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2SIMATIC PCS 7 The process control system for Totally Integrated Automation

Using Totally Integrated Automation (TIA), it is Siemens' intention to provide uniform automation technology on the basis of one single platform for the com-plete process sequence, starting with input logistics, covering production or primary processes as well as down-stream (secondary) processes, up to output logistics. This uniform automa-tion technology also refers to the opti-mization of all company operations, covering the enterprise resource plan-ning (ERP) level, the management exe-cution system (MES) level, the control level, down to the field level.

As the process control system in the company-wide automation network called Totally Integrated Automation, SIMATIC PCS 7 uses selected standard hardware and software components from the TIA building block system. Its uniform data management, communi-cation and configuration offer an open platform for modern, future-oriented and economical automation solutions in all sectors of the process industry, production industry and hybrid industry (mixture of continuous/batch processes and discrete production, e.g. in the glass or pharmaceuticals industries).

Whereas secondary and logistics pro-cesses are frequently automated by motion control and SIMATIC compo-nents in the process and hybrid indus-tries, the primary processes are a domain of the SIMATIC PCS 7 process control system.

Within the TIA network, SIMATIC PCS 7 not only handles standard process engi-neering tasks, it can also automate sec-ondary processes (e.g. filling, packag-ing) or input/output logistics (e.g. material flows, storage) for a produc-tion location.

By linking the automation level to the IT world, the process data become avail-able throughout the company for the evaluation, planning, coordination and optimization of operational sequences, production processes and commercial processes. Also taken into account are the requirements of scattered, globally active companies.

3Its pioneering design, modular and open architecture based on state-of-the-art SIMATIC technology, consistent use of industrial standards and the I & C functionalities paired with high perfor-mance mean that the SIMATIC PCS 7 process control system can achieve cost-effective implementation and eco-nomical operation of I & C plants during all phases of their life and with consider-ation of all aspects: covering planning, engineering, commission, training, operation, maintenance, servicing, expansion and renovation. In the pro-cess, SIMATIC PCS 7 unifies high perfor-mance and reliability, simple and safe operation, and maximum convenience.

You particularly profit from Totally Inte-grated Automation and the SIMATIC PCS 7 process control system through the calculable development, implemen-tation and life cycle costs, the minimiza-tion of engineering requirements, the facilities for process optimization, the adaptability when requirements change, and the advantages resulting from the use of standard SIMATIC com-ponents.

Horizontal integration

Horizontal integration means that uni-form and standard hardware/software components from the SIMATIC range are used for the complete production process covering input logistics, pri-mary and secondary processes, up to output logistics. The SIMATIC PCS 7 basic components are therefore HMI systems (WinCC), automation sys-tems, communication networks, distrib-uted I/Os and engineering tools from the SIMATIC modular system which can be supplemented specific to the solu-tion by systems engineering or OEM equipment via stable standard interfaces, or expanded by a wide range of components from the extensive scope of Siemens Automation and Drives products.

This results in advantages for you which are otherwise only typical to those pro-vided by the large manufacturing quan-tities of SIMATIC as the world leader:

Low hardware and engineering costs

Proven quality and stability

Simple, fast definition and selection of system components

Low costs for spare parts

Short delivery times for spare parts and expansion components

Worldwide availability

Savings in logistics, maintenance and training costs.

Vertical integration

A feature of the vertical integration is the uniform and transparent data com-munication covering the ERP, MES, con-trol and field levels. This is characterized by the increased fusion of automation technology and information technology together with their standards in the course of establishment of company-wide information networks. This per-mits modularity and standardization for complete partial processes, associated with a considerable increase in produc-tion flexibility.

The vertical integration of SIMATIC PCS 7 into the company environment comprises two aspects:

Integration into the company-wide information network

Integration of field systems.

Horizontal and vertical integration with SIMATIC PCS 7

4SIMATIC PCS 7 The process control system for Totally Integrated Automation

The SIMATIC PCS 7 process control sys-tem can be seamlessly incorporated into the company-wide information network using interfaces based on international industrial standards for data exchange such as Ethernet, TCP/IP, OPC or @aGlance. The process data are then available at every location and at every time, e.g. for:

ERP (enterprise resource planning)

MIS (management information systems)

MES (manufacturing execution systems)

Advanced process control

Diagnostics and remote maintenance using the Internet.

SIMATIC PCS 7 can be incorporated into the SIMATIC IT framework, and inte-grated in this manner into the com-pany-wide information network.

The OPC interface present in the SIMATIC PCS 7 operator stations as well as @PCS 7 offer further facilities for sim-ple access to the IT world.

The SIMATIC PCS 7 operator station can either be an OPC server as the data source for Windows IT applications, or an OPC client which accesses the data of OPC server applications.

The @PCS 7 server and the correspond-ing Web@aGlance/IT client mean that processes can be globally monitored online via intranet or Internet. In addi-tion to this, host information systems possessing an @aGlance interface can be connected to SIMATIC PCS 7 using @PCS 7.

Integration of field systems

Integration of field systems

SIMATIC PCS 7 is optimized for integra-tion of distributed field systems into the process control system, and is based on PROFIBUS technology. PROFIBUS is sim-ple, rugged and reliable, and is used worldwide in all sectors of the process, production and hybrid industries for input/output logistics just as for primary and secondary processes. It supports redundancy and fail-safety as well as online expansions, and can be used in standard environments or in hazardous areas. It is insignificant whether the plant is equipped with classical signal inputs/outputs on the ET 200 distrib-uted I/O station, or with state-of-the-art, intelligent field devices.

The intelligent field devices are con-nected either directly via the PROFIBUS or via the HART interface modules in the remote I/Os, and can also be redundant. With PROFIBUS, field devices can be directly connected in the Ex zones 0, 1 or 2. Communication between SIMATIC PCS 7 and the intelligent field devices is carried out on the basis of international standards and specifications such as IEC 61158.

Classical and HART field devices are preferably connected to the PROFIBUS using distributed I/Os from the ET 200 range. These sensors/actuators can also be used in the Ex zones 0, 1 or 2. The connection is preferably made via ET 200M in standard environments or Ex zone 2, or via ET 200iS in Ex zone 1. Applications are also possible under special ambient conditions such as extended temperature ranges or increased condensation demands.

5PROFIBUS can also be used to integrate variable-speed drives, motor manage-ment components and electric actua-tors into SIMATIC PCS 7. It is additionally possible to integrate local operator ter-minals in the field using PROFIBUS also in hazardous areas.

The use of communication standards such as PROFIBUS and HART enables problem-free use of SIMATIC PCS 7, and also of components from other vendors in the context of Totally Integrated Automation, e.g. using a Modbus con-nection via CP 341 in the ET 200M.

PROFIBUS components can also be used to link simple actuators and sensors with an AS-Interface or building auto-mation components on the EIB (Euro-pean Installation Bus) to the system.

Using the SIMATIC PDM Process Device Manager (which can be used locally or integrated in the central engineering system of the SIMATIC PCS 7 process control system), it is possible to param-eterize, commission, diagnose or main-tain automation components and field devices with a PROFIBUS or HART inter-face throughout the plant. The interna-tional standards and specifications of the PNO (PROFIBUS International), e.g. the EDDL technology, are the basis for the simple integration of field devices into SIMATIC PDM.

Uniform and homogeneous complete system

As a modern process control system, SIMATIC PCS 7 on its own or in combina-tion with motion control and SIMATIC is a uniform and homogeneous complete system. Its attractiveness grows parallel to the requirement for seamless and uniform automation technology as defined by continuing competition and price pressures, the demand for increas-ingly flexible production plants, and the necessity to increase productivity.

Against the background of permanently increasing complexity, especially result-ing from the fusing together of automa-tion and information technologies, sys-tem platforms which provide horizontal and vertical uniformity are becoming increasingly significant compared to automation solutions with so-called best-of-breed products. Incorporated into Totally Integrated Automation, SIMATIC PCS 7 is therefore perfectly pre-pared for future demands.

High performance and exceptional sys-tem properties together with uniform data management, communication and configuring guarantee that the typical demands placed on a process control system can be comprehensively fulfilled by SIMATIC PCS 7:

Simple and safe process control

Convenient operation and visualiza-tion

Powerful, fast and uniform engineer-ing throughout the system

Online modifications possible throughout the system

System openness at all levels

Flexibility and scaleability

Redundancy at all levels

Fail-safe automation solutions

Comprehensive fieldbus integration

Flexible solutions for batch processes

Direct interfacing to the IT world.

Open for the future

SIMATIC PCS 7 is based on modular hardware and software components from the scope of Totally Integrated Automation, and are perfectly matched to one another. These can be expanded and innovated seamlessly and with a small outlay, and are open for the future through the use of interfaces with long-term stability. This means that it is pos-sible to provide long-term protection for customer investments despite high innovation speeds and short product life cycles.

SIMATIC PCS 7 consistently applies state-of-the-art, powerful technologies together with internationally estab-lished industrial standards such as IEC, XML, PROFIBUS, Ethernet, TCP/IP, OPC, @aGlance, ISA S88 or S95, just to men-tion a few.

SIMATIC PCS 7's openness covers all lev-els and applies to automation systems and process I/Os just as to operator and engineering systems, industrial com-munication networks or the SIMATIC IT framework as the link to the informa-tion, coordination and planning tools for company management.

However, the openness is not only char-acterized by the system architecture, horizontal/vertical integration and com-munication, but also by the program-ming and data exchange interfaces for user programs as well as import/export functions for graphics, text and data, e.g. from the CAD/CAE world.

SIMATIC PCS 7 can therefore also be combined with components from other vendors, and integrated into existing infrastructures.

6Flexibility and scaleability from small laboratory system up to distributed client/server solution

As a result of the modular architecture based on selected hardware and soft-ware components from the standard SIMATIC range, SIMATIC PCS 7 can be flexibly adapted during plant configur-ing to various customer demands and plant sizes, and later expanded or reconfigured without problem should subsequent expansion of the capacities or technological qualifications necessi-tate this. SIMATIC PCS 7 therefore cov-ers all plant sizes: SIMATIC PCS 7 simply grows in line with the plant!

SIMATIC PCS 7 is scaleable from a small single system with approx. 160 measur-ing points (common synonym: tags), e.g. for laboratory automation or use in research institutes, up to a distributed multi-user system with client/server architecture and approx. 60,000 mea-suring points for automation of a very large production plant or plant network at one production location.

Depending on the requirements, the user and the planning engineer

can select from various automation systems of different performances,

incorporate distributed or central I/Os step-by-step,

dimension and configure display and operating components: from single-user starter system up to distributed multi-user system,

select the engineering system accord-ing to the scaling of process objects,

configure communication networks and determine network components,

specifically expand the functionalities of the operator stations by adding various hardware and software mod-ules, e.g. using SIMATIC BATCH or with a stand-alone, redundant archive server,

integrate applications for connecting SIMATIC PCS 7 to the IT world.

Highlights Scaleable from small laboratory system for approx. 160 measuring points up to

a distributed system with client/server architecture for up to 60,000 measuring points

Uniform control system platform based on standard SIMATIC components Cost savings resulting from personnel know-how, reduced stocking of spare

parts Cost savings resulting from further use of application engineering (e.g.

research institutes)

Optimum adaptation to respective plant size No provision of expensive spare capacity Grows together with plant expansions

Wide range of expansion facilities for adaptation of functionalities Best possible adaptation to individual plant requirements Optimum price/performance ratio

7Redundancy at all levels

SIMATIC PCS 7 offers a comprehensive redundancy concept extending over all I & C levels. The client/server architec-ture of the process control system per-mits up to 32 OS/SIMATIC BATCH clients to access the data of an OS/batch server. Using the multi-screen technology, up to 4 process monitors can be connected to a client.

An OS Ethernet LAN with ring configu-ration is used as standard for client-server and server-server communica-tion. This avoids communication fail-ures should e.g. the line be damaged or interrupted at any point.

To increase the availability even further, it is possible to divide the OS LAN into several segments.

OS and batch servers can have a redun-dant design if required. Synchronization of the redundant servers is then carried out automatically and at high speed. Using a health check, important OS/SIMATIC BATCH applications of the server are monitored for faults which may result in switching over of the redundancy. A redundant archive server can be configured for central saving and for increasing the availability of process data relevant to quality.

Communication between automation systems and with the engineering sys-tem and operator stations is carried out via the Industrial Ethernet plant bus which can be operated at 100 Mbit/s. The plant bus can be implemented with a ring configuration, and can also have a redundant design for increased avail-ability demands (two CP communica-tions processors per AS, OS and ES). In this manner, double faults such as an OSM failure on ring 1 with a simulta-neous interruption in the bus cable of ring 2 can also be tolerated.

The redundant, fault-tolerant AS 414 H and AS 417 H automation systems are connected as standard to the plant bus using one communications processor per partial AS.

Several PROFIBUS DP lines with distrib-uted process I/Os can be operated on each partial AS via the internal PROFIBUS DP interface or with the assis-tance of further communications pro-cessors.

The ET 200M distributed I/O systems are connected via two IM 153-2 modules on a special bus module to two redundant PROFIBUS DP lines, the intelligent field devices on PROFIBUS PA via a redundant DP/PA link with two IM 157 modules.

Using the Y-link it is also possible to con-nect non-redundant PROFIBUS DP devices to the redundant PROFIBUS DP.

In the case of the ET 200M distributed I/O system, the redundancy extends down to the module level, i.e. redun-dant selection of input/output modules for fail-safe and standard applications is possible.

8Interfacing to the IT worldwith SIMATIC IT and @PCS 7

For plant owners, information technol-ogy (IT), process data management and production planning have become important elements for reducing costs and optimizing processes. Global com-petition means that companies distrib-uted over several locations must be able to manufacture customer-specific prod-uct ranges more rationally and flexibly, and introduce them increasingly rapidly on the market.

The obligation for consolidation, opti-mization and rationalization, as well as the extension of regulatory pressure by the manufacturer on the supplier, means that the fusing together of pro-cess automation systems with MES and ERP systems (e.g. SAP/R3) is becoming increasingly significant.

The SIMATIC PCS 7 process control system provides an open and uniform system platform for vertical integration of the process automation, operational management and company manage-ment levels, and is thus appropriately equipped for future demands.

Integration and synchronization of all processes using SIMATIC IT

The optimization of the interaction between planning, development and procurement, as well as the same or dif-ferent manufacturing procedures at various locations, is a complex task. SIMATIC IT makes these processes trans-parent, and helps to optimize them.

SIMATIC IT is a technology platform for e-manufacturing in compliance with the ISA S95 standard for coordinating functionalities according to explicit commercial and production rules such that an optimum workflow is achieved.

The main elements of SIMATIC IT are:

SIMATIC IT Framework

SIMATIC IT Components

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

Advantages when using SIMATIC IT

SIMATIC IT Framework contains the fol-lowing functions: Services, Server, Adapter, Production Modeler, Work-bench and Application Developer. SIMATIC IT Framework permits integra-tion of heterogeneous applications as well as easier handling and control of complex production processes. Pro-cesses and communication are effec-tively synchronized, coordinated and optimized by SIMATIC IT Framework, both within a company and between the locations.

SIMATIC IT Framework is not only able to integrate current SIMATIC IT compo-nents, but also existing and cross-ven-dor IT products. The SIMATIC PCS 7 pro-cess control system can be incorporated into the SIMATIC IT Framework using an adapter.

SIMATIC IT components are standard products made available to various industrial sectors as a result of branch-independent and branch-specific IT functionalities defined in line with ISA S95. Examples of SIMATIC IT compo-nents include Detailed Production Scheduler, Historian, Maintegrity, Mate-rial Manager, Production Order Man-ager or Unilab.

In addition to the SIMATIC IT compo-nents, largely sector-independent SIMATIC IT suite libraries provide useful basic units and procedures which facili-tate the implementation of the various applications. In addition to this, func-tionalities tailored to special sectors are available in industrial suite libraries.

9Company-wide availability of process data with @PCS 7

@PCS 7 a simple and cost-effective facil-ity for remote access to the process data recorded using SIMATIC PCS 7. The data can be displayed and processed further using the @aGlance standard on any computers with various operating sys-tems also via intranet/Internet.

@aGlance is already integrated in a @PCS 7 server in every SIMATIC PCS 7 operator system. In order to read data, it is only necessary to have a Web@aGlance package and a standard Web browser on the target PC. In order to write data and to communicate with other @aGlance servers, a correspond-ing license is simply activated in the operator station.

The integration of @aGlance/IT means that SIMATIC PCS 7 is able to communi-cate with a wide range of software products for the operational manage-ment and company management lev-els. @PCS 7 permits access via the @aGlance interface to data of the PCS 7 operator system including archives and messages.

An intelligent log-on procedure pro-vides the @aGlance product range with a Plug&Play character without neglect-ing security aspects. Access protection is achieved using a powerful administra-tion tool.

A further advantage of the open archi-tecture of this client/server technology is free selection of the operating sys-tems or applications on the server or client side of the @aGlance/IT software package. This also means that the implementation of @aGlance is inde-pendent of any existing hardware and software architecture. Therefore there are no dependencies on certain suppli-ers, on systems already existing in the company, or systems still to be imple-mented. Costs resulting from changes in system can be avoided.

SIMATIC PCS 7 offers various @PCS 7 versions with the following functions:

Reading of OS data (process data, messages, archive data) via Inter-net/intranet

Reading and writing of OS data

Communication with @aGlance/IT client applications, e.g. the InfoPlus.21 information manage-ment system

Communication with server applica-tions of the @aGlance/IT server add-ons

@PCS 7 offers the following advan-tages:

@PCS 7 makes process data available throughout the company. All process data can then be visualized, analyzed and processed further on any desktop

@PCS 7 permits access to all data of PCS 7 operator stations, e.g. to archived data

All client/server applications which have an @aGlance interface can be connected to @PCS 7

@PCS 7 is based on @aGlance tech-nology; @aGlance has established itself as the de facto standard for interface software (Middleware) with Internet link

@PCS 7 provides process data at the operational management and com-pany management levels; based on client/server technology

It is additionally possible to develop own client/server applications based on the @aGlance product range.

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Automation of batch processeswith SIMATIC BATCH

HighlightsModular architecture with flexible scaleability (hardware and software) Optimum adaptation to plant size and individual requirements Grows together with plant expansions; no extensive spare capacities

High availability with redundant batch servers No loss of batch data Automatic adjustment of batch data

Homogeneous integration of SIMATIC BATCH into the HMI strategy and the SIMATIC PCS 7 engineering via the system interface No customer-specific interfaces No double configuring of batch-specific engineering data

Unit-independent recipes Significant reduction in recipe administration and validation Flexible mode of operation and optimum plant utilization resulting from

assignment of units during runtimeHierarchical recipes according to ISA S88.01 Process-oriented recipe creation Simple, fast creation with minimum faults

Saving, archiving and comprehensive recording of batch data on basis of mod-ern XML format Production becomes transparent and comprehensible Reliable operator prompting, safe response to process faults

Reduction in engineering and validation input as result of: type/invocation concept of SFC, separation of procedure and formula, ROP library and configuring independent of units Multiple usage, central modification

Validation support according to 21 CFR Part 11 using audit trail (logbook of modifications), version assignments for recipes, recipe operations and formu-las, user administration with access protection and electronic signature

The SIMATIC PCS 7 process control sys-tem always offers the appropriate solu-tion for low-cost, effective implementa-tion of batch processes. Automation of simple batch processes with parameter-izable sequential controls is carried out using the SFC and CFC tools included in the engineering system.

SIMATIC BATCH is the convenient solu-tion for more complex tasks with recipe-controlled operation. This permits sim-ple, flexible processing of complex tasks with changing control sequences.

Modular architecture

SIMATIC BATCH is configured either as a single-user system or as a client/server system, and can be used in plants of any size thanks to its modular architecture and flexible scaleability in four steps with 150, 600, 1800 and >1800 batch process objects (invocations of units and technical equipment).

Typical automation of a batch process comprises a batch server and several batch clients which process a plant project together. The batch server may also have a redundant design (hot standby) to increase the availability.

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Integration in SIMATIC PCS 7

SIMATIC BATCH is fully integrated in SIMATIC PCS 7. The plant data can be completely configured using the engi-neering system. The engineering sys-tem passes on all data required for recipe creation to the batch server, meaning that recipe processing is possi-ble separate from the engineering system. Changes to the configuration which are made on the engineering sys-tem can be transmitted to the batch server using an update function (online/offline).

The hardware of the batch server can be separate from the OS servers. SIMATIC BATCH clients and OS clients can be executed on separate or com-mon basic hardware. The PCS 7 opera-tor stations relevant to the batch are made known to the batch server during configuring of the batch plant.

SIMATIC BATCH communicates with the automation systems via the PCS 7 oper-ator stations. Operator instructions and dialogs can also be integrated into the communication. These functions can be used to draw attention to necessary operator inputs, or to offer a facility for data input, e.g. for laboratory values. SIMATIC BATCH provides special stan-dard faceplates for operation and moni-toring of units and technical functions.

SFC invocations derived from a particu-lar type of SFC are generally used as the interface to the subordinate automa-tion level. The properties of the SFC type such as modes of operation, set-points/actual values, invocation param-eters, times etc. can be defined using a features dialog. However, it is also pos-sible to use special batch interface blocks for communication with the pro-cessing programs in the automation systems, e.g. for plant expansions or when connecting non-SIMATIC sys-tems.

The main components of SIMATIC BATCH as far as the user is concerned are:

Batch Control Center (BatchCC)

Recipe editor

Batch Control Center

The Batch Control Center (BatchCC) is the "command center" for monitoring and controlling batch processes with SIMATIC BATCH. Using BatchCC it is pos-sible to manage all data relevant to SIMATIC BATCH by means of a GUI. Con-venient planning of orders and batches is also possible using BatchCC, as is the graphic display of unit assignments.

BatchCC offers powerful functions for the following tasks:

Reading-in of plant data associated with basic automation

Definition of user privileges for all functions, for clients, or for units of SIMATIC BATCH

Definition of names and codes of used material

Administration of master recipes, and starting of recipe editor for input of recipe structure

Administration of libraries with recipe elements (library operations)

Editing of formula categories, and administration of associated formulas (parameter sets)

Planning of production orders with master recipes and batches

Start and control batch processing

Monitoring and diagnostics of batch processing

Recording and archiving of recipes and batch data

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Automation of batch processeswith SIMATIC BATCH

Recipe editor

The recipe editor is a convenient tool for simple, intuitive creation and modifica-tion of master recipes and library opera-tions, and possesses a GUI, editing func-tions typical to Microsoft Windows for single and group objects, and a struc-tural syntax test. The batch objects from the batch plant configuring using the SIMATIC PCS 7 engineering system are the basis for recipe creation, i.e. units and technological functions. The batch recipe editor can be started individually, but can also be called from BatchCC.

The recipe editor can be used to:

Create new master recipes and library operations

Modify existing master recipes and library operations (change structure or parameters)

Document master recipes and library operations

Carry out plausibility tests

Assign releases for testing or produc-tion of master recipes and library operations

Hierarchical recipes according to ISA S88.01

Batch Report

Batch Report is used to generate recipe and batch reports which can be dis-played and printed using BatchCC. Batch reports contain the data required for reproduction of the batch process, for proof of quality, and for compliance with statutory requirements, e.g.

identification data, control recipe data, effective production data, step sequences, error messages and fault signals, operator interventions and process values.

The recipe reports include the produc-tion data, e.g. recipe header data, list of used and produced materials, process regulations.

Batch data archiving and logging in XML format

The batch data which are only accessi-ble for authorized persons or systems are saved in XML format. A batch report based on the XML data is available as standard. However, the XML data can also be processed further using an external logging system.

Hierarchical recipes according to ISA S88.01

SIMATIC BATCH and SIMATIC PCS 7, as a functional unit, completely cover the models described in the ISA S88.01 standard.

The hierarchical recipe structure is mapped on the plant model as follows:

Recipe procedure for controlling the process or the production in a plant

Partial recipe procedure for control-ling a part of the process on a unit

Recipe operation/function for the pro-cess engineering task/function on a technical unit

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Neutrality and assignment of units

A uniform class strategy supports the simple creation of recipes which are independent of the unit. As a result, the partial recipe procedures are only assigned unit classes when the recipes are created. Only one recipe need then be created if there are several units of the same type. This minimizes the engi-neering requirements, and provides substantial advantages for validation.

Various strategies are available for the assignment of units, permitting opti-mum alignment to the particular plant situation:

"Preferred unit" for preselection when the recipe is created

Determination of the unit which has not been used for the longest period in order to achieve uniform utilization

The unit to be used can be defined for SIMATIC BATCH using an external module (e.g. scheduler) by means of process parameters.

The final assignment of the units is car-ried out during runtime. In the case of longer batches where the units are not to be already assigned and occupied when the batch is started, they are only assigned when they are required. Con-flicts in assignment of the units are detected and indicated by the system.

Separation of procedure and formula

The flexibility achieved by recipes which are independent of units can be increased even further if the procedure and parameter sets (formulas) are sepa-rated from one another. Various master recipes can be created by linking several formulas using a recipe procedure. This enables central modification of proce-dures. The formula structure is deter-mined by the formula category defined by the user.

Library with recipe operations (ROP)

The management of recipe operations is conveniently supported by a user library (ROP library). Library recipe oper-ations can be inserted as a reference in recipe procedures and can thus be mod-ified centrally. This reduces the require-ments for engineering and validation. By resolving the reference, the recipe operation becomes a fixed component of the recipe procedure, and is thus independent of further central modifi-cations.

MIS/MES interfacing

Interfacing of MIS/MES systems is made possible by:

Integration of SIMATIC PCS 7 in SIMATIC IT Framework

An open interface (API) for customer-specific expansions

Validation according to 21 CFR Part 11

The number of plants to be validated for the observation of quality standards because of marketing and statutory requirements is permanently increas-ing. The process control system and the manufacturer thereof are becoming increasingly important in the validation process.

In addition, SIMATIC BATCH supports the validation according to 21 CFR Part 11 by means of the following func-tions:

Audit trail (logbook of modifications): - Logging of modifications to recipes

and recipe operations (stored when object changed)

- Logging of modifications during production (in the batch report), including the operations at the indi-vidual control level associated with the corresponding batch

Version assignment (recipe life cycle, recipe operations, formulas)

Access protection using central user administration based on Windows 2000

Electronic signature

Furthermore, Siemens as a manufac-turer of process control systems has specially trained personnel as well as many years of experience in quality management and in the validation of plants.

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Operation and monitoringwith the SIMATIC PCS 7 operator systems

Highlights Flexible, modular architecture with scaleable hardware and software

components for single-user and multi-user systems

High-performance operator stations based on standard PC technology with Microsoft Windows 2000 can be used in office or industrial environments

Client/server multi-user systems with up to 12 OS servers/pairs of servers for 5,000 measuring points each and up to 32 OS clients per server/pair of servers

High-performance archive system based on Microsoft SQL server with cyclic archives and integral archive backup, optionally with archive server

OS health check for monitoring important server applicationsOnline modifications without interference with operation, and online testing

with selective loading of redundant servers

Optimized AS/OS communication: AS response cycle can be 500 ms, data transmission only following change in data; suppression of unsteady messages

Convenient process control and high operational reliability, also together with multi-screen technology

Expanded status display from combination of status or analog values with alarm information

Alarm priorities as additional attribute for filtering important messages Central user management, access control, electronic signature Sign-of-life monitoring for subordinate systems connected to plant bus System-wide time synchronization based on UTC (Universal Time Coordinated)

The operator system is the human-machine interface of the SIMATIC PCS 7 process control system, and thus repre-sents the window and door to the pro-cess for the user. The operator system is extremely variable, and can be flexibly adapted to different plant sizes and cus-tomer requirements.

The basis for this are the perfectly matched operator stations for single-user systems and multi-user systems with client/server architecture.

Operator stations

All operator stations are based on mod-ern PC technology with graded perfor-mances optimized for use as OS single station, OS client or OS server, com-bined with the Microsoft Windows 2000 operating system. The use of standard components and interfaces from the PC world means that the operator stations are open for options and expansions specific to customers or sectors. They can be used in rough industrial environ-ments just as in offices. OS single sta-tions and OS clients use multi-VGA graphics to permit process control of several plant areas on up to 4 process monitors.

The system software of the operator station can be scaled with respect to the number of process objects (PO) (250, 2000, 3000 or 5000 POs per OS single station; 2000, 3000, 5000 or 8500 POs per OS server). Their number can be increased at any time using PowerPacks should requirements rise or plant expansions be carried out.

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Single-user system (OS Single Station)

In the case of a single-user system, the complete operation and monitoring functionality for a project (plant/unit) is concentrated in one station. This OS single station can be connected to the Industrial Ethernet plant bus in two manners:

Via a CP 1613 communications pro-cessor or

via a simple LAN card (Basic Communication Ethernet for communication with max. 8 automa-tion systems).

The OS single station can be operated parallel to other single-user systems or a multi-user system on the plant bus.

Multi-user system with client/server architecture

A multi-user system consists of operator terminals (OS clients) which are pro-vided with data (project data, process values, archives, alarms and messages) from one or more OS servers via an OS LAN (Local Area Network). The OS-LAN can share the transmission medium with the plant bus, or be designed as a separate bus (Ethernet with TCP/IP).

The OS servers may also have a redun-dant design (hot standby) if increased availability demands exist. Important applications of the OS server are moni-tored for software faults using a health check, resulting in switching over of the redundancy if necessary. Synchroniza-tion of the redundant OS servers is car-ried out automatically and at high speed.

OS clients cannot only access the data of an OS server/pair of servers, they can also simultaneously access several OS servers/pairs of servers (multi-client mode). It is then possible to divide a plant into technological units, and to distribute the data accordingly to sev-eral OS servers/pairs of servers. In addi-tion to scaleability, the advantage of distributed systems is the decoupling of plant components, resulting in increased availability.

SIMATIC PCS 7 supports multi-user systems with up to 12 OS servers or 12 redundant pairs of OS servers. In multi-client mode, OS clients can access some or all of the 12 OS servers/pairs of servers in parallel (all simultaneously with up to 32 OS clients).

The OS servers have additional client functions which permit them to access the data (archives, messages, tags, variables) of the other OS servers of the multi-user system. This means that pro-cess images on one OS server can also be linked to variables on other OS servers (area-independent displays).

Like the OS single stations, the OS servers can be connected to the Industrial Ethernet plant bus using a communications processor or a simple LAN card.

OS quantity breakdown

Max. number of OS servers/pairs of servers 12

Max. number of OS clients In multi-client mode 1)

per multi-user system

1) If every OS client has access to all OS servers/pairs of servers

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Number of measuring points Per OS server Per multi-user system

Approx. 5,000Approx. 60,000

High-performance archive system (Microsoft SQL server) for: Process values Messages

Approx. 10,000/s (with archive server)Permanent load approx. 100/s (per server)Rush of messages approx. 15,000 / 10 s

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Operation and monitoringwith the SIMATIC PCS 7 operator systems

High-performance archive system and central archive server

A high-performance archive system based on Microsoft SQL server technol-ogy and with online configuration facil-ities records process values and mes-sages in cyclic archives, and permits the exporting and saving of old data using an integral archive backup. Each server of a multi-user system can archive e.g. approx. 100 messages/s. The operator system is also able to handle a brief rush of approx. 15,000 messages in 10 s.

A central archive server which is prefer-ably redundant can be additionally pro-vided for process values. Using such an archive server, an operator system can save approx. 10,000 process values/s.

Usability, system performance, and processing of mass data

Operator systems of the SIMATIC PCS 7 process control system are optimized for processing large quantities of data. Even with high quantity breakdowns, they are characterized by a high perfor-mance, yet are still simple and intuitive to use.

Often small aspects have an advanta-geous effect on the total performance of an operator system:

Extended status displays: status or analog values can be combined with alarm information using simple con-figuring without the application of scripts. Such extended status and analog-value displays reduce the sys-tem loading and improve display selection times.

Optimized communication between operator system and automation sys-tem: the response cycle of the auto-mation system can be 500 ms, data transmission then only takes place when data have changed.

QTM message and acknowledgment procedure for suppressing unsteady messages in the automation system. The repeated transmission of a mes-sage only takes place following previ-ous acknowledgment in the operator system.

GUI for OS process control with movable windows

Engineering

Engineering of the SIMATIC PCS 7 pro-cess control system is concentrated as standard in a separate engineering sys-tem. In the single-user systems for small plants, engineering and operator func-tionalities can be combined in one sta-tion.

All project modifications carried out on the engineering system can be loaded online into the OS servers and clients via the OS-LAN plant bus without interfer-ing with online operation. A central dia-log controls this procedure, and ensures that the sequence is correct.

GUI

The predefined GUI of the operator sys-tem complies with all features typical to a control system. It is multilingual, clearly structured, ergonomic and understandable. The operator can sur-vey the process extremely easily, and rapidly navigate between different plant views. A picture tree manager pro-vides support, organizing the picture hierarchy according to user require-ments, and permitting direct selection of subordinate areas during process control.

Process displays and measuring points can also be called using their names. An online language selector permits the user to change the language during runtime.

Standard and server views are available for the technological display of a plant, and their area overviews can have a dif-ferent design. Both views are provided, inter alia, with:

Message line for last message

Date, time and operator name

Area overview with up to 36/49/64 areas (depending on resolution of process monitor)

Working area for plant displays and movable windows for faceplates, curves etc.

System function keys

17

It is possible in a special message view to switch between I & C message pages such as new list, old list, list of DOWN messages, operator inputs list, I & C list or history.

Curves can be output as full-screen dis-plays or as a window in the working area. Certain curves/groups of curves are already predefined during plant configuring. The operator can also assign a few curves online and select them using measuring point names.

SFC visualization

The SFC visualization of the operator system permits display and operation of the sequential controls configured using the SFC tool in the same manner as on the engineering system. Addi-tional configuring overhead is unneces-sary. In an overview display, it is possi-ble e.g. to open step and transition displays, and to display step comments or online step criteria.

Messages/alarms

The assignment of message priorities as an additional attribute to the known message classes means that the han-dling of messages in the case of larger quantity breakdowns becomes clearer, and important messages can be sepa-rated more easily from less important ones.

Current messages are signalled by com-mon displays representing views of message/alarm lists predefined accord-ing to message groups.

The last message which has arrived the one with the highest priority if prior-ities are assigned is displayed at the top edge of the standard view. A pre-defined window with further messages can be displayed using the "Extended message line" button.

Fast determination and elimination of the cause of the fault are supported by the "Loop-in-alarm" and "Select display using measuring point" functions. Using "Loop-in-alarm", the operator can directly access the process display in which the fault has occurred, and can then use the measuring point to also call the associated faceplate (loop dis-play).

Flexible sound settings support audible signalling of messages/alarms via a sound card or by controlling external buzzers via a signal module.

Central user management, access control and electronic signature

SIMATIC Logon offers central user administration with access control based on Windows 2000 for the SIMATIC PCS 7 system components as well as non-SIMATIC components con-nected via API. It corresponds to the val-idation requirements of 21 CFR Part 11. The electronic signature function is also a component of SIMATIC Logon.

A chipcard reader can be additionally used for access control to the operator stations, and checks the operator privi-leges stored on a chipcard.

Sign-of-life monitoring

The sign-of-life monitoring function enables the operator system to check the correct functioning of all subordi-nate systems connected to the plant bus. A graphic plant configuration dis-play shows the monitored bus stations with their respective status.

Time synchronization

Within the SIMATIC PCS 7 process con-trol system, the operator system can use the time synchronization based on UTC (Universal Time Coordinated). This particularly provides advantages for widely distributed plants present in dif-ferent time zones, e.g. pipelines.

Script languages

Visual Basic and C can be used as script languages for user-specific program-ming of OS applications.

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System-wide engineeringwith the central engineering system

The central engineering system of the SIMATIC PCS 7 process control system is based on the same hardware as the OS single station of the operator sys-tem. It features powerful PC technology which can be used equally well in an office or industrial environment, and, together with the Windows 2000 oper-ating system, provides an optimum engineering platform. Increased config-uring convenience is provided by expansion of the working area by con-necting up to four process monitors via a special multi-VGA graphics card. The system software of the engineering sys-tem can be scaled with respect to the number of process objects (PO): 250, 2000, 3000, 5000 or unlimited. If required, their number can be increased at any time using PowerPacks.

The engineering system has tools opti-mally matched to one another for sys-tem-wide and project-oriented engi-neering:

of the hardware and field devices,

of the communication networks,

of continuous and sequential process sequences,

of the operation and monitoring strategies, and

of SIMATIC BATCH.

The engineering toolset matched to technological requirements together with predefined blocks and charts mean that technologists as well as process and production engineers can carry out planning and configuring in a terminol-ogy environment which is known to them.

Typical automation components such as motors, valves or PID controllers are already stored as standardized software objects (measuring point types) in an I & C library, and need only be incorpo-rated into the process sequences and graphically interconnected. This can also be carried out easily and rapidly by technologists without programming knowledge. When interconnecting dis-play objects, the associated OS variables are created in the background, and also the associated blocks in the block list if applicable.

The uniform database of the engineer-ing system means that data which have been entered once are available throughout the system.

All project modifications relevant to the automation systems, operator systems and SIMATIC BATCH can be compiled and loaded in one working step. The engineering system automatically observes the correct sequence. The pro-cedure is displayed and controlled in a central dialog.

Short turnaround times result in short waiting times for the commissioning engineer, and have a favorable effect on commissioning costs. Changes to the configuration can be loaded online into the corresponding system compo-nents.

The engineering system supports the implementation of large projects together with the associated processing of mass data by providing appropriate functions such as:

Plant hierarchy (plant view)

Project library for measuring point types as well as import/export of mea-suring points (process object view)

Multi-project engineering

Branch & merge

Extended renaming of objects

Version cross-checker

Import/export wizard

SFC type

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SIMATIC Manager

The SIMATIC Manager is simultaneously the integration platform for the engi-neering toolset, and the basis for the complete engineering of the SIMATIC PCS 7 process control system. The SIMATIC PCS 7 project is managed, archived and documented here. The SIMATIC Manager offers tools for con-figuring the automation systems, pro-cess I/Os and communication networks, and permits selection of the required hardware from an electronic catalog.

The various tasks for creation of a plant project are optimally supported by three layers of the SIMATIC Manager:

Component view for configuring hardware such as automation sys-tems, bus components or process I/Os

Plant view for hierarchical structuring of the plant

Process object view as central devel-opment environment for all aspects of measuring points/process objects

Plant view (plant hierarchy)

The plant view is used to divide and dis-play a project according to technologi-cal aspects. A technologically-oriented project structure enables technologists to achieve rapid orientation. OS areas and the display hierarchy can also be derived from this technological hierar-chy. Furthermore, this is the basis for the plant-oriented identification of pro-cess objects.

Overview displays for units can also be generated automatically, and permit positioning and interconnection of all operator-accessible and monitored CFC blocks

HighlightsCentral hardware and software configuring uniform throughout the system

using one engineering system Full-graphic configuring with user-friendly GUI Integral configuring of field devices Parameterization of communication without complex configuring Same configuration for redundant and non-redundant applications Configuring of fail-safe applications already included

Central dialog for compilation and loading of all AS, OS and SIMATIC BATCH modifications Optimization of all steps, and summary in a dialog with sequence check Compilation and loading in one operation with minimum turnaround times

Configuring of large plants using distributed, parallel multi-project engineer-ing with branch & merge

Technology-based configuring without special programming knowledge Hierarchical structure of functions divided according to plants, units, tech-

nical equipment Hardware-independent engineering: AS assignment and I/O modules can be

subsequently selected Expandable using sector-specific add-ons via standard data exchange inter-

faces

Process object view for display and processing of all aspects of measuring points/process objects Convenient spreadsheet processing at central point Project library with measuring-point types as well as import/export function

Special SFC functionalities Status administration in conformance with ISA S88 for configuring of sepa-

rate sequence chains for statuses such as holding, aborting or safe state Connections also for SFCs Use of SFC invocations as block in CFC

Reduction in engineering and validation input as result of: Comprehensive libraries with predefined, tested standard blocks, faceplates

and symbols Ready-made charts from the library Project library for measuring-point types with import/export function in the

process object view Simple duplication of units by copying, extended renaming and compiling Type invocation concept of SFC with central modification facility for all invo-

cations Import/export wizard for bulk engineering (configuring of bulk data) Numerous configuring steps automatically controlled by the system (auto-

engineering)

Auto-engineering for: Correction of OS interconnections when changing name in AS Optimization of block execution sequence in the CFC Connection of block interconnections containing text

Version cross-checker Documentation of engineering modifications by comparing versions and

providing graphic display of differences

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System-wide engineeringwith the central engineering system

Process object view

The process object view of the SIMATIC Manager permits a universal view of the measuring point. It shows the techno-logical hierarchy as a tree display in combination with a tabular view of all aspects of the measuring point/process object (general, parameters, signals, messages, display objects and mea-sured-value archives).

All objects in the marked hierarchy branch are displayed in the table and can also be directly edited there.

Configuring in the process object view is very appropriate to the process engi-neer's way of working oriented accord-ing to measuring points. The engineer is supported by convenient functions such as

block-by-block copying/insertion,

search/replace,

reversal,

two-stage filtering,

import/export of measuring points and example solutions, or

data exchange with Microsoft Excel/Access using clipboard.

An integral project library contains pre-configured types of measuring point, and permits users to incorporate their own types.

Filtering, sorting, editing in the process object view of the engineering system

Multi-project engineering

Multi-project engineering permits divi-sion of a comprehensive project into several subprojects according to tech-nological aspects in order to subse-quently edit them in parallel by several teams. To achieve this, a host "Multi-project" is defined in the SIMATIC Man-ager. Individual projects can be inserted at any time into a multi-project, or removed from it. Furthermore, projects can be branched and merged.

The projects belonging to a multi-project are all saved on a central server, and sent to a local engineering system for editing. The engineering perfor-mance is then not impaired by network access.

Branch & Merge

Branch & Merge is provided for multi-project engineering, and supports the branching and merging of projects from a technological viewpoint. Charts or units can be copied into another project and edited there.

Charts with the same name in the origi-nal object are overwritten during Branch & Merge. Interconnections which are not specific to a project, typi-cally e.g. for interlocking, become text interconnections when branched. When merging, these text interconnec-tions including self-entered can be closed by pressing a key.

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Efficient mass data editing using the import/export wizard

The import/export wizard is a tool for engineering large plants with repeat-edly used components, e.g. based on standardized types of measuring point. It significantly shortens the time required for configuring; plant data which have already been configured (such as measuring point lists or charts from the CAD/CAE world) can be imported into the engineering system and used for largely automatic genera-tion of measuring points. Existing PCS 7 projects can be both exported and reim-ported.

Editing of mass data with import/export wizard

The import/export wizard offers the fol-lowing advantages:

Importing of previously configured plant data such as measuring point list from CAD/CAE world No multiple inputs, minimizes

sources of error Simple handling, convenient

graphic environment

Automatic generation of measuring points based on imported measuring point lists and Typicals Generation of technological hier-

archy Charts of the individual measuring

points Drastically reduced time require-

ments, and avoidance of errors as result of automatic/reproducible generation

Automatic derivation of the OS dis-play hierarchy, automatic intercon-nection of blocks and positioning in displays Significant time and cost savings

Commissioning of individual measur-ing points using the convenient graphic tools CFC and SFC

Exporting of parameters optimized during commission back to the CAD/CAE world Consistent data in the higher-level

planning tools

Extended rename

When renaming objects, the logic oper-ations associated with visualization (dis-play objects or variables in archives and scripts) are modified accordingly. This function has an enormous rationaliza-tion potential which is particularly sig-nificant for plants with repeated struc-tures or those requiring validation.

For example, if a completely configured and tested unit is copied with all charts, sequential controls and displays, and if the copied charts/displays are subse-quently renamed, all internal intercon-nections are automatically adapted. Complex units or complete lines in a plant can be multiplied in this manner in a very short time.

Version cross-checker

The version cross-checker determines differences between various release versions of a project:

Comparison of CFCs/SFCs, block types, signals and sequences in order to determine additional, missing or different objects

Graphic display of comparison results in a combination of tree and table

Colored identification of objects and attribute values.

Continuous function chart (CFC)

CFC is the tool for graphic configuring of continuous automation functions. Supported by powerful autorouting and integral message configuration, pre-defined blocks can be positioned on CNCs, parameterized and intercon-nected.

When creating a new CFC, a sequence group is generated with the chart name. All blocks installed in the charts are automatically added to this sequence group. The sequence can be optimized when compiling. An algorithm initially determines the optimum block sequence, and then the sequence of groups.

I & C libraries

The predefined and tested blocks, face-plates and symbols organized in I & C libraries are the basic elements for the graphic configuring of automation solu-tions. Use of these library elements makes a significant contribution to min-imization of engineering requirements and project costs.

The comprehensive range of blocks includes simple logic and driver blocks, technological blocks with integral oper-ation and signalling response such as PID controllers, motors or valves, and also blocks for integration of PROFIBUS field devices according to PROFIBUS PA Profile 3.0 (including standardized eval-uation of process value status).

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System-wide engineeringwith the central engineering system

Sequential function chart (SFC)

SFC can be used for graphic configuring of sequential controls for batch produc-tion. Each SFC has inputs and outputs for controlling and for status informa-tion. If necessary, an SFC can be directly position and interconnected in the CFC. The desired CFC block connections are selected using simple actions, and con-nected to the steps or transitions of the sequencers.

Status management in conformance with ISA S88 permits configuring of up to 8 separate sequence chains per SFC for special operations, e.g. for statuses such as holding or aborting, for safe state, or for various operating modes.

SFC configuring is supported by conve-nient editing functions as well as pow-erful test and commissioning functions.

SFC type

An SFC type can be multiplied just like a normal function block in the form of invocations which are positioned, parameterized and interconnected in a CFC. The SFC type can therefore be used repeatedly and modified centrally. A change to the SFC type causes all invocations to be automatically modi-fied accordingly. A CPU stop is not required. This saves engineering input, and is particularly advantageous for plants requiring validation.

An SFC type can also be provided with chart connections analogous to the CFC. The sequence of SFC invocations can be accessed and monitored by the operator using the SFC faceplate and the SFC visualization of the operator system. SFC test mode can also be used without limitation for the SFC invoca-tions.

Automatic interconnection of blocks

The function "Generate module driver" automatically generates and positions diagnostics blocks for the input/output components of the S7-400 automation system, the ET 200M, ET 200iS, ET 200S, ET 200X distributed I/O sys-tems, and for PROFIBUS field devices according to the PROFIBUS PA Profile 3.0 and field devices with HART commu-nication. The blocks are interconnected by a wizard on the basis of the symbolic addresses.

Graphics designer and faceplate designer

The project data for engineering of the operator systems are organized using the SIMATIC Manager. All measuring point data relevant to operation and monitoring, such as messages and vari-ables, are already generated during definition of the automation function. A powerful graphics designer is avail-able for the graphic generation of plant displays.

The faceplate designer can be used to generate customer-specific faceplates if required for operation and monitoring of measuring points or plant compo-nents.

F-Tool (S7 F systems)

The F-Tool (S7 F systems) is used to automatically supplement user-defined CFCs by the functions required for fault detection and response when configur-ing fail-safe systems.

PCS 7 PID-Tuner

The PCS 7 PID-Tuner integrated in the CFC determines optimum parameters for PID, PI and P controllers of a loop in defined steps. The transient response of the controllers can be investigated by entering step changes in order to test the controller parameters determined in manual/automatic mode.

DOCPRO

DOCPRO generates plant documenta-tion in accordance with the standards for SIMATIC PCS 7 projects as well as cir-cuit documentation in which special requirements can also be entered.

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EngineeringSIMATIC PDM engineering tool

SIMATIC PDM (Process Device Manager) is a central tool for configuring, param-eterization, commissioning and diag-nostics of intelligent process devices and is integrated in the PCS 7 engineer-ing system. SIMATIC PDM enables you to configure a large number of process devices from Siemens and other ven-dors using one software and with one uniform GUI. With respect to device integration, SIMATIC PDM is the most powerful process device manager avail-able worldwide.

The display of device parameters and functions is uniform for all supported process devices, and independent of their communications interface.

Core functions of SIMATIC PDM are the adjustment, modification, plausibility testing, management, simulation and diagnostics of process devices. In addi-tion, SIMATIC PDM permits online mon-itoring of process values, alarms and status signals of the devices.

SIMATIC PDM can also be used as a stand-alone version on a personal computer or programming device with Windows 95/98 or NT/2000/XP operat-ing system.

GUI

The SIMATIC PDM GUI complies with the VDI/VDE GMA 2187 and IEC 65/349/CD guidelines. Even devices with several hundred parameters can be processed clearly and rapidly. Navigation is possi-ble extremely simply with SIMATIC PDM even in highly complex stations such as remote I/Os up to the connected field devices.

The GUI supports several views:

Hardware project view (integrated in SIMATIC PCS 7)

Process device plant view as tag-based view, also with display of diag-nostics information

Parameter view for parameterization of field devices

Lifelist view for identification/diag-nostics of field devices and their online parameterization

Process device network view for stand-alone application

Communication

SIMATIC PDM supports several commu-nication protocols and components for communication with:

Devices with PROFIBUS DP/PA inter-face

Devices with HART interface

Devices with Modbus interface

Devices with special interface from Siemens

Routing

Every field device which can be parame-terized can be reached throughout the plant with SIMATIC PDM from the cen-tral engineering system via the various bus systems and remote I/Os. It is then possible from a central position to:

Read diagnostics information from the field devices

Modify device settings

Calibrate and adjust field devices

Monitor process values

Generate simulation values in the field device

Modify the field device parameters.

Device integration

SIMATIC PDM supports field devices in line with the PROFIBUS PA profile descriptions provided by PROFIBUS International (PNO), as well as field devices which are described by an Elec-tronic Device Description (EDD) and HART Device Description (HART-DD).

The design and functions of the field devices are described by the Electronic Device Description Language EDDL specified by the PNO. SIMATIC PDM automatically creates its GUI with the corresponding field device information using these descriptions. The HART field devices described by HART-DDL are inte-grated into SIMATIC PDM using the HCF catalog (Hart Communication Founda-tion). HART-DDL is standardized, multi-vendor, and very widely used. Further HART field devices are incorporated into SIMATIC PDM via EDD.

The SIMATIC PDM device catalog cur-rently comprises more than 1,000 field devices from various vendors. Further process devices from Siemens as well as devices from other vendors can be sim-ply integrated into SIMATIC PDM by importing their device descriptions (EDD, GSD).

Parameter view of SIMATIC PDM with curve and online display

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CommunicationIndustrial Ethernet for plant bus and OS-LAN

The SIMATIC PCS 7 communication con-cept is based on proven worldwide stan-dards, and guarantees reliable data transfer between all levels and compo-nents of an I & C plant. Powerful and rugged network components from SIMATIC NET are used for communica-tion. All SIMATIC NET products have been specially developed for industrial applications, and can therefore be opti-

mally used for plants in all sectors. They satisfy highest requirements, and can also be used in areas with extreme envi-ronmental influences (interfering elec-tromagnetic fields, corrosive liquids and atmospheres, explosion hazards, high degree of contamination or mechanical loads).

Plant bus / OS-LAN Industrial Ethernet

Number of stations Up to approx. 1,000

Network size Local network

WAN

Electric: up to approx. 1.5 kmOptic: up to approx. 150 kmWorldwide with TCP/IP

Topology Linear, tree, ring, star, redundant

Fieldbus PROFIBUS DP PROFIBUS PA

Number of stations 32 per segmentMax. 125

32 per segment64 per DP/PA link,max. 125

Network size Electric: up to approx. 10 kmOptic: up to approx. 100 km

Electric: up to approx. 1.9 km

Topology Linear, tree, ring, star, redundant

Linear, tree, star

The buses of the SIMATIC NET range permit trouble-free and uniform com-munication between all system compo-nents: engineering stations, operator systems, automation systems, process I/Os and field components.

Industrial Ethernet is used as the plant bus. The Basic Communication Ethernet integrated as standard is available for small process control systems, and per-mits implementation of the plant bus even without communications proces-sors.

Fast Ethernet technology

State-of-the-art Fast Ethernet technol-ogy is used by SIMATIC PCS 7 for higher demands in medium-sized and large plants.

Fast Ethernet advantages:

High communication speed of 100 Mbit/s

Switching technology

Redundancy using optical rings

The increasing acceptance of Fast Ether-net (100 Mbit/s) is due to its great simi-larity with the well-known Ethernet. The data format and access procedure are identical. Industrial twisted pair (ITP) and fiber-optic (FO) cables as well as existing technology know-how can be applied further. The costs, work and learning overhead are therefore rela-tively small when converting to Fast Ethernet.

Existing plants or plant sections with 10 Mbit/s Ethernet (triaxial cables, OLMs, star couplers) can be incorpo-rated into communication networks with 100 Mbit/s Fast Ethernet simply and cost-effectively using optical switch modules OSM from the SIMATIC NET range. The OSM thus permits step-by-step conversion to the 100 Mbit/s tech-nology.

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Communicationat the field level with PROFIBUS

At the field level, distributed I/Os such as input/output modules, transmitters, drives, valves or operator terminals communicate with the automation sys-tems via a powerful real-time bus sys-tem. This communication features cyclic transmission of process data plus acyclic transfer of alarms, parameters and diagnostics data.

PROFIBUS - which, with its communi-cation protocol, permits fast communi-cation with the distributed I/Os (PROFIBUS DP) as well as the direct con-nection of bus-based, intelligent field devices including power supply accord-ing to IEC 61158 (PROFIBUS PA) - is truly predestined for such tasks.

It is simple, rugged and reliable, and supports online parameterization of the distributed components, communica-tion with HART field devices, as well as redundancy and fail-safe functions. It can be expanded online by new distrib-uted components, and can be used equally well in standard environments or hazardous areas. As a results of these features, it has now become established in all sectors of the production, process and hybrid industries, and has devel-oped into the most successful open fieldbus worldwide. This is confirmed by more than 9 million installed PROFIBUS DP nodes and more than 210,000 installed PROFIBUS PA loads.

SIMATIC PCS 7 has consistently used the advantages of PROFIBUS right from the beginning:

Optimum distributed plant structure: small space requirements, low cabling requirements

Effective engineering through stan-dardization of process signals, diag-nostics and profiles

Shortened commissioning times resulting from loop checks, simple parameterization, and omission of adjustment work

Optimum life cycle management through optimum diagnostics and preventive maintenance

PROFIBUS PA profile

The transmission technology of the PROFIBUS PA profile is tailored to the requirements of the process industry. The standardized communication ser-vices guarantee interoperability between field devices from different vendors, as well as remote parameter-ization of the field devices during runt-ime. Information and power supply are transferred on a two-wire line.

In the case of SIMATIC PCS 7, communi-cation between the automation sys-tems and the field devices is carried out by proxy blocks in the CPU which cover all types of field device. These are con-figured using the engineering system which also generates the configuration data which are loaded during startup into the DP/PA link and the field devices. Parameterization, commissioning and diagnostics are handled by the SIMATIC PDM Process Device Manager integrated in the engineering system.

Advantages of distributed field automa-tion using the PROFIBUS PA profile include low hardware overheads, cost-effective engineering, increased opera-tional reliability and problem-free main-tenance. These advantages are under-lined by the following features:

Modularity and uniformity from sen-sor up to the control level permit new plant concepts

Implementation of intrinsically-safe applications by using the fieldbus in potentially explosive atmospheres

Reduced configuring costs as result of simple, centralized engineering of field devices (PROFIBUS PA and HART with SIMATIC PDM, also cross-vendor)

Simple installation using two-wire line for common power supply and data transmission

Reduced commissioning costs as result of simplified loop check

Low servicing costs thanks to simple wiring and comprehensive diagnos-tics facilities

PROFIBUS DP/PA gateway

The DP/PA link is a very simple gateway which connects the PROFIBUS DP and PROFIBUS PA bus systems together yet decouples the transmission rates. This means that PROFIBUS DP and PROFIBUS PA can be combined together without influencing the PROFIBUS DP performance.

The DP/PA link can be used on PROFIBUS DP standard masters, and permits the design of large plants with extensive addressing volumes and high cycle time requirements.

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Automationwith selected SIMATIC S7-400 components

Changes to configuration during runtime

Functionality for all automation systems

Add new slave/remove slave Add new module/remove module Modify parameters of inserted module

Additional functionality for fault-tolerant automation systems

Modification of memory configuration Modification of CPU parameters Add/remove S7-400 modules

Highlights Flexibility at various availability and safety levels:

Standard systems (S systems), Fault-tolerant systems (H systems), Fail-safe systems (F systems), Fail-safe and fault-tolerant systems (FH systems)

Wide range of automation systems with different CPUs in all performance classes

Complete ordering units for automation systems with CPU, memory card, subrack, power supply and PROFIBUS DP interface; the systems are delivered completely assembled and tested

Changes to the configuration are possible during runtime Complete redundancy of the AS 414 H / AS 417 H automation systems:

Identical application program in both CPUs; simultaneous processing of both CPUs (synchronous)

Bumpless switchover Separate design possible

Selected SIMATIC S7-400 components can be combined together in the auto-mation systems of the SIMATIC PCS 7 process control system. The following SIMATIC S7-400 properties make it extremely suitable as the automation system for SIMATIC PCS 7: modular, fan-free and rugged design, high degree of expansion, single or redun-dant design, comprehensive communi-cation facilities, integral system func-tions, simple connection of central or distributed I/Os.

The available types can be flexibly adapted to different requirements in line with their price/performance ratio. The PROFIBUS DP fieldbus connection is already integrated as standard in all automation systems. If necessary, addi-tional PROFIBUS communications mod-ules can be inserted.

Components

The automation systems are delivered as completely preassembled and tested systems without extra charge, and com-prise:

Subracks with 9 or 18 slots, also sepa-rate for redundant systems

Standard CPU 414-3, 416-2, 416-3 or 417-4 as well as redundant CPU 414-4H or 417-4H

24 V DC or 120/230 V AC power supply

Main memory from 768 KB to 20 MB

Memory card with 1 to 8 MB RAM

Runtime license for the PCS 7 library

Interface to Industrial Ethernet

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AutomationFault-tolerant automation systems

The objective for using fault-tolerant automation systems is the reduction in the risk of production failures. The higher investment costs for fault-toler-ant automation systems are often negli-gible compared to the costs resulting from production failures. The higher the costs resulting from a production stand-still, the more applicable the use of a fault-tolerant system.

The SIMATIC PCS 7 AS 414 H and AS 417 H are two fault-tolerant auto-mation systems based on the 1-out-of-2 principle which switch over to the standby system in the event of a fault. Such an automation system is a com-pletely redundant design to ensure that it always remains available. This means that all major components such as CPU, power supply and hardware for cou-pling the two CPUs are present twice. The additional components which are to be present twice for availability rea-sons must be selected individually depending on the respective automa-tion requirements.

The two partial systems of a redundant automation system are electrically iso-lated from one another. This increases the system stability with respect to EMC interferences. A redundant automation system can be installed in one or two subracks. Automation systems in two subracks are used e.g. if both partial AS systems have to be installed sepa-rated from one another by a fire-resis-tant wall. Appropriate complete units are available for every type of applica-tion. Mixed operation of redundant and single systems is also possible.

Typical quantity breakdowns for SIMATIC PCS 7 automation systems

AS 414-3 AS 416-3 AS 417-4 AS 414 H AS 417 H

Motors 30 100 140 30 112

Valves 40 150 200 40 160

Fixed setpoint controls 40 60 80 40 64

Analog-value measurements 50 120 150 50 120

Sequencers with 9 steps each 10 40 50 10 40

Dosing 5 20 25 5 24

or:

Binary inputs Binary outputs

180130

650450

880620

180130

704496

Analog inputs Analog outputs

9540

20060

25580

9540

20864

Note:The values listed here are not maximum AS-specific values for the respective item, they rep-resent a typical distribution of the total AS capacity available for mixed operation of all items of an associated block. Individual calculation of these quantity breakdowns is possible using the configurator software present on the current CD-ROM of the interactive catalog CA 01.

28

AutomationFail-safe automation systems

Fail-safe automation systems (F/FH sys-tems) are used for critical applications where a fault can result in danger to persons, plant damage or environmen-tal pollution. The systems detect pro-cess faults as well as their own internal faults, and automatically set the plant to a safe state in the event of a fault.

The fail-safe automation systems (F/FH systems) based on the AS 414 H and AS 417 H automation systems com-bine standard process automation with safety technology in one single system. They are TV-certified, and comply with the safety requirement classes SIL 1 to SIL 3 according to IEC 61508, require-ment classes AK 1 to AK 6 according to DIN V 19250/DIN V VDE 0801, and cat-egories 2 to 4 according to EN 954-1.

Using redundant, diversity command processing, the safety function config-ured by the user in the CFC is processed twice in different parts of a CPU. Any faults are detected when the results are subsequently compared.

Fail-safe automation systems can have a single-channel design (F systems with one CPU) or a redundant design (FH sys-tems).

The redundancy of the FH systems is not relevant to fail-safety. It is not used for fault detection, it only serves to increase the availability of the fail-safe automa-tion systems.

Safety functions

The safety functions of the F/FH systems are present in the F program of the CPU and in the fail-safe ET 200 I/O modules. The PROFIsafe profile is used for the safety-oriented PROFIBUS DP communi-cation between CPU and process I/Os. Using this additional safety message, F/FH systems and F I/O modules can rec-ognize falsification of data and can ini-tiate appropriate fault reactions.

Standard modules can be used in F/FH systems in addition to fail-safe I/O modules. A plant containing safety-oriented and standard areas can there-fore be automated using the same sys-tem and configured using uniform stan-dard tools.

The F-Tool engineering tool (S7 F sys-tems) integrated in the SIMATIC Man-ager enables parameterization of the CPU and the F signal modules as well as generation of fail-safe applications in the CFC based on predefined, TV-approved blocks. The fail-safe blocks are extremely versatile and detect program-ming errors such as division by zero or out-of-range values. It is unnecessary for the user to carry out diversity pro-gramming for fault detection and response. Functions such as the com-parison of F programs, the detection of changes in F program using a check-sum, or access privileges using pass-words provide further support and guar-antee simple, safe operation.

The application program may contain fail-safe programs (F) and non-fail-safe standard programs (S), where strict sep-aration of F and S program components together with data exchange via special conversion blocks prevent mutual influ-encing. An error detected in the F pro-gram does not result in stopping of the CPU, it leads to triggering of config-urable shutdown logic which sets either the associated F sequence group or the complete F program to a safe state. The standard program is not influenced, and continues further. Following elimina-tion of the fault, the F program can be started again with the CPU still running.

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Fail-safe I/O modules

The special safety functions of the F sys-tems are matched to the fail-safe mod-ules of the ET 200M and ET 200S distrib-uted I/O systems which also support plant safety in the event of a CPU fail-ure. The F signal modules of these I/O systems (digital inputs/outputs, analog inputs) can be used for diagnostics of internal and external faults, have a redundant design because of the safety requirements, and comply with the requirements up to SIL 3 (IEC 61508) or AK 6 (VDE 0801).

The input modules function with 2-out-of-3 (F-AI module only) or 2-out-of-2 channel evaluation. A safety reaction is triggered immediately if differences occur. If one output is faulty, the digital output modules permit safe shutdown via a second path.

The PM-E F power module of the ET 200S serves to transfer standard ET 200S modules in the same subrack to a safe state.

Fail-safe ET 200M I/O modules:

Digital input DI 24 x DC 24 V

Digital input DI 8 x NAMUR [EEx ib]

Digital output DO10 x DC 24 V/2 A

Analog input AI 6 x 13 bit

Fail-safe ET 200S I/O modules:

Digital input F-DI 4/8 channels PROFIsafe DC 24 V

Digital output F-DO 4 channels PROFIsafe DC 24 V/2 A

Power module PM-E F DC 24 V PROFIsafe; with diagnostics

HighlightsUse of standard SIMATIC S7 components for fail-safe applications Safety levels SIL 3, AK 6 can be achieved with just one CPU Safe communication via PROFIBUS with PROFIsafe Safe communication via Industrial Ethernet plant bus Standard and fail-safe functions can be mixed in the same automation system Standard and fail-safe I/Os can be operated on the same PROFIBUS DP lineConfiguring of standard and fail-safe functions using one CFC engineering tool F-Tool (S7 F systems) provides support for TV acceptance:

Separation of standard and fail-safe functions Checksum by means of application program Comparison function Access protection to fail-safe functions through password

Reduction of engineering costs through simple data exchange between standard and fail-safe systems

Minimum acquaintance requirements since same tools used for standard and fail-safe systems

Simple fault analysis since same operation and monitoring for standard and fail-safe systems (message sequence)

Low hardware costs through mixed configurations: optimum for small applications

Minimization of life cycle costs

30

Process I/OsCentral and distributed process I/Os

The SIMATIC PCS 7 process control sys-tem offers many facilities for connec-tion of I/O devices and for the recording and output of process signals via sen-sors and actuators:

Analog and digital input/output mod-ules of the SIMATIC S7-400 used cen-trally in the automation system

ET 200M, ET 200S, ET 200iS, ET 200X distributed I/O systems (remote I/Os) connected to the automation system via PROFIBUS DP with a comprehen-sive range of cost-effective sig-nal/function modules

Direct AS interfacing of intelligent, distributed field/process devices and operator terminals via PROFIBUS DP/PA (also redundant or in potentially explosive atmospheres of zone 0, 1 or 2)

SIMATIC S7-400 signal modules used centrally in the automation system are primarily used for small applications or plants with a small distributed struc-ture.

Features such as

modularity and uniformity, flexible adaptation to the plant struc-

ture, small cabling and engineering

requirements, low commissioning, servicing and life

cycle costs, as well as the large technical bandwidth

are decisive that distributed process I/Os are mainly used nowadays: ET 200 remote I/Os in conjunction with classical field/process devices and HART field devices or intelligent field/process devices directly on the PROFIBUS.

Possible online modifications for I/Os

ET 200M Add/remove ET 200M stations Add/remove new input/output modules Parameterization of input/output modules as well as HART field

devices connected to HART modules via SIMATIC PDM

ET 200S, ET 200iS, ET 200X

Add/remove ET 200S/iS/X stations ET 200iS: parameterization of input/output modules as well as HART

field devices connected to HART modules via SIMATIC PDM

PROFIBUS DP, PROFIBUS PA

Add/remove PROFIBUS DP stations Add/remove DP/PA links and field devices Parameterization of field devices using SIMATIC PDM

SIMATIC ET 200M

Within the ET 200 range, the ET 200M is the main distributed I/O system for pro-cess applications with SIMATIC PCS 7. It supports online modifications (design with active bus modules) and possesses a wide range of S7-300 I/O modules, also with special I & C functions:

Standard S7-300 signal modules

Redundant S7-300 signal modules (DI 16 x DC 24 V, with