
◾ Uniform presentation and operation of devices dling field devices in the hardware configuration editor
◾ Uniform representation of diagnostic information of the engineering station or locally at the field device
◾ Indicators for preventive maintenance and servicing via a mobile SIMATIC PDM client
◾ Detection of changes in the project and device ◾ Configuration and service tool in the SIMATIC PCS 7
◾ Increasing the operational reliability Maintenance Station for field device handling via the
◾ Reducing the investment, operating and maintenance operator stations of the maintenance station or via a
costs mobile SIMATIC PDM client locally on the field device
◾ Forwarding of device information to higher-level
maintenance stations
For additional information on SIMATIC PDM, see:
www.siemens.com/simatic-pcs7/pdm
Device integration
SIMATIC PDM supports all devices defined by the Electronic
Device Description (EDD). At the same time, it is the guide-
line of the established organizations, such as:
◾ PROFIBUS & PROFINET International (PI)
◾ FieldComm Group (FCG)
The devices are integrated directly in SIMATIC PDM through
a company-specific EDD or the current libraries of the
FieldComm Group. To achieve improved transparency, they
can be managed in project-specific device libraries. The
range of devices can be updated and expanded at any time
by importing the device description of the manufacturer.
Core functions
◾ Creation of project-specific device libraries
◾ Adjustment and modification of device parameters
◾ Comparing, e.g. project and device data
◾ Validation of data input
◾ Device identification and testing
◾ Device status indication (operating modes, alarms, states)
◾ Simulation
◾ Diagnostics (standard, detail)
◾ Management, e.g. networks and computers
◾ Export/import (parameter data, logs, documents) SIMATIC PDM, parameter view and trend window
◾ Commissioning functions, e.g. measuring circuit tests of
device data Communication and routing
◾ Lifecycle management functions, e.g. for device replace- SIMATIC PDM supports several communication protocols
ment and components for communicating with devices that
◾ Global and device-specific change log for user opera- have the following interfaces (others on request):
tions (audit trail) ◾ PROFIBUS DP/PA interface
◾ Device-specific calibration reports ◾ FOUNDATION Fieldbus (FF) interface
◾ Graphic presentations of echo envelope trends, trend ◾ PROFINET interface
displays, valve diagnostics results etc. ◾ HART interface (modem, wireless)
◾ Display of incorporated manuals ◾ Modbus interface
◾ Bulk operations ◾ HART over PROFIBUS/PROFINET
S7-400 S7-400
PROFINET
ET 200M SIMOCODE
PROFIBUS PA
IE/PB Link PN IO
RS 232/RS 485
PA Link Compact ET 200M SIMOCODE ET 200iSP HART
FF Link multiplexer
PROFIBUS PA FF H1
HART
HART
G_PCS7_XX_00386
SIMATIC PDM Maintenance Station, consisting of preinstalled SIMATIC IPC 427E Microbox PC as well as software and function licenses
The SIMATIC PCS 7 Maintenance Station is used to manage All activities are documented on the maintenance station
a company's assets that are used for production. It is dedi- without gaps – automatically and without additional con-
cated to the "Plant Asset Management", in other words, figuration overhead.
the efficient administration and management of the equip-
ment of a technological plant, especially instrumentation Typical maintenance cycle
and control systems, with the goal of value preservation ◾ Monitoring the status of components/devices:
and appreciation. It thus makes a valuable contribution to – Recording of diagnostics information of network
minimizing the total cost of ownership of a plant over its components and PC basic devices per OPC coupling
entire life cycle. – Intelligent sensors detect and signal impending
failures long before the actual failure
While the plant operator obtains all relevant information ◾ Signal "maintenance required" in a group display, in
that is necessary for focused intervention in a process via symbol displays of the affected components/devices and
the operator system, maintenance and service personnel in an alarm log
can check the hardware components of the automation ◾ Select component/device with maintenance require-
system (assets) and process their diagnostic messages and ment and retrieve specific data, for example, the pro-
maintenance requests using the maintenance station. For cess tag number, installation location, device type
this the maintenance station offers access to: ◾ Retrieve device and manufacturer-specific detailed
◾ Components of the process control system: intelligent diagnostics information, for example,
field devices and I/O modules, fieldbus, controller, net- – Error description
work components and plant bus, as well as servers and – Cause of error
clients of the operator systems. – Trend statement
◾ Mechanical assets (pumps, motors, centrifuges, heat – Handling instruction
exchangers etc.) or control circuits represented by proxy ◾ Evaluation, commenting and changing the priority of
objects in which the diagnostics rules are stored the maintenance requirement when needed
◾ Initiate maintenance measure per maintenance request
Plant operators and service personnel are able to con-
and track progress; current status of maintenance is
stantly react to the following, for example:
visualized symbolically
◾ Service requests
◾ Conclusion of maintenance measure; all status displays
◾ Service approvals
are reset to their normal state
◾ Placing an asset in "In Service" status
◾ Information regarding completed servicing
G_PCS7_XX_00072
and information depend on the components. This makes
working with the SIMATIC PCS 7 Maintenance Station easy Change in Maintenance Maintenance
and intuitive. A time-consuming training period is not configuration alarm job
detected (high) in progress
required.
The hierarchical structuring of information and the uni- Extract from the PCS 7 asset management symbol set
form symbols support the overview, facilitate orientation
and permit the maintenance engineer to rapidly access
detailed information starting from the plant overview.
Group displays in the plant overview visualize the diag-
nostics status of the subordinate structures/components
according to a type of traffic light with red, yellow or
green.
Automation systems
Scalable performance for every requirement
Automation systems in the models shown above are Depending on the scale of performance and perspective
available for the SIMATIC PCS 7 process control system. orientation, they can be differentiated across classes as:
The automation performance can therefore be finely ◾ AS 410 automation systems
scaled within wide limits. Scaling of universally applicable CPU type based on the
number of process objects
SIMATIC S7-400 modular automation systems with ◾ Complementary SIMATIC S7-400 systems
hardware controller Scaling of the hardware based on the performance
The selected components of the SIMATIC S7-400 are com- levels of the CPU types
bined in bundles based on the task with consideration of
The rugged AS 410 is a modern, future-oriented, all-round
the price/performance ratio. These automation systems
system for the process industry. Due to its versatility, it
are extremely rugged and feature a high processing and
can be used in every domain – as a standard AS 410S
communication performance. Other outstanding features
system, as a high-availability AS 410H or as safety-related
include:
AS 410F/FH. More and more innovative functions are
◾ Modular, fan-free design
being exclusively combined with this automation system,
◾ Extremely rugged and expandable
for example, redundant PROFINET configurations and
◾ Single and redundant versions
configuration changes during operation for PROFINET in
◾ Comprehensive communication facilities
singular and redundant applications.
◾ Integrated system functions
◾ Integratable safety functions (Safety Integrated)
The CPU for all automation systems of the S7-400 series
◾ Simple linking of central or distributed I/O
is already equipped as standard with the PROFIBUS DP
◾ Redundant PROFINET IO support
fieldbus connection. Depending on the type of CPU, one
They can be classified according to their functionality as: or two additional PROFIBUS DP interfaces can be employed
◾ Standard automation systems using additive IF 964-DP interface modules. If needed,
◾ Fault-tolerant automation systems up to 10 PROFIBUS communication modules can be addi-
◾ Safety-related automation systems tionally operated on a CPU. A PROFINET IO connection
can be made via the CPU interface or a communication
module, depending on the type.
Automation systems 37
© Siemens AG 2018
38 Automation systems
© Siemens AG 2018
Automation systems 39
© Siemens AG 2018
AS 410 automation systems The CPU offers battery-free operation for easier handling
The AS 410 is an automation system of the SIMATIC and higher availability through retentive load memory.
S7-400 series that is envisaged for use in the SIMATIC For program and data, 48 MB of retentive load memory
PCS 7 process control system. With the innovative and 32 MB work memory are integrated.
"CPU 410-5H Process Automation" and appropriately
optimized firmware, the complete performance range of The AS 410 controller supports active security in the pro-
the complementary S7-400 automation systems can be duction area. It triggers security events at the controller
covered (from AS 412H and AS 414-3 to AS 417H). The level and contributes to timely detection of security inci-
achieved reduction in the number of types not only simpli- dents.
fies the stocking of spare parts, but also provides advan-
tages for the complete lifecycle of the process control The SIMATIC CPU 410E offers an optimal automation
system. solution for applications with a limit of up to 200 pro-
cess objects. In combination with the CPU 410-5H, the
The performance levels are based on process objects (PO) CPU 410E can also be used as a distributed automation
of differently dimensioned system expansion cards. If its solution, e.g. for highly modular technological modules,
performance limit is reached during configuration, com- that can be integrated in the overall plant via Plug-and-
missioning or operation, a subsequent increase in perfor- Produce.
mance is possible with Expansion Packs. Hardware need
not be exchanged in this case. • CPU 410 - Scalable performance for all applications
• CPU 410E - Version for smaller applications
• CPU 410SIS - for small and medium-sized safety applications
In addition to the CPU, the SIMATIC PCS 7 AS 410 bundles
include an aluminum rack, communication modules and
Price
CPU
CPU 410
selected power supply modules with an additional enamel max
417
coating (conformal coating). The AS 410 XTR bundles
CPU 410 min
created for higher temperatures up to 70 °C (Extended CPU
Temperature Range) extend the application range. 416
CPU 414
The CPU 410-5H Process Automation is equipped with one
CPU 410E
PROFIBUS DP and two PROFINET IO interfaces with a 2-port
switch. Two integrated slots allow the synchronization CPU 410SIS
of two redundant subsystems via sync modules and sync CPU 412
cables. Performance
Automation system AS AS AS AS AS AS AS AS AS AS AS
with APL 412H 414-3 414-3IE 414H 416-2 416-3 416-3IE 416H 417-4 417H RTX
Analog value measurements 10 150 150 100 300 500 500 400 800 600 300
Digital value measurements 20 300 300 250 600 1 000 1 000 800 1 400 1 000 600
Steps 0 150 150 150 700 1 000 1 000 1 000 2 000 2 000 800
Dosing 0 5 5 3 20 25 25 25 50 50 50
Digital inputs DI 30 450 450 300 900 1 500 1 500 1 200 2 200 1 800 1 200
Digital outputs DO 10 150 150 110 300 500 500 400 750 650 400
Analog inputs AI 15 225 225 150 450 750 750 600 1 100 900 600
Process objects (PO) 30 450 450 350 900 1 500 1 500 1 200 2 200 2 000 1 200
Typical mixed configuration limits for SIMATIC PCS 7 automation systems, based on the SIMATIC PCS 7 Advanced Process Library (APL)
40 Automation systems
© Siemens AG 2018
Automation systems 41
© Siemens AG 2018
Compact systems
SIMATIC PCS 7 BOX – complete control system in compact design
The product range is primarily differentiated by the auto-
mation functionality, that is, by the controller type and the
type of communication in the field area:
◾ SIMATIC PCS 7 BOX RTX with integrated WinAC RTX
software controller, optionally with PROFIBUS or
PROFINET interface
◾ SIMATIC PCS 7 BOX in combination with a separate
external controller:
– Microbox automation system as SIMATIC PCS 7 AS RTX
PROFIBUS/PROFINET
– Modular automation system of the S7-400 series with
PROFIBUS and PROFINET interface as single or redun-
dancy station
The selection depends on the price/performance ratio and
on the supported hardware and software functionalities.
42 Compact systems
© Siemens AG 2018
Software
Supported functions and limits
AS/OS Engineering ● ● ● ●
OS Runtime Single Station up to
● ● ● ●
2 000 OS runtime PO
PCS 7 APL ● ● ● ●
SIMATIC PDM PCS 7 ● ● ● ●
SIMATIC PCS 7 Maintenance Station ● ● ● ●
SIMATIC BATCH up to 10 units ● ● ●
Web server for up to 2 Web clients ● ● ●
OS Single Station Redundancy ● ● ●
S7 F Systems ●
SIMATIC Safety Matrix ●
Hardware
Controller (AS) independent of the
● ● ●
BOX PC system
AS-to-AS communication ● ● ● ●
Routing ● 1)
● 1)2)
● ●
PROFIBUS DP/PA ● ● ● ●
FOUNDATION Fieldbus (FF) ● ●
PROFINET IO ● ● ● ●
Configuration in RUN (CiR) ● ●
High-precision time stamps ● ●
S7 Block Privacy ● ●
Block type change in Run (TCiR) ● (AS 410) ● (AS 410)
Retentive AS data ● (Only with UPS) ● (Only with UPS) ● ●
Max. AS Runtime PO 3)
1 200 1 200 2 000 2 000
Design versions
The compact systems are operated and monitored as
standard using separate control units (mouse, keyboard,
process monitor).
SIMATIC PCS 7 BOX with panel front, side and front views
Compact systems 43
© Siemens AG 2018
Industrial Communication
Fast and reliable communication for plant bus and terminal bus
Control Level
OS OS Batch
Secure remote server server server
access
SCALANCE SCALANCE
SCALANCE SCALANCE XM-400
G_IK10_XX_10395
XM-400 XM-400 XM-400
Safety related Standard Fault tolerant Standard
automation systems automation systems automation systems automation systems
Field Level
PROFINET PROFIBUS PROFINET
44 Industrial Communication
© Siemens AG 2018
1)
Please note that when SCALANCE XF-200BA is used, at present the
diagnostics can only be carried out by one CPU in the H-system and
configuration changes during operation (CiR function) are not
supported (Firmware update under development).
Industrial Communication 45
© Siemens AG 2018
PROFINET combines the advantages of PROFIBUS, the most PROFINET fully complies with the Ethernet standard in
popular fieldbus system worldwide, with modern Ethernet IEEE 802.3 and is thus the reliable future-proof standard
technology. PROFINET allows easy setup of flexible com- that paves the way for digitalization in the process envi-
munication networks and ensures integrated, reliable and ronment.
secure communication throughout the plant – in real time!
Combine investment protection with security for the
Greater flexibility, efficiency and performance in industrial future: On the one hand, the open Industrial Ethernet
communication – PROFINET has already proven successful standard supports the integration of existing plant units
for many years in the manufacturing and machine envi- and technologies. Appropriate solutions and products,
ronment and is the preeminent global standard in automa- such as the IE/PB LINK for integration of PROFIBUS DP
tion. and the SIMATIC CFU PA for integration of PROFIBUS PA,
are available for this. On the other hand, worldwide stan-
PROFINET more than meets the special requirements of the dardization in accordance with IEC 61158/61784 and con-
process industry regarding availability, flexibility, real-time sistent ongoing development ensure the use of PROFINET
capability and ruggedness. At the same time, the Ethernet- over the entire life cycle of the plant and beyond. Even
based technology convinces with its easy handling. wireless communication technologies such as WLAN in
accordance with IEEE 802.11 and mobile communications
The process industry is also benefiting from the modern can be reliably integrated.
communication technology, and the foundation has now
been laid for the SIMATIC PCS 7 process control system: Intelligent field devices autonomously supply status
◾ Scalable system redundancy information regarding diagnostics and maintenance.
◾ Changes possible during operation ("Configuration This information is rounded out by the PROFINET diagnos-
in Run") tics. Network problems and device conflicts are reliably
◾ High-precision time-of-day synchronization for detected and can be quickly remedied. Digitalization and
sequence of events ("SoE") the accompanying Big Data call for integrated communica-
tion down to the field level and require flexible as well as
reliable communication networks.
Industrial Ethernet
CPU 410-5H
One CPU for all SCALANCE SCALANCE
applications TAP104 XF204-2BA
incl. safety
PROFINET, redundant
PROFIBUS DP SIMATIC
ET 200SP HA
SIMATIC SCALANCE
BANY 4...20 mA/HART
ET 200M XF204-2BA DNA
Agent
(Y-Switch)
XP-200
SIMATIC
Integrated drives ET 200M
SIMOCODE
SINAMICS MTA
4...20 mA/HART
G_PCS7_XX_00632
SIMATIC CFU PA
PROFIBUS PA
46 Industrial Communication
© Siemens AG 2018
Step-by-step into the future Redundant network configuration R1, S2 and MRP
Existing fieldbuses in the "installed base" can integrate
PROFIBUS to PROFINET in steps because the systems are (626
compatible.
6LQJOH'HYLFH6 6,0$7,&&)83$
MRP
Modular system redundancy (R1) The SIMATIC ET 200SP HA distributed I/O and the
“Compact Field Unit” field distributor (SIMATIC CFU PA)
&38+ have a PROFINET interface for S2 redundancy. This pro-
R 1 UHGXQGDQW duces flat and flexible architectures that support easier
plant expansions without having to maintain reserves and
offer potential for significant savings in cabling. The motto
5HG'HYLFH5
"One cable for all purposes" supports parallel operation
of profiles such as PROFIsafe, PROFIdrive and other TCP/IP
protocols without impacting basic plant communication.
<6ZLWFK 6LQJOH'HYLFH6
These hardware components use the BusAdapter tech-
nology, which supports simple and flexible connection to
the PROFINET network either with copper cables (RJ45 or
FastConnect) or fiber-optic cables.
The hardware portfolio has undergone fundamental
further development in order to make full use of the new PROFINET in combination with appropriate hardware com-
PROFINET options: ponents supports you during planning, operation and com-
◾ CPU 410-5H V8.2 missioning: Easy device replacement without additional
◾ SIMATIC ET 200SP HA tools through automatic neighborhood detection as well
◾ SIMATIC CFU PA as clear and simple installation guidelines including auto-
◾ SCALANCE XF204-2BA DNA ("Y-switch") matic addressing and name assignment.
The SIMATIC PCS 7 CPU 410-5H with firmware version
Configuration in Run (CiR)
V8.2 enables setup of redundant automation systems and
To maintain plant availability during this work,
redundant devices (R1) for a high-availability H-system
CiR the components allow changes to be made in the
through redundant PROFINET IO configuration.
plant during operation ("Configuration in Run",
CiR) without affecting the production process.
Through the "Y-switch" SCALANCE XF204-2BA DNA,
This is available for an H-system (H-CiR) and for a single
a network configuration with system redundancy (S2)
station (CiR).
to the field level can be connected to an H-system (R1).
MRP networks are also supported by the switch.
Advantages of PROFINET at a glance
The redundant communication of devices in the ring
◾ Ethernet at the field level
is established through the Media Redundancy Protocol
(MRP). ◾ Maximum availability if required
◾ More flexibility
◾ Easy handling
◾ Investment protection
Industrial Communication 47
© Siemens AG 2018
OS multi-clients
Engineering
station
Maintenance/
OS server
Industrial Ethernet
SIMATIC PCS 7
automation system
PROFIBUS DP
G_PCS7_XX_00247
System integration of PROFIBUS PA and FOUNDATION Fieldbus H1 via PROFIBUS DP
48 Industrial Communication
© Siemens AG 2018
PROFIBUS PA and FOUNDATION Fieldbus H1 provides the power supply to the field devices as well as
The direct connection of transmitters and actuators includ- digital data transmission with a constant transfer rate of
ing power supply via the communication medium, as well 31.25 Kbps over a two-wire cable.
as detailed diagnostics, are particularly relevant to the
automation of industrial processes that frequently take The physical bus systems of PROFIBUS PA and FF H1 are
place in corrosive, harmful and hazardous environments. largely identical in accordance with IEC 61158. Both can
be integrated seamlessly in the SIMATIC PCS 7 process
This requirement profile is met by PROFIBUS PA and control system using PROFIBUS DP as link. PROFIBUS PA
FOUNDATION Fieldbus H1 (FF H1). Both fieldbuses are and FOUNDATION Fieldbus H1 thus profit equally from
optimally suitable for direct integration of field devices in the higher-level PROFIBUS DP architecture. SIMATIC PCS 7
operating environments up to Ex zone 1/21 or 0/20 into customers are therefore not restricted to a specific field-
the process control system. The intrinsically-safe transmis- bus but can freely select one to obtain the optimum field
sion technology MBP (Manchester Coded; Bus Powered) instrumentation.
Industrial Communication 49
© Siemens AG 2018
G_PCS7_XX_00527
With the linear architecture, the AFS linked to the two
coupling partners of the gateway interconnects the line
segment to which it is attached with the respective active
coupler partner. A coupler partner can be replaced without
interrupting ongoing operation.
Example for fieldbus architectures, here with PROFIBUS PA
Ring architecture
Maximum availability is achieved with a ring segment. Enhanced fieldbus diagnostics for PROFIBUS PA with
Active field distributors integrate the field devices into this AFDiSD
ring segment via short-circuit proof spur lines. An exten- AFDiSD diagnostics are limited to short-circuits, loss
sion on the fieldbus or replacement of a coupler during of redundancy, detection of chatter, and failure of
operation is possible. The ring architecture provides the field devices. This functionality can be extended for
following benefits: PROFIBUS PA with a commissioning wizard, continuous
◾ Maximum availability avoids unplanned plant down- operational monitoring and support for troubleshooting.
times This enables comprehensive diagnostics of the entire
◾ Simple and safe installation PROFIBUS PA segment. Errors in the configuration or
◾ Automatic termination defects can thus be quickly identified and remedied.
◾ Automatic, bumpless isolation of faulty subsegments
◾ Topology can be repaired or expanded during ongoing Extended PROFIBUS PA diagnostics enables identification,
operation detection and monitoring of:
◾ Topology (DP/PA coupler, AFDiSD)
◾ Voltage and currents on the main and spur lines
◾ Signal and noise levels
◾ Capacitive unbalance to shield of main line
50 Industrial Communication
© Siemens AG 2018
Process I/O
The right solution for any requirement
S7-400 signal modules that can be operated centrally in ET 200iSP ◾ Adding of ET 200iSP stations
◾ Adding of modules to the station
the automation system are an alternative to distributed
◾ Changing the parameter settings of
I/O for small applications or plants with limited distributed
modules
expansion. ◾ Parameterization of connected HART field
devices with SIMATIC PDM
Process I/O 51
© Siemens AG 2018
Design
Degree of protection IP20 IP20 IP30 IP20 IP20 IP65/IP66/IP67
Model Compact Modular Modular Modular Discretely scalable Modular
Mounting Mounting rail Mounting rail Mounting rail Mounting rail Standard sectional Mounting rail
rail
Connection system Multi-conductor Multi-conductor Multi-conductor Single-conductor Single/multi- M8, M12, M23
for sensors/actuators connection connection connection connection conductor
Screw-type Push-in-terminals Spring-loaded/ Spring-loaded/ connection
system screw-type screw-type system, Push-in-terminals
system FastConnect,
TopConnect
Special applications
Safety – – ● ● – ●
For use in hazard. areas Zones 2, 22 Zone 2 Zones 1, 21 Zone 2 Zone 2 –
Increased availability Redundant Switched, Switched, Switched, – –
redundant redundant redundant
Temperature range -40 ... +70 °C -40 ... +70 °C -20 … +70 °C 0 … +60 °C 0 ... +60 °C -25 … +55 °C
(horizontal) (horizontal) (horizontal)
Vibration resistance 1g 1g 1g 1g up to 5 g 5 g (module-
(continuous) dependent)
Communication
PROFIBUS (Cu/FO) –/– –/– ● / – (1.5 Mbps) ● / – (12 Mbps) –/– ● / ● (12 Mbit/s)
PROFINET (Cu/FO) ●/● ●/● –/– ●/– ●/● –/–
System functions
Permanent wiring ● ● ● ● (insertion and ● –
removal)
Hot swapping – ● ● ● (with active ● ●
backplane bus)
Expansion/configura- ●/● ●/● ●/● ●/● –/– –/–
tion during ongoing
operation
Diagnostics Channel-discrete Channel-discrete Channel-discrete Channel-discrete Channel-discrete Channel-discrete
(module-dependent)
Functions
Digital channels ● ● ● ● ● ●
Analog channels ● ● ● ● ● ●
incl. HART PROFIBUS PA ● ● ● ● –
Motor starter – Under developm. – – – –
Pneumatic interface – Under developm. ● – – –
Technological Under developm. Under developm. Counting, frequen- Counting/measur- – –
functions cy measuring ing, controlling,
weighing
52 Process I/O
© Siemens AG 2018
Industrial Ethernet
S7-4001)
Hazardous area
ET 200SP ET 200SP HA
PROFINET
Ex e, Ex d Actuators/
sensors
Ex e, Ex d
Actuators/
sensors
ET 200M
Ex i, Ex e, Ex d
Actuators/
sensors
HART
Fieldbus ET 200iSP3) 4)
Isolating Transformer
PROFIBUS DP-iS Ex i
Actuators/
Ex i, Ex e
sensors
Compact FF link/ HART
AFD
G_PCS7_XX_00635
PA link
AFDiSD
PROFIBUS PA/FF H1
PROFIBUS DP
1)
With DC power supply PS 405
2)
SIMATIC CFU in aluminum housing also for dust environments in Ex zone 22
3)
Dust atmospheres: installation of components always in an enclosure with IP6x degree of protection
4)
Also complies with FM/UL according to Class I Division 2
Field devices on the PROFIBUS PA fieldbus or SIMATIC ET 200SP HA and SIMATIC CFU
FOUNDATION Fieldbus H1 ET 200SP HA and CFU are designed for use in the control
Field devices located in Ex zones 0, 1, 2, 20, 21 or 22 can cabinet and also allow installation in hazardous areas up to
be integrated in SIMATIC PCS 7 via various active field dis- Ex zone 2-22.
tributors on the PROFIBUS PA or FOUNDATION Fieldbus H1.
The active field distributor AFDiSD is required for this pur- ET 200iSP
pose for field devices in Ex zones 0, 1, 20 or 21. ET 200iSP remote I/O stations suitable for gas/dust atmo-
spheres can be installed directly in Ex zones 1, 2, 21 or 22
SIMATIC ET 200M and SIMATIC ET 200SP as well as in non-hazardous areas. The intrinsically-safe
ET 200M and ET 200SP remote I/O stations can be used sensors, actuators and HART field devices can also be
in Ex zone 2 or 22 as well as in non-hazardous areas. The located in zone 0 or 20 if necessary.
actuators/sensors can also be positioned in Ex zone 1 or
21. Special Ex I/O modules are available for this in the SIMATIC ET 200pro
ET 200M product range. ET 200pro remote I/O stations are designed for use in
non-hazardous areas.
Process I/O 53
© Siemens AG 2018
SIMATIC ET 200SP HA: Depending on the application, the distributed I/O can be operated redundantly with two interface modules or as a single
station with one interface module.
Enclosed space in a plant is in short supply and cost-in- Other advantages are "Change in Run" (CiR) through
tensive. The compact, modular SIMATIC ET 200SP HA I/O redundant design and increase of the module count on
creates space in the control cabinet – that saves costs the head station from 12 to 56. The SIMATIC ET 200SP HA
associated with enclosed space, air conditioning and the is designed for use in the control cabinet as well as for
energy demand of I/Os in the control cabinet. Its highly hazardous areas up to Ex zone 2. The extended tempera-
scalable configuration enables the control cabinet to be ture range from -40 to +70 °C and the conformal coating
sized exactly to the actual requirements. Its new design of all components allow direct installation in the field.
allows up to 56 I/O modules per station to be used. An
especially high channel density of up to 32 channels on
a module that is only 22.5 cm wide ensures maximum SIMATIC ET 200SP HA at a glance
economy in the control cabinet.
◾ Compact I/O modules
The high-performance SIMATIC ET 200SP HA maximizes – Up to 32 channels on a module that is 22.5 mm
availability through redundant PROFINET connections. wide
These allow the connection to high-availability controllers – Up to 56 modules per station
via two independent networks with a choice of copper or
fiber-optic cables. The system can be scaled and extended ◾ Perfectly suited for applications in the field
in small steps using a variety of available modules, for – Installation in hazardous areas up to Ex zone 2-22
example, with digital and analog I/Os as well as NAMUR, – Extended temperature range: -40 to +70 °C
HART and other protocols. – Enhanced interference immunity in accordance
with NAMUR recommendation NE21
All 24 V standard signals are connected via an identical – Conformal coating on all components
terminal block type, which allows a high degree of stan- – Can be used at altitudes of up to 4 000 meters
dardization for the control cabinets. And, the tool-free ◾ Wide range of supported module types
connection system with push-in terminals and permanent – 16×AI/8×AO HART, 16×DI, 16×DO etc.
wiring lowers the effort for engineering, installation and
cabling. ◾ Standard I/O terminal block
– For all 24 V signals AI, AO, DI, DO
54 Process I/O
© Siemens AG 2018
Are you ready for a change in perspective in the field? Greater flexibility thanks to consistent decentralization
Digitalization provides an important impulse for the The decentralized installation of the SIMATIC CFU makes
process industry, as well. You can benefit from even traditional control cabinets dispensable. A significant
more flexibility and easier handling coupled with maxi- reduction in cables and terminal points and less effort
mum availability. With our new approach to field device for planning and documentation are the advantage. The
connection, the SIMATIC CFU makes it possible for you to high granularity (16 I/O per SIMATIC CFU) enables flexible
transfer your conventional system concept into the digital assignment to the higher-level controllers.
world.
The new SIMATIC CFU is a real game changer in field SIMATIC CFU at a glance
device connection and offers you entirely new prospects
regarding simplicity and flexibility. This compact field dis- ◾ Simpler thanks to plug-and-produce
tributor, which is installed in the vicinity of the process, – Fast and reliable device integration
is directly connected to the process control system via – Easy and reliable device replacement without inter-
PROFINET and forms the foundation for digitalization in vention in the engineering system
the field. Through the use of digital fieldbus communica-
tion, the field device connection becomes much simpler This makes device integration easy and reliable,
than with conventional 4 to 20 mA technology . and the time required is reduced from half an
hour or more to less than a minute.
Simpler thanks to plug-and-produce
Digitalization requires integrated digital communica- ◾ Greater flexibility thanks to consistent decentraliza-
tion down to the sensor and actuator. You make use of tion
the established PROFIBUS PA standard for this purpose. – No more individualized control cabinets
This has been implemented in the PA Edition of the – Reduction in marshalling and cabling effort
SIMATIC CFU, thus combining ruggedness and easy han- – Less effort for planning and documentation
dling with the advantages of the Industrial Ethernet-based – Standardized mounting technology – no hardware
PROFINET standard. Connected devices are addressed FAT required
automatically, and the device is integrated very simply via – Parallelization of project processes
standardized communication profiles. – Flexible plant expansion without the need to main-
tain reserves
This innovative new implementation of the PROFIBUS PA – Reduction of installation effort, complexity and
concept makes it possible to combine the simplicity of a maintenance costs
point-to-point wiring system with the scalability of digital Up to 70% fewer terminal points and 30% or more
PROFIBUS PA fieldbus communication. As with digital field reduction in cabling costs
devices, it is not necessary to know prior to connection
whether the discrete field device is a sensor or actuator.
This can be easily configured afterwards with software.
Process I/O 55
© Siemens AG 2018
Drives
Recommended devices
56 Process I/O
© Siemens AG 2018
Terminal bus
Plant bus
G_PCS7_XX_00053
only on AS mode
Automation
systems
◾ Modular architecture with flexible scalability (hard- ◾ Hierarchical recipes according to ISA-88.01
ware and software) – Creation of recipes oriented according to process
– Optimum scaling to plant size and individual require- engineering
ments – Quick, easy and fault-minimizing creation
– Grows with the plant configuration; no expensive
◾ Logging of recipes and batch data
spare capacities
◾ Importing and exporting of master recipes, formulas
◾ High availability thanks to redundant batch servers
and library objects
– No loss of production and batch data
– Automatic synchronization of batch data ◾ Storage of batch data and archiving, for example, in
the Process Historian
◾ High availability, improved deterministics and fast step
– Production becomes transparent and comprehen-
transitions when executing the recipe logic in the
sible
automation system
– Viewer for archived batches
◾ Homogeneous integration of SIMATIC BATCH into the
◾ Reduction in engineering and validation overhead
HMI strategy and the engineering of SIMATIC PCS 7
through:
via system interface
– Type/instance concept of SFC
– No customized interfaces
– Separation of procedure and formula
– No double configuring for batch-specific engineering
– ROP library and configuration independent of unit
data
– Multiple uses, central modification
– Reliable operator prompting, safe response to
process faults ◾ Validation support according to 21 CFR Part 11
– OS Controls for integration in process displays through:
– Operator control of the OS Controls via a Web client – Audit Trail (change log)
– Free and system-aided versioning
◾ Recipes independent of unit
– Libraries with recipe operations and formulas
– Considerable simplification in recipe management
– User administration with access protection and
and validation
electronic signature
– Flexible control strategy and optimum plant utiliza-
tion through allocation strategies and assignment of
units during batch runtime
Terminal bus
G_PCS7_XX_00052
Plant bus
Automation
systems
Route Control Center (RCC) If no saved route is available, the RC Server starts the route
The Route Control Center (RCC) is a synonym for the Route search and, if possible, combines the statically defined
Control client. It can be installed on an OS client, a batch partial routes into one complete transport route. From
client or separate client hardware. It displays all route data there on, Route Control takes over the control and moni-
and error information relevant to material transport in toring of all RC elements involved in the transport route.
several coordinated views. The process cell control only has to switch the individual
technological functions. When errors occur, the operator
Route Control Server receives detailed diagnostics information about the cause,
After the configuration of the route network and testing e.g. why the search for a transport route failed.
the material handling variants, the Route Control con-
figuration data are transferred to the Route Control Server For maintenance purposes, an automation system can be
(RC Server). They can then be activated at a point in time specifically set to "in maintenance" (out of service). The
suitable from the perspective of the technical process. The material transports operating via this automation system
activated data are included in the route search. are then completed, but no more new ones are permitted.
The RC server supplies the RC clients with the necessary WAIT elements allow delayed (cascaded) control of the on/
data and forwards their commands to the automation off sequence for actuators, for example, during transport
systems. of solid materials on conveyor belts. When liquids are
transported in pipes, the order and the time intervals for
If a material transport is waiting, a route is requested cleaning the valves with pulsing are also adjustable with
either via the controller or by the operator at the RCC. WAIT elements.
Apart from specifying the source, destination and up to
10 optional plant locations (intermediate points), this also
includes creating a start signal on the route control block
of the automation system.
◾ Flexible, modular and scalable architecture for ◾ Reduction in configuration overhead and commis-
single-user and multiple station systems sioning times
– Optimum adaptability to plant size and individual – Configuring partial routes by means of repeated
requirements application
– No expensive reserve capacities – Data export to Microsoft Excel and re-importing
– High availability thanks to redundant Route Control – Reduction in complex, repeated tasks through
Servers RC wizard
– Graphical offline route search determines all route
◾ Homogeneous integration into the HMI strategy and
combinations in advance and finds undesired
the engineering of SIMATIC PCS 7
routes
◾ Can be combined with SIMATIC BATCH –
◾ Consideration of material compatibilities to avoid
Material transports from a batch control recipe
undesired mixing
◾ Mapping of route network of the plant through partial
◾ Offline testing for completeness, inconsistencies and
routes
undesired combinations
◾ Fast response to plant modifications during configura-
◾ Detailed diagnostics of material transport require-
tion, commissioning or runtime
ment faults and current material transport
◾ Exclusive assignment of RC elements and partial routes
◾ Saved static routes are executed with priority when a
involved in material transport
route is requested
◾ Definition of on/off switching sequences using stag-
gered control of actuators, e.g. for conveyor belts
The process industry frequently features complex pro- The enormous potential of Safety Integrated for Process
duction sequences where materials and mixtures which Automation can best be exploited in conjunction with
are explosive or dangerous to health are produced or SIMATIC PCS 7. Thanks to the modularity and the flexi-
processed. A fault or failure could have disastrous conse- bility of the safety-related products this combination is
quences. extremely variable. It is not just the degree of integra-
tion of safety-related systems that can be individually
Therefore the objective of Siemens safety technology is defined in the process control system, it is also the degree
to minimize potential hazards for personnel, plant and of redundancy for controllers, fieldbus and process I/O
environment by means of technical measures, without (Flexible Modular Redundancy). Thanks to the reduced
adversely affecting the production process. A reliable spatial requirements, the scope of hardware and wiring,
Safety Instrumented System (SIS) is therefore required as well as reduced mounting, installation and engineer-
which is able to automatically place the plant into a safe ing overhead, complete integration of the safety-relevant
state should critical events occur, to continue operating it systems in SIMATIC PCS 7 offers the greatest cost advan-
safely under defined conditions and to limit any negative tages viewed over the entire lifecycle of a plant.
effects in the event of a safety-related event.
Both the safety technology and the safety applications
Safety Integrated for Process Automation provides a implemented with it are characterized by great efficiency
comprehensive range of products and services for safe, and comply with both national and international stan-
fault-tolerant applications in the process industry – based dards, such as:
on the Siemens safety-related system. It offers complete ◾ IEC 61508 – basic standard for specifications, as well as
safety-related functionality – extending from safe instru- for the design and operation of safety-related systems
mentation for signal recording and conversion, to safe and ◾ IEC 61511 – application-specific standard for the
fault-tolerant control, up to the actuator (e.g. positioner, process industry
valve or pump).
Product range
Safety Integrated for Process Automation – product spectrum for SIMATIC PCS 7
Engineering Configuration of safety functions (up to SIL 3)
using TÜV-certified function blocks and
Continuous Function Chart (CFC) or
SIMATIC Safety Matrix (cause&effect matrix)
PROFIsafe with PROFIBUS For standard and safety-related communication on just one bus
PROFIsafe with PROFINET cable, certified according to IEC 61508 (SIL 3)
SIMATIC ET 200 ET 200M: Modular I/Os for high density applications with safety-
related signal modules F-DI 12/24 × DC 24 V, F-DI 4/8 × NAMUR
[EEx ib], F-DO 10 × DC 24 V/2 A, F-DO 8 × DC 24 V/2 A,
F-AI 3/6 × 0 … 20 mA or 4 … 20 mA (HART), SIL 2/SIL 3;
IP20 degree of protection
ET 200iSP: Modular, intrinsically-safe I/O with safety-related
electronic modules F-DI Ex 4/8 × NAMUR,
F-DO Ex 4 × DC 17.4 V/40 mA, F-AI Ex HART 4 × 0 … 20 mA or
4 … 20 mA, SIL 3, IP30 degree of protection
ET 200S: Bit-modular I/O with safety-related electronic modules
F-DI 4/8 × DC 24 V, F-DO 4 × DC 24 V/2 A and safety-related motor
starters; SIL 2/SIL 3, IP20 degree of protection
ET 200pro: Modular, very compact I/O with safety-related
electronic modules F-DI 8/16 × DC 24 V,
F-DI/DO 4/8 × DC 24 V (DI) and 4 × DC 24 V/2 A (DO); SIL 2/SIL 3;
F-switch for switch-off of standard I/O and control of motor
switches; IP65/66/67 degree of protection
Process instruments, Safe process instruments on PROFIBUS:
Drives Pressure transmitter SITRANS P DS III PA (SIL 2) with PROFIsafe,
SIMOCODE pro with DM-F local/PROFIsafe (SIL 3),
SIPART PS2 PA (SIL 2)
Safe process instruments/devices for connection to
ET 200M remote I/Os:
SITRANS P DS III analog/HART (SIL 2), SITRANS TW Series (SIL 1),
SITRANS TH200/300 (SIL 2), SITRANS TR200/300 (SIL 2),
SITRANS LVL200 (SIL 2), SITRANS LR250 HART (SIL 2),
SITRANS FC430 (SIL 2), SIPART PS2 2/4-wire (SIL 2)
Safety
application
SIS controller
SINAMICS drives with fail-safe function
ET 200M DP/PA coupler Safety
tion
ET 200M PA Link
ET 200M PROFIBUS PA
F-modules
F-modules
ET 200M
ET 200M
PA Link
F- and standard modules
F- and standard modules with redundant
PA couplers
Active field
ET 200iSP ET 200iSP splitter
PA Link
PA Link ET 200M with redundant
Module or channel PA couplers
PROFIBUS PA redundancy over
several separate Active field distributors
stations
G_PCS7_XX_00130
F- and standard modules
ET 200pro PROFIBUS DP
F- and standard modules PROFIBUS PA
The PROFIsafe profile allows safety-related communica- Safety-related design versions with PROFIBUS
tion for between the controller and the process I/O via the In the case of a safety-related system with PROFIBUS com-
open standard buses PROFIBUS and PROFINET. PROFIsafe munication integrated into SIMATIC PCS 7, a distinction
expands the frames by additional information with which is made across all architecture levels between two design
the PROFIsafe communications partners can recognize and versions:
compensate transmission errors such as delays, incorrect ◾ Single-channel, non-redundant design
sequences, repetitions, losses, addressing errors or data ◾ Redundant, high availability and fault-tolerant design
falsification.
Both alternatives are extremely variable and offer
generous scope for design. At the individual architectural
Since PROFIsafe is implemented as an additional software
levels (controller, fieldbus, distributed I/O), the configura-
layer within the devices/systems without modifying the
tion options shown in the diagram are available depending
standard communication mechanisms, standard compo-
on the process I/O used.
nents and safety components can operate on the same
bus. This makes a separate and expensive safety bus
Standard (basic process control) and safety-related func-
unnecessary.
tions can be combined flexibly, not only in the area of
the distributed I/O. Even at the controller level, they can
However, the decision between PROFIBUS or PROFINET has
combined in one system or separate. In addition, there are
seriously affects the architecture of the safety engineering
numerous possibilities using flexible modular redundancy
system.
(FMR).
PROFIBUS DP
G_PCS7_XX_00212
G_PCS7_XX_00227
2oo3
1oo2
PROFIBUS DP 1oo2 Flow 2oo3 PT
Flexible Modular Redundancy using the example of a safety-oriented, Safety-related and fault-tolerant architecture based on a PROFIBUS PA
fault-tolerant plant configuration ring architecture
Depending on the automation task and the associated Not only can FMR be applied to plant configurations with
safety requirements, the degree of redundancy may distributed I/O systems, but it can also be transferred
be defined separately for the controller, fieldbus and to configurations with direct connection of devices via
distributed I/O level and coordinated with the field instru- the PROFIBUS PA fieldbus. As shown in the example,
mentation. In this way, individual fault-tolerant architec- the PROFIBUS PA ring architecture likewise permits cost-
tures which are precisely tailored to the individual tasks effective, safety-related and fault-tolerant applications
can be implemented and tolerate several faults occurring with minimum use of devices and cables.
at once. As FMR provides redundancy only where it is
actually required, comparatively more attractive and AFD active field distributors can be used in operating
cost-effective applications are possible than with conven- environments up to Ex Zone 2/22 and AFDiS active field
tional redundancy architectures. distributors in operating environments up to Ex Zone 1/21.
AFD active field distributors integrate field devices allo-
As shown in the example of a process cell with ET 200M cated to the same hazardous area over spur lines. The spur
distributed I/O, the total of the tasks can produce a mix of lines of AFDiS can be laid up to zone 0/20 for connecting
different degrees of redundancy within one architecture suitable devices.
level (1oo1, 1oo2, 2oo3).
AS redundancy
PROFINET supports safety-related systems on the basis of
station with safety-related SIMATIC PCS 7 automation systems (F/FH)
PROFINET CPU and ET 200M remote I/Os. With a safety-related system
with PROFINET communication, the ring is the topology
PROFINET of choice from the point of view of availability. The media
ET 200M ET 200M redundancy of the ring means that bus interruptions or
failure of a node will not result in failure of the entire
SCALANCE X
segment.
ET 200M ET 200M
PROFINET ring on a redundant controller (AS Redun-
dancy Station). In such a configuration, the structure of
PROFINET IO communication referred to as system redun-
dancy enables the I/O devices to establish a communica-
tion connection to each CPU of the AS Redundancy Station
Safety-related design versions with AS redundancy station and
PROFINET IO communication
over the topological network.
Engineering of safety-related applications using CFC Safety Matrix: assignment of exactly defined reactions (effects) to
occurring events (causes)
The F block library in S7 F systems and the SIMATIC Safety
Matrix are available for configuring and programming SIMATIC Safety Matrix
safety-related controllers. The SIMATIC Safety Matrix which can be used in addition
to S7 F Systems is an innovative safety lifecycle tool from
S7 F systems with F block library Siemens, that can be used not only for the user-friendly
The S7 F Systems engineering tool permits parameteriza- configuration of safety applications, but also for their
tion of safety-related controllers as well as safety-related operation and service. The tool, which is based on the
F-modules of the ET 200 series. It supports configuration proven principle of a cause & effect matrix, is ideally suited
by means of functions for: to processes where defined states require specific safety
◾ Comparison of safety-related F-programs reactions.
◾ Recognition of changes in the F-program using the
checksum The Safety Matrix not only means that programming of the
◾ Separation of safety-related and standard functions. safety logic is significantly simpler and more convenient,
but also much faster than in the conventional manner.
Access to the F-functions can be password-protected.
The F block library integrated in S7 F Systems contains During the risk analysis of a plant, the configuration
predefined function blocks for generation of safety-related engineer can assign exactly defined reactions (effects)
applications with the CFC or the Safety Matrix based on it. to events (causes) which may occur during a process.
The certified F-blocks are extremely rugged and intercept The possible process events (inputs) are initially entered
programming errors such as division by zero or out-of- in the horizontal lines of a matrix table comparable to a
range values. Diverse programming tasks for detecting and spreadsheet program and then their type and quantity,
reacting to errors can thus be omitted. logic operations, any delays and interlocks as well as any
tolerable faults are configured. The reactions (outputs) to
a particular event are then defined in the vertical columns.
CPU 410SIS
The basic hardware for SIMATIC SIS compact is CPU 410SIS,
which is based on CPU 410. It has 4 MB main memory and
no limitation for the cycle times.
Industrial Security
Comprehensive protective measures for I&C plants
Front-end
Domain MES/MIS COMOS plant firewall
controller SIMATIC IT lifecycle management
Engineering
station
Terminal bus
Plant bus
G_PCS7_XX_00145
Example of staggered security architecture
Progressive standardization, opening and networking of The strengths of this holistic concept lie rather in the inter-
control systems has been accompanied by an enormous action of a host of security measures in the plant network:
increase in security risks for a process control plant. The ◾ Design of a network architecture with graded security
potential dangers arising from destructive programs and levels (defense in depth), combined with segmenting of
access by unauthorized personnel range from network the plant into security cells
overloads or failures, theft of passwords and data, to ◾ Network management, network segmentation
unauthorized access to process automation. Apart from ◾ Operating plants in Windows domains
material damage, specifically targeted sabotage can also ◾ Administration of Microsoft Windows and SIMATIC
have dangerous consequences for personnel and the envi- PCS 7 operator privileges;
ronment. integration of SIMATIC PCS 7 operator privileges into
the Windows administration
SIMATIC PCS 7 security concept ◾ Reliable control of time synchronization
The SIMATIC PCS 7 security concept, which is described ◾ Management of security patches for Microsoft products
in the manual "Security Concept PCS 7 & WinCC (Basic)" ◾ Use of virus scanners and firewalls
manual and in detail in other documents, provides ◾ Support and remote access (VPN, IPSec)
far-reaching recommendations (best practices) for safe-
guarding a process plant based on a defense-in-depth
security architecture. It is not only restricted to the use of
individual security methods (e.g. encryption) or devices
(e.g. firewalls).
72 Industrial Security
© Siemens AG 2018
Industrial Security 73
© Siemens AG 2018
Virtualization
OS OS Eng.
Thin Clients Service
client client system
Zero Clients Package
SIMATIC
Remote protocol
Virtual
Virtualization
Virtual SIMATIC PCS 7 system
Machines as a Service
OS OS OS Eng.
Plant bus server client 1 client 2 system
G_PCS7_XX_00336
Pre-installed Configured
Hypervisor VMware ESXi
SIMATIC PCS 7 Hypervisor Host
controller Host hardware
Virtualization solutions based on SIMATIC PCS 7 have For additional information, see:
currently been approved for clients (OS, Batch, Route www.siemens.com/sivaas
Control) and Process Historian/Information Server as well
as add-ons such as SFC Visualization, OpenPCS 7/OS Client,
PCS 7 Web Server or PCS 7 terminal server or WinCC Data
Monitor. Servers (OS, Batch, Route Control), engineering
system or OS single station or maintenance station can
also be operated in the virtual environment specific to the
project.
74 Virtualization
© Siemens AG 2018
Telecontrol
Telecontrol with SIMATIC PCS 7 TeleControl
Control center
SIMATIC PCS 7 TeleControl
Ethernet
G_PCS7_XX_00175
+ TIM 3V-IE or PN interface
TIM 3V-IE DNP3
S7-400 S7-400 S7-400
+ TIM 4R-IE or + TIM 4R-IE or + CP 443 or S7-400
TIM 4R-IE DNP3 TIM 4R-IE DNP3 PN interface + CP 441
Plants often extend over huge areas, especially in the This results in significant advantages compared to conven-
water & wastewater and oil & gas industries. In such cases tional solutions in which central and remote plant areas
it is necessary to integrate outstations for monitoring and are configured as separate units and then combined in a
controlling highly remote units (usually with a small or higher-level network control system. Benefits include:
medium degree of automation) into the control system of ◾ Uniform process control
the complete plant. This is carried out by means of tele- ◾ Simple and user-friendly data management
control protocols over a WAN (Wide Area Network). ◾ Integrated engineering for central and remote plant
units
The telecontrol center for the outstations (consisting ◾ Lower service and training costs
usually of simpler remote terminal units (RTUs)) can be
The telecontrol center is integrated into the SIMATIC PCS 7
integrated directly into the process control system using
process control in the form of an operator station in single
SIMATIC PCS 7 TeleControl.
station or server design (also redundant as option). This
PCS 7 TeleControl Operator Station is dedicated to tele-
control operation. However, with smaller configurations,
it can also control SIMATIC PCS 7 automation systems in
central plant areas in parallel with telecontrol systems
(dual-channel operation).
76 Telecontrol
© Siemens AG 2018
There are no differences between central and remote These blocks support SIMATIC PCS 7 compliant operator
automation with regard to operating philosophy and alarm control by means of symbols and faceplates, as well as the
response. Data from the RTUs of the telecontrol system hierarchy of SIMATIC PCS 7 fault messages. If necessary,
can be displayed in one process picture together with data the library can be expanded for specific projects with new
from SIMATIC PCS 7 automation systems. script-based object types.
Telecontrol 77
© Siemens AG 2018
Switchgear Automation
Integration of switchgear/controlgear automation in the process industry
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Ɣ([WUXGHUVPL[HUV
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Ɣ%XLOGLQJLQIHHG
/9PRWRUV09PRWRUV
An electrical switchgear distributes or transforms electrical ◾ Rational, integrated engineering and fast commis-
energy, bundling loads/consumers into load groups. Using sioning
switching devices, network nodes implemented as busbars ◾ Lower administration, service and training costs thanks
connect incoming and outgoing cables known as feeders. to uniform holistic view
The switchgear design takes into account the change to ◾ Cost-effective modernization of plants using an existing
the network topology in the event of faults and the isola- PROFIBUS DP infrastructure
tion and grounding of equipment for maintenance work.
Integration of devices for switchgear automation
Intelligent electronic devices (IEDs) for protection, control,
SIMATIC PCS 7 PowerControl puts an end to the strict
measurement and monitoring in the electric power trans-
separation between process automation of plants and
mission and distribution are integrated into the SIMATIC
automation of the power generation for the process. The
PCS 7 process control system as follows:
process automation and automation of electrical switch-
◾ Via Ethernet TCP/IP communication with IEC 61850
gear for medium-voltage can be combined in a single
transmission protocol
control system. This results in numerous advantages with
– Direct on the plant bus
substantial cost savings over the entire lifecycle of the
– Via a station controller on the plant bus
plant, which is gaining in importance with increasing
– Via a station gateway (single or redundant) on the
decentralization due to increased use of renewable energy
plant bus
sources, for example:
◾ With driver blocks of the PCS 7 PowerControl PROFIBUS
◾ Simpler plant structures with more transparency in the
Driver Library
technological dependencies
– On PROFIBUS DP (SIPROTEC protection devices)
◾ Further increase in the level of integration of the plant
◾ Uniform process control supports merging of operator
task areas
◾ Long-term investment security thanks to globally valid
standard IEC 61850
78 Switchgear Automation
© Siemens AG 2018
SIMATIC PCS 7
Engineering and Operator Station Clients
Maintenance Station
Terminal bus
PROFIBUS DP
Standard + 4200
Safety I/O
Ethernet FO Ethernet FO Ethernet FO
Standard +
SIPROTEC IEDs
Safety I/O
G_PCS7_XX_00356
265XQWLPH *DWHZD\ &RQWUROOHU 352),%86
Process Control - SIMATIC PCS 7 Power Control - SIMATIC PCS 7 PowerControl
Switchgear Automation 79
© Siemens AG 2018
0LQG6SKHUH
Management
Energy Analytics
Acquisition
Automation-integrated
consumption detection
Measuring devices
Energy-saving motors
Energy-efficient motors have a power loss reduced by up
to 42%. Since the share of energy costs in the total costs of
a motor over its complete lifecycle is approximately 98%,
enormous cost savings are attainable for new plants or
through modernization of existing plants.
SIMATIC Energy Manager PRO
Frequency converters with braking energy recovery
◾ SIMATIC Energy Manager PRO for optimization of opera- Frequency converters make it possible for the equipment
tional energy management in plants, such as pumps, fans or compressors, to always
– Company-wide transparency thanks to gap-free operate within the optimum working range. Energy
energy and material balancing of power generation savings of up to 50% can then be achieved compared to
and consumption equipment conventional control procedures.
– Usage-based allocation of energy costs and transfer to
the accounting system, e.g. SAP R/3 CO
– Key performance indicators for reliable statements on
raising the efficiency of power generation plants and Energy prices
consumers Optimize energy procurement
– Production-based prediction of loads and require- Ɣ Short-term contracts (annual contracts)
ments to improve planning security Ɣ Change in tariff systems, e.g. time-variable tariff
– Support of cost-effective purchasing of energy systems, time-of-use tariff (TOU)
Ɣ Counteract increasing energy procurement costs
– Monitoring and reporting of greenhouse gas emis-
sions (CO2) in accordance with legal requirements
– Integrated project management to continuously Reduce energy consumption
improve the energy efficiency Ɣ Detect losses
Total Ɣ Detect hidden reserves
Optimization of energy utilization energy costs Ɣ Provide incentive schemes,
60 %
Energy saving
Furthermore, the optimization of processes using 50 %
Advanced Process Control (APC) as well as plant-level asset 40 %
management with the PCS 7 Maintenance Station provide 30 %
a significant contribution to energy-efficient plant opera- 20 %
Energy consumption
tion. 10 % with frequency converter
0%
0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
For additional information, see: Flow rate
www.siemens.com/simatic-pcs7/energy-management
Energy saving potential through frequency converters
SIMATIC PCS 7
Operator station Engineering station
Industrial Ethernet
Shared Memory/OPC
Remote Control
Virtual Controller
Alternative
interfaces
PROFIBUS DP
PROFINET IO
PRODAVE
(MPI/IE)
PROFIBUS DP
SIMIT
ET 200M
Field
devices SIMIT
UNIT
Technological plant/unit
LT
T2659
G_PCS7_XX_00552
WT
Reactor
Manufacturing Process Real plant Simulated, virtual plant
Application and integration options of SIMIT Simulation Framework and SIMIT Virtual Controller
Bringing products to the market faster and with consis- Many efficient tests for detection and elimination of poten-
tently high quality requires an optimized engineering work- tial faults can already be carried out before the real plant
flow in the automation and the shortest possible assembly is even available, e.g. application of correct identifications,
and commissioning times for new production lines. The testing of interconnection or interlocking logic. In this way,
SIMIT simulation software enables real-time simulation it is possible to optimize the quality of the configuration
and emulation for comprehensive checking of automation process without putting the real plant at risk.
solutions.
SIMIT can also be used to train personnel to handle the real
SIMIT is based on a uniform simulation platform that SIMATIC PCS 7 automation system. In this case, the plant
enables not only the virtual commissioning of the automa- response is simulated for testing and commissioning.
tion technology of systems, machines and processes, but
also realistic training environments for plant operators. Experienced specialists in the plant simulation sector pro-
This can be done quite easily directly at the workstation, vide comprehensive consulting, training and support for
even without requiring equipment or the need for in-depth customized plant modeling.
knowledge of simulation. Either a real or virtual auto-
mation system is used for the control, for example, the SIMIT can run on current computers and virtual systems
SIMIT Virtual Controller. (VMware). It can be flexibly used and can be integrated
in production automation with SIMATIC S7 and SIMATIC
WinCC or in process automation with SIMATIC PCS 7 via
open interfaces.
LT
Technological plant/
Plant unit
◾ CONTEC
SIMIT, Graphical User Interface (GUI)
Production technology
Component-based, signal flow oriented modeling of the
Abstraction levels of the simulation plant with expandable base libraries via the graphical user
interface of SIMIT. The project flow is controlled by an
Efficient simulation is based on the abstraction on three integrated workflow management. Special simulation skills
different levels: signals, devices (e.g. actuators and sen- are not required.
sors) and technological characteristics. In this case, the
technological characteristics are mapped mathematically Additive libraries support simulation of the technological
and logically or through additional libraries. characteristics.
◾ FLOWNET for simulation of dynamic curves of pressures,
Since the models can be calculated in real-time, SIMIT can flows and temperature distribution of water in pipeline
be linked to the real automation technology ("Hardware networks
in the loop"). The SIMIT unit is used for the interfacing via ◾ CONTEC for simulation of material handling equipment.
PROFINET or PROFIBUS A "Software in the loop" test is also ◾ CHEM BASIC for simulation of models of pipeline net-
possible through virtualization of the automation system works in the chemical and pharmaceutical industries
using the S7-PLCSIM, S7-PLCSIM Advanced emulation soft-
ware or the integrated SIMIT Virtual Controller.
Arguments for SIMIT
Interfacing to the real automation system is usually made
via PROFIBUS DP or PROFINET IO. Interfaces (SIMIT units) ◾ Testing of original automation project
simulate the devices on PROFIBUS DP/PROFINET IO in this
◾ High quality thanks to early detection and elimina-
case. A PRODAVE coupling can also be used for the MPI/DP
tion of configuration errors
or IE interface of the automation system for process data
traffic with SIMIT. ◾ Virtual commissioning shortens project commis-
sioning times and reduces project costs
SIMIT supports the joint operation with other simulation
◾ No simulation-specific programming required in
models through:
the automation project
◾ Data exchange via standardized interfaces such as
OPC DA, OPC UA (client) and shared memory
◾ Synchronization via the remote control interface (with
SIMIT in the role as master or client) Using virtual time For additional information, see:
management, simulations can also be implemented www.siemens.com/simit
faster or slower than in real-time.
Interfacing to IT systems
Office LAN
Front
Firewall
Back Process
Firewall Historian
Terminal bus
OS server
Plant bus
G_PCS7_XX_00144
Evaluating and managing process data Integration and synchronization of all business
with OpenPCS 7 processes with SIMATIC IT
Systems for process data evaluation and management The competitiveness of a company depends on a quick
(OPC clients) that are at a higher level than the process response to market requirements and optimization of the
control system can access SIMATIC PCS 7 process data supply chain. At the interface between production and
by means of an OpenPCS 7 server. This server collects management, Manufacturing Execution Systems (MES)
data distributed across different SIMATIC PCS 7 stations ensure uniform optimization of corporate processes and
(OS server, Process Historian) depending on the system therefore greater efficiency, integrated transparency and
configuration. OpenPCS 7 utilizes both the DCOM tech- consistent quality.
nology and the advanced OPC Specification OPC UA
(Unified Architecture). With SIMATIC IT, Siemens has one of the most powerful
and flexible MES systems on the market. SIMATIC IT works
Access to OPC interface Data type/ homogeneously with all major ERP and process control
station Access type systems. Modeling of the entire product manufacturing
OS Server DA or UA DA Read/write access to process
know-how, precise definition of the operating processes
(Data Access) values and real-time data acquisition from the ERP and the
production level enable SIMATIC IT to control operating
A&E Read and acknowledging access
(Alarm & Events) to alarms and messages
processes more effectively, to minimize downtimes,
production waste and follow-up work and to optimize
OS Server/ HDA (Historical Read access to archived process stockholding.
Process Data Access) values
Historian
H A&E (Historical Read access to archived alarms
Alarms & Events) and messages You can find detailed information about SIMATIC IT
suites, components and libraries in the Internet:
www.siemens.com/mes
Simple, standardized direct access to the archive data in
the Microsoft SQL server database of the operator system
is possible with the OLE-DB. Through this, all OS archive
data are accessible with the accompanying process values,
message texts and user texts.
86 Interfacing to IT systems
© Siemens AG 2018
S7-1200
ET 200M ◾ Definition of the process variables to be archived
Communication via ◾ Creation of trends
WinCC channel ◾ Export/import for mass data processing
◾ Type editor for creation of function block images of the
existing controller
Example for the integration of third-party controllers and package units – Creation of data structures (structure types)
in PCS 7/OPEN OS – Import/export and documentation of types
– Creation of type from instance
As a result of developments over many years, I&C plants – Integration of type into another type
frequently have heterogeneous structures in which system Further relevant PCS 7/OPEN OS functions
components from different manufacturers are combined. ◾ PH synchronization: alignment of plant hierarchy with
During plant modernizations, owners endeavor to increase existing PCS 7 project
the efficiency of process control by simplifying the HMI ◾ Multi-project engineering: division into several DBA
level. In the case of plant expansions where control desks projects, e.g. system-granular
are merged or existing plants are migrated step-by-step, ◾ Online scripting: creation of scripts for supplementary
the challenge is to integrate different types of controller in functions, for execution during runtime
one HMI system.
Handling package units
The SIMATIC PCS 7 operator system can be expanded by Package units can be created once in PCS 7/OPEN OS
PCS 7/OPEN OS for such purposes. It can be used to inte- and supplied as an OS typical on CD or per download.
grate the following controllers into the process manage- On site, the configuration engineer imports this typical
ment: and generates instances from it according to the number
◾ Third-party controllers of control systems of units. The package units can subsequently be visualized
◾ Programmable logic controllers from Siemens and other in the SIMATIC PCS 7 process displays.
manufacturers
◾ Package units
Depending on the technical situation of the controller to
be integrated, connection to the PCS 7/OPEN OS operator
station is possible via OPC (OPC DA and OPC A&E) or the
existing WinCC channels (e.g. S7 channel or Modbus TCP
channel). In the case of OPC communication, the OPC
server can be executed on separate hardware or together
with the OPC client on the PCS 7/OPEN OS operator sta-
tion.
Services
Industry Services
Service
Programs and
Spare Parts Agreements
Services
Process control customers are confronted with the chal- Support and consulting services
lenge to optimize operations, productivity and total cost Industry Online Support is round-the-clock service on
of their plants and to react to changing market conditions. the Internet that provides extensive product information
In this context, it is important for them to minimize down- and software downloads. Customers can also ask support
time, optimize the use of resources and energy, develop questions or share information with other users.
new optimization potential through data analysis and
protect against cyber threats. The specialists at Technical and Engineering Support
provide 24/7 consultation and answer any questions con-
The service experts from Siemens support them through- cerning functionality, operation and troubleshooting.
out the entire lifecycle of the system with a comprehen-
sive range of services, the Industry Services. The dedica- Information & Consulting Services are designed to analyze
ted team of engineers, technicians and specialists have the condition and serviceability of systems and to gain
in-depth knowledge about products, systems and tech- insights into the service life of the products used.
nologies and understand the specific requirements of the
industries.
Services 89
© Siemens AG 2018
Services
90 Services
© Siemens AG 2018
As well as global service and support, the range of ser- Selected services from the portfolio form the basis for
vices also includes special services for the process industry personalized SIMATIC PCS 7 Lifecycle Service contracts that
that can be used independently of each other and flexibly are reflected in typical contract profiles:
adapted and combined.
Services 91
© Siemens AG 2018
Siemens AG
Process Industries and Drives
Security information
Automation and Engineering Siemens provides products and solutions with Industrial
76181 Karlsruhe Security functions that support the secure operation of
Germany
plants, systems, machines and networks.
In order to protect plants, systems, machines and networks
© Siemens AG 2017
Subject to change without prior notice
against cyber threats, it is necessary to implement – and
Article No. E86060-A4678-A131-B6-7600 continuously maintain – a holistic, state-of-the-art
W-FPN7Z-PD-PA299 / Dispo 45000 industrial security concept. Siemens’ products and
BR 1017 3. WÜN 92 En solutions form only one element of such a concept.
Printed in Germany
Customers are responsible for preventing unauthorized
access to their plants, systems, machines and networks.
The information provided in this brochure contains merely general Systems, machines and components should only be con-
descriptions or characteristics of performance which in case of actual
use do not always apply as described or which may change as a result
nected to the enterprise network or the Internet if and to
of further development of the products. the extent necessary and with appropriate security mea-
An obligation to provide the respective characteristics shall only exist if sures (e.g. use of firewalls and network segmentation) in
expressly agreed in the terms of contract. Availability and technical place.
specifications are subject to change without notice.
Attention should also be paid to Siemens’ recommenda-
All product designations may be trademarks or product names
of Siemens AG or supplier companies whose use by third parties for tions on appropriate protective measures. For more infor-
their own purposes could violate the rights of the owners. mation about Industrial Security, visit
www.siemens.com/industrialsecurity.
The products and solutions from Siemens undergo
continuous development to make them even more secure.
Siemens strongly recommends applying product updates as
soon as they are available and always using the latest
product versions. Using versions that are obsolete or no
longer supported increases the risk of cyber threats.
To stay informed about product updates as they occur,
subscribe to the Siemens Industrial Security RSS feed at
www.siemens.com/industrialsecurity.
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