Product Brief February 2003

SIMATIC PCS 7 Process Control System

SIMATIC 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 complete process sequence, starting with
input logistics, covering production or
primary processes as well as downstream (secondary) processes, up to
output logistics. This uniform automation technology also refers to the optimization of all company operations,
covering the enterprise resource planning (ERP) level, the management execution 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, communication and configuration offer an open
platform for modern, future-oriented
and economical automation solutions
in all sectors of the process industry,
production industry and hybrid industry
(mixture of continuous/batch processes
and discrete production, e.g. in the
glass or pharmaceuticals industries).
Whereas secondary and logistics processes are frequently automated by
motion control and SIMATIC components in the process and hybrid industries, 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 engineering tasks, it can also automate secondary processes (e.g. filling, packaging) or input/output logistics (e.g.
material flows, storage) for a production location.
By linking the automation level to the
IT world, the process data become available throughout the company for the
evaluation, planning, coordination and
optimization of operational sequences,
production processes and commercial
processes. Also taken into account are
the requirements of scattered, globally
active companies.

Its pioneering design, modular and

open architecture based on state-ofthe-art SIMATIC technology, consistent
use of industrial standards and the I & C
functionalities paired with high performance mean that the SIMATIC PCS 7
process control system can achieve
cost-effective implementation and economical operation of I & C plants during
all phases of their life and with consideration of all aspects: covering planning,
engineering, commission, training,
operation, maintenance, servicing,
expansion and renovation. In the process, SIMATIC PCS 7 unifies high performance and reliability, simple and safe
operation, and maximum convenience.
You particularly profit from Totally Integrated Automation and the SIMATIC
PCS 7 process control system through
the calculable development, implementation and life cycle costs, the minimization of engineering requirements, the
facilities for process optimization, the
adaptability when requirements
change, and the advantages resulting
from the use of standard SIMATIC components.
Horizontal integration
Horizontal integration means that uniform and standard hardware/software
components from the SIMATIC range
are used for the complete production
process covering input logistics, primary and secondary processes, up to
output logistics. The SIMATIC PCS 7
basic components are therefore
HMI systems (WinCC), automation systems, communication networks, distributed I/Os and engineering tools from
the SIMATIC modular system which can
be supplemented specific to the solution 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.

Horizontal and vertical integration with SIMATIC PCS 7

This results in advantages for you which

are otherwise only typical to those provided by the large manufacturing quantities 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 communication covering the ERP, MES, control 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 companywide information networks. This permits modularity and standardization for
complete partial processes, associated
with a considerable increase in production 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.

SIMATIC PCS 7
The process control system for Totally Integrated Automation

Integration of field systems

The SIMATIC PCS 7 process control system can be seamlessly incorporated

into the company-wide information
network using interfaces based on
international industrial standards for
data exchange such as Ethernet, TCP/IP,
OPC or @aGlance. 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 integrated in this manner into the company-wide information network.
The OPC interface present in the
SIMATIC PCS 7 operator stations as well
as @PCS 7 offer further facilities for simple 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 corresponding Web@aGlance/IT client mean that
processes can be globally monitored
online via intranet or Internet. In addition to this, host information systems
possessing an @aGlance interface can
be connected to SIMATIC PCS 7 using
@PCS 7.

Integration of field systems

SIMATIC PCS 7 is optimized for integration of distributed field systems into the
process control system, and is based on
PROFIBUS technology. PROFIBUS is simple, 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 distributed I/O station, or with state-of-the-art,
intelligent field devices.
The intelligent field devices are connected 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.

PROFIBUS can also be used to integrate

variable-speed drives, motor management components and electric actuators into SIMATIC PCS 7. It is additionally
possible to integrate local operator terminals 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 connection 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 automation components on the EIB (European 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 parameterize, commission, diagnose or maintain automation components and field
devices with a PROFIBUS or HART interface throughout the plant. The international 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 combination 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 increasingly flexible production plants, and the
necessity to increase productivity.
Against the background of permanently
increasing complexity, especially resulting from the fusing together of automation and information technologies, system 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 prepared for future demands.
High performance and exceptional system 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 visualization
Powerful, fast and uniform engineering 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 longterm stability. This means that it is possible 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 established industrial standards such as IEC,
XML, PROFIBUS, Ethernet, TCP/IP, OPC,
@aGlance, ISA S88 or S95, just to mention a few.
SIMATIC PCS 7's openness covers all levels and applies to automation systems
and process I/Os just as to operator and
engineering systems, industrial communication networks or the SIMATIC IT
framework as the link to the information, coordination and planning tools
for company management.
However, the openness is not only characterized by the system architecture,
horizontal/vertical integration and communication, but also by the programming 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.

Flexibility and scaleability

from small laboratory system
up to distributed client/server solution

As a result of the modular architecture

based on selected hardware and software components from the standard
SIMATIC range, SIMATIC PCS 7 can be
flexibly adapted during plant configuring to various customer demands and
plant sizes, and later expanded or
reconfigured without problem should
subsequent expansion of the capacities
or technological qualifications necessitate this. SIMATIC PCS 7 therefore covers 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 measuring 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 measuring 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

specifically expand the functionalities

operating components: from singleuser starter system up to distributed

multi-user system,
select the engineering system according to the scaling of process objects,
configure communication networks
and determine network components,

of the operator stations by adding

various hardware and software modules, 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

Redundancy at all levels

SIMATIC PCS 7 offers a comprehensive

redundancy concept extending over all
I & C levels. The client/server architecture of the process control system permits 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 configuration is used as standard for clientserver and server-server communication. This avoids communication failures 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 redundant 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 system 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 availability demands (two CP communications processors per AS, OS and ES). In
this manner, double faults such as an
OSM failure on ring 1 with a simultaneous 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 distributed process I/Os can be operated

on each partial AS via the internal
PROFIBUS DP interface or with the assistance of further communications processors.
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 connect 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. redundant selection of input/output modules
for fail-safe and standard applications is
possible.

Interfacing to the IT world

with SIMATIC IT and @PCS 7

Advantages when using SIMATIC IT

For plant owners, information technology (IT), process data management and
production planning have become
important elements for reducing costs
and optimizing processes. Global competition means that companies distributed over several locations must be able
to manufacture customer-specific product ranges more rationally and flexibly,
and introduce them increasingly rapidly
on the market.
The obligation for consolidation, optimization and rationalization, as well as
the extension of regulatory pressure by
the manufacturer on the supplier,
means that the fusing together of process 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 management 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 different manufacturing procedures at
various locations, is a complex task.
SIMATIC IT makes these processes transparent, 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 management and planning levels. SIMATIC
IT Framework is cross-industry integration and coordination platform for operating processes, data and functionalities and possesses the facility for plant
and production modeling in addition to
the basic functions for internal
sequence control, user administration
etc.

SIMATIC IT Framework contains the following functions: Services, Server,

Adapter, Production Modeler, Workbench and Application Developer.
SIMATIC IT Framework permits integration of heterogeneous applications as
well as easier handling and control of
complex production processes. Processes and communication are effectively 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 components, but also existing and cross-vendor IT products. The SIMATIC PCS 7 process 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 branchindependent and branch-specific IT
functionalities defined in line with
ISA S95. Examples of SIMATIC IT components include Detailed Production
Scheduler, Historian, Maintegrity, Material Manager, Production Order Manager or Unilab.
In addition to the SIMATIC IT components, largely sector-independent
SIMATIC IT suite libraries provide useful
basic units and procedures which facilitate the implementation of the various
applications. In addition to this, functionalities tailored to special sectors are
available in industrial suite libraries.

Company-wide availability of process

data with @PCS 7
@PCS 7 a simple and cost-effective facility 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 systems 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 corresponding license is simply activated in the
operator station.
The integration of @aGlance/IT means
that SIMATIC PCS 7 is able to communicate with a wide range of software
products for the operational management and company management levels. @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 provides the @aGlance product range with
a Plug&Play character without neglecting security aspects. Access protection
is achieved using a powerful administration tool.
A further advantage of the open architecture of this client/server technology
is free selection of the operating systems or applications on the server or
client side of the @aGlance/IT software
package. This also means that the
implementation of @aGlance is independent of any existing hardware and
software architecture. Therefore there
are no dependencies on certain suppliers, on systems already existing in the
company, or systems still to be implemented. 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 Internet/intranet
Reading and writing of OS data
Communication with @aGlance/IT
client applications, e.g. the
InfoPlus.21 information management system
Communication with server applications of the @aGlance/IT server addons

@PCS 7 offers the following advantages:

@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 technology; @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 company management levels; based on
client/server technology
It is additionally possible to develop
own client/server applications based
on the @aGlance product range.

Automation of batch processes

with SIMATIC BATCH

The SIMATIC PCS 7 process control system always offers the appropriate solution for low-cost, effective implementation of batch processes. Automation of
simple batch processes with parameterizable sequential controls is carried out
using the SFC and CFC tools included in
the engineering system.
SIMATIC BATCH is the convenient solution for more complex tasks with recipecontrolled operation. This permits simple, flexible processing of complex tasks
with changing control sequences.

Highlights
Modular 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 runtime
Hierarchical 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 modern 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 formulas, user administration with access protection and electronic signature

10

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.

Integration in SIMATIC PCS 7

SIMATIC BATCH is fully integrated in
SIMATIC PCS 7. The plant data can be
completely configured using the engineering system. The engineering system passes on all data required for
recipe creation to the batch server,
meaning that recipe processing is possible separate from the engineering
system. Changes to the configuration
which are made on the engineering system 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 common basic hardware. The PCS 7 operator 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 operator 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 standard faceplates for operation and monitoring of units and technical functions.

SFC invocations derived from a particular type of SFC are generally used as the
interface to the subordinate automation level. The properties of the SFC
type such as modes of operation, setpoints/actual values, invocation parameters, times etc. can be defined using a
features dialog. However, it is also possible to use special batch interface
blocks for communication with the processing programs in the automation
systems, e.g. for plant expansions or
when connecting non-SIMATIC systems.
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 possible to manage all data relevant to
SIMATIC BATCH by means of a GUI. Convenient 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

11

Automation of batch processes

with SIMATIC BATCH

Batch Report
Batch Report is used to generate recipe
and batch reports which can be displayed 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 production 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 accessible 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

Recipe editor
The recipe editor is a convenient tool for
simple, intuitive creation and modification of master recipes and library operations, and possesses a GUI, editing functions typical to Microsoft Windows for
single and group objects, and a structural 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.

12

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 production of master recipes and library
operations

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 controlling a part of the process on a unit
Recipe operation/function for the process engineering task/function on a
technical unit

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 engineering requirements, and provides
substantial advantages for validation.
Various strategies are available for the
assignment of units, permitting optimum 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 carried 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. Conflicts 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 separated from one another. Various master
recipes can be created by linking several
formulas using a recipe procedure. This
enables central modification of procedures. The formula structure is determined 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 operations can be inserted as a reference in
recipe procedures and can thus be modified centrally. This reduces the requirements 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 modifications.
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 customerspecific 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 increasing. 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 functions:
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 individual 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 manufacturer 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 monitoring

with the SIMATIC PCS 7 operator systems

The operator system is the humanmachine interface of the SIMATIC PCS 7

process control system, and thus represents the window and door to the process for the user. The operator system is
extremely variable, and can be flexibly
adapted to different plant sizes and customer requirements.
The basis for this are the perfectly
matched operator stations for singleuser systems and multi-user systems
with client/server architecture.

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 applications
Online 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)

14

Operator stations
All operator stations are based on modern PC technology with graded performances optimized for use as OS single
station, OS client or OS server, combined 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 environments just as in offices. OS single stations 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.

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 processor or
via a simple LAN card
(Basic Communication Ethernet for
communication with max. 8 automation 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 provided 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 redundant design (hot standby) if increased
availability demands exist. Important
applications of the OS server are monitored for software faults using a health
check, resulting in switching over of the
redundancy if necessary. Synchronization of the redundant OS servers is carried 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 several OS servers/pairs of servers. In addition to scaleability, the advantage of
distributed systems is the decoupling of
plant components, resulting in
increased availability.

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

32

Number of measuring points

Per OS server
Per multi-user system

Approx. 5,000
Approx. 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

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

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 process 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.

15

Operation and monitoring

with the SIMATIC PCS 7 operator systems

Engineering
Engineering of the SIMATIC PCS 7 process control system is concentrated as
standard in a separate engineering system. In the single-user systems for small
plants, engineering and operator functionalities can be combined in one station.
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 interfering with online operation. A central dialog controls this procedure, and ensures
that the sequence is correct.

GUI for OS process control with movable windows

High-performance archive system

and central archive server
A high-performance archive system
based on Microsoft SQL server technology and with online configuration facilities records process values and messages 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 preferably redundant can be additionally provided 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 performance, yet are still simple and intuitive
to use.

16

Often small aspects have an advantageous effect on the total performance

of an operator system:
Extended status displays: status or
analog values can be combined with
alarm information using simple configuring without the application of
scripts. Such extended status and
analog-value displays reduce the system loading and improve display
selection times.
Optimized communication between
operator system and automation system: the response cycle of the automation 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 message only takes place following previous acknowledgment in the operator
system.

GUI
The predefined GUI of the operator system complies with all features typical to
a control system. It is multilingual,
clearly structured, ergonomic and
understandable. The operator can survey the process extremely easily, and
rapidly navigate between different
plant views. A picture tree manager provides support, organizing the picture
hierarchy according to user requirements, 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 different 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

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 displays 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. Additional configuring overhead is unnecessary. In an overview display, it is possible 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 handling of messages in the case of larger
quantity breakdowns becomes clearer,
and important messages can be separated more easily from less important
ones.
Current messages are signalled by common displays representing views of
message/alarm lists predefined according to message groups.
The last message which has arrived
the one with the highest priority if priorities are assigned is displayed at the
top edge of the standard view. A predefined 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 display).
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 connected via API. It corresponds to the validation 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 privileges 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 subordinate systems connected to the plant
bus. A graphic plant configuration display shows the monitored bus stations
with their respective status.
Time synchronization
Within the SIMATIC PCS 7 process control 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 different time zones, e.g. pipelines.
Script languages
Visual Basic and C can be used as script
languages for user-specific programming of OS applications.

17

System-wide engineering
with 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 system. It features powerful PC technology
which can be used equally well in an
office or industrial environment, and,
together with the Windows 2000 operating system, provides an optimum
engineering platform. Increased configuring convenience is provided by
expansion of the working area by connecting up to four process monitors via
a special multi-VGA graphics card. The
system software of the engineering system 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.

18

The engineering system has tools optimally matched to one another for system-wide and project-oriented engineering:
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 terminology 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 incorporated into the process sequences and
graphically interconnected. This can
also be carried out easily and rapidly by
technologists without programming
knowledge. When interconnecting display 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 engineering 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 procedure 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 components.
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 measuring points (process object view)
Multi-project engineering
Branch & merge
Extended renaming of objects
Version cross-checker
Import/export wizard
SFC type

SIMATIC Manager
The SIMATIC Manager is simultaneously
the integration platform for the engineering 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 configuring the automation systems, process 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 systems, bus components or process I/Os
Plant view for hierarchical structuring
of the plant
Process object view as central development environment for all aspects
of measuring points/process objects
Plant view (plant hierarchy)
The plant view is used to divide and display a project according to technological 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 hierarchy. Furthermore, this is the basis for
the plant-oriented identification of process objects.
Overview displays for units can also be
generated automatically, and permit
positioning and interconnection of all
operator-accessible and monitored
CFC blocks

Highlights
Central 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 engineering with branch & merge
Technology-based configuring without special programming knowledge
Hierarchical structure of functions divided according to plants, units, technical equipment
Hardware-independent engineering: AS assignment and I/O modules can be
subsequently selected
Expandable using sector-specific add-ons via standard data exchange interfaces
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 separate 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 invocations
Import/export wizard for bulk engineering (configuring of bulk data)
Numerous configuring steps automatically controlled by the system (autoengineering)
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

19

System-wide engineering
with the central engineering system

Multi-project engineering
Multi-project engineering permits division of a comprehensive project into
several subprojects according to technological aspects in order to subsequently edit them in parallel by several
teams. To achieve this, a host "Multiproject" is defined in the SIMATIC Manager. 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 multiproject are all saved on a central server,
and sent to a local engineering system
for editing. The engineering performance is then not impaired by network
access.

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

Process object view

The process object view of the SIMATIC
Manager permits a universal view of the
measuring point. It shows the technological 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 measured-value archives).
All objects in the marked hierarchy
branch are displayed in the table and
can also be directly edited there.

20

Configuring in the process object view

is very appropriate to the process engineer's way of working oriented according 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 preconfigured types of measuring point,
and permits users to incorporate their
own types.

Branch & Merge

Branch & Merge is provided for multiproject 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 original object are overwritten during
Branch & Merge. Interconnections
which are not specific to a project, typically e.g. for interlocking, become text
interconnections when branched.
When merging, these text interconnections including self-entered can be
closed by pressing a key.

Editing of mass data with

import/export wizard

Efficient mass data editing using the

import/export wizard
The import/export wizard is a tool for
engineering large plants with repeatedly 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 generation of measuring points. Existing PCS 7
projects can be both exported and reimported.

The import/export wizard offers the following 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 hierarchy
Charts of the individual measuring
points
Drastically reduced time requirements, and avoidance of errors as
result of automatic/reproducible
generation
Automatic derivation of the OS display hierarchy, automatic interconnection of blocks and positioning in
displays
Significant time and cost savings
Commissioning of individual measuring 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 operations associated with visualization (display objects or variables in archives and
scripts) are modified accordingly. This
function has an enormous rationalization potential which is particularly significant for plants with repeated structures 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 subsequently renamed, all internal interconnections 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, predefined blocks can be positioned on
CNCs, parameterized and interconnected.
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, faceplates and symbols organized in I & C
libraries are the basic elements for the
graphic configuring of automation solutions. Use of these library elements
makes a significant contribution to minimization of engineering requirements
and project costs.
The comprehensive range of blocks
includes simple logic and driver blocks,
technological blocks with integral operation 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 evaluation of process value status).

21

System-wide engineering
with the central engineering system

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 systems, and for PROFIBUS field devices
according to the PROFIBUS PA Profile
3.0 and field devices with HART communication. The blocks are interconnected
by a wizard on the basis of the symbolic
addresses.

Sequential function chart (SFC)

SFC can be used for graphic configuring
of sequential controls for batch production. Each SFC has inputs and outputs
for controlling and for status information. If necessary, an SFC can be directly
position and interconnected in the CFC.
The desired CFC block connections are
selected using simple actions, and connected 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 convenient editing functions as well as powerful test and commissioning functions.

22

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 modified 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 invocations.

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 variables, are already generated during
definition of the automation function.
A powerful graphics designer is available 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 components.
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 configuring 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 documentation in accordance with the standards
for SIMATIC PCS 7 projects as well as circuit documentation in which special
requirements can also be entered.

Engineering
SIMATIC PDM engineering tool

SIMATIC PDM (Process Device Manager)

is a central tool for configuring, parameterization, commissioning and diagnostics of intelligent process devices
and is integrated in the PCS 7 engineering system. SIMATIC PDM enables you
to configure a large number of process
devices from Siemens and other vendors using one software and with one
uniform GUI. With respect to device
integration, SIMATIC PDM is the most
powerful process device manager available 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 addition, SIMATIC PDM permits online monitoring 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 operating 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 possible 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 tagbased view, also with display of diagnostics information
Parameter view for parameterization
of field devices
Lifelist view for identification/diagnostics of field devices and their
online parameterization
Process device network view for
stand-alone application

Parameter view of SIMATIC PDM with curve and online display

Communication
SIMATIC PDM supports several communication protocols and components for
communication with:
Devices with PROFIBUS DP/PA interface
Devices with HART interface
Devices with Modbus interface
Devices with special interface from
Siemens
Routing
Every field device which can be parameterized can be reached throughout the
plant with SIMATIC PDM from the central 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 Electronic 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 integrated into SIMATIC PDM using the HCF
catalog (Hart Communication Foundation). HART-DDL is standardized, multivendor, and very widely used. Further
HART field devices are incorporated into
SIMATIC PDM via EDD.
The SIMATIC PDM device catalog currently comprises more than 1,000 field
devices from various vendors. Further
process devices from Siemens as well as
devices from other vendors can be simply integrated into SIMATIC PDM by
importing their device descriptions
(EDD, GSD).

23

Communication
Industrial Ethernet for plant bus and OS-LAN

The buses of the SIMATIC NET range

permit trouble-free and uniform communication between all system components: 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 permits implementation of the plant bus
even without communications processors.

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 km

Optic: up to approx. 150 km
Worldwide with TCP/IP

Topology

Linear, tree, ring, star, redundant

Fieldbus

PROFIBUS DP

PROFIBUS PA

Number of stations

32 per segment
Max. 125

32 per segment
64 per DP/PA link,
max. 125

Network size

Electric:
up to approx. 10 km
Optic:
up to approx. 100 km

Electric:
up to approx. 1.9 km

Topology

Linear, tree, ring, star,

redundant

Linear, tree, star

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

24

mally used for plants in all sectors. They

satisfy highest requirements, and can
also be used in areas with extreme environmental influences (interfering electromagnetic fields, corrosive liquids and
atmospheres, explosion hazards, high
degree of contamination or mechanical
loads).

Fast Ethernet technology

State-of-the-art Fast Ethernet technology 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 Ethernet (100 Mbit/s) is due to its great similarity 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 relatively small when converting to Fast
Ethernet.
Existing plants or plant sections with
10 Mbit/s Ethernet (triaxial cables,
OLMs, star couplers) can be incorporated 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-bystep conversion to the 100 Mbit/s technology.

Communication
at 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 systems via a powerful real-time bus system. This communication features
cyclic transmission of process data plus
acyclic transfer of alarms, parameters
and diagnostics data.
PROFIBUS - which, with its communication protocol, permits fast communication with the distributed I/Os
(PROFIBUS DP) as well as the direct connection of bus-based, intelligent field
devices including power supply according 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, communication with HART field devices, as well as
redundancy and fail-safe functions. It
can be expanded online by new distributed 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 developed 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 standardization of process signals, diagnostics 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 services guarantee interoperability
between field devices from different
vendors, as well as remote parameterization of the field devices during runtime. Information and power supply are
transferred on a two-wire line.
In the case of SIMATIC PCS 7, communication between the automation systems and the field devices is carried out
by proxy blocks in the CPU which cover
all types of field device. These are configured 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 automation using the PROFIBUS PA profile
include low hardware overheads, costeffective engineering, increased operational reliability and problem-free maintenance. These advantages are underlined by the following features:
Modularity and uniformity from sensor 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 diagnostics 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.

25

Automation
with selected SIMATIC S7-400 components

Selected SIMATIC S7-400 components

can be combined together in the automation 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 redundant design, comprehensive communication facilities, integral system functions, 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, additional PROFIBUS communications modules can be inserted.

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

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 faulttolerant automation systems

Modification of memory configuration

Modification of CPU parameters
Add/remove S7-400 modules

26

Components
The automation systems are delivered
as completely preassembled and tested
systems without extra charge, and comprise:
Subracks with 9 or 18 slots, also separate 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

Automation
Fault-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-tolerant automation systems are often negligible compared to the costs resulting
from production failures. The higher the
costs resulting from a production standstill, 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 automation 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 completely redundant design to ensure that
it always remains available. This means
that all major components such as CPU,
power supply and hardware for coupling the two CPUs are present twice.
The additional components which are
to be present twice for availability reasons must be selected individually
depending on the respective automation requirements.
The two partial systems of a redundant
automation system are electrically isolated 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 separated from one another by a fire-resistant wall. Appropriate complete units
are available for every type of application. 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

20

25

24

Binary inputs
Binary outputs

180
130

650
450

880
620

180
130

704
496

Analog inputs
Analog outputs

95
40

200
60

255
80

95
40

208
64

or:

Note:
The values listed here are not maximum AS-specific values for the respective item, they represent 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.

27

Automation
Fail-safe automation systems

Fail-safe automation systems (F/FH systems) are used for critical applications
where a fault can result in danger to
persons, plant damage or environmental pollution. The systems detect process 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 combine 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, requirement classes AK 1 to AK 6 according to
DIN V 19250/DIN V VDE 0801, and categories 2 to 4 according to EN 954-1.
Using redundant, diversity command
processing, the safety function configured 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.

28

Fail-safe automation systems can have

a single-channel design (F systems with
one CPU) or a redundant design (FH systems).
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 automation 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 communication between CPU and process I/Os.
Using this additional safety message,
F/FH systems and F I/O modules can recognize falsification of data and can initiate appropriate fault reactions.
Standard modules can be used in
F/FH systems in addition to fail-safe
I/O modules. A plant containing safetyoriented and standard areas can therefore be automated using the same system and configured using uniform standard tools.

The F-Tool engineering tool (S7 F systems) integrated in the SIMATIC Manager enables parameterization of the
CPU and the F signal modules as well as
generation of fail-safe applications in
the CFC based on predefined, TVapproved blocks. The fail-safe blocks are
extremely versatile and detect programming errors such as division by zero or
out-of-range values. It is unnecessary
for the user to carry out diversity programming for fault detection and
response. Functions such as the comparison of F programs, the detection of
changes in F program using a checksum, or access privileges using passwords provide further support and guarantee simple, safe operation.
The application program may contain
fail-safe programs (F) and non-fail-safe
standard programs (S), where strict separation of F and S program components
together with data exchange via special
conversion blocks prevent mutual influencing. An error detected in the F program does not result in stopping of the
CPU, it leads to triggering of configurable 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 elimination of the fault, the F program can be
started again with the CPU still running.

Highlights
Use 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 line
Configuring 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

Fail-safe I/O modules

The special safety functions of the F systems are matched to the fail-safe modules of the ET 200M and ET 200S distributed I/O systems which also support
plant safety in the event of a CPU failure. 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).

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

The input modules function with 2-outof-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

29

Process I/Os
Central and distributed process I/Os

The SIMATIC PCS 7 process control system offers many facilities for connection of I/O devices and for the recording
and output of process signals via sensors and actuators:
Analog and digital input/output modules of the SIMATIC S7-400 used centrally 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 comprehensive range of cost-effective signal/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 structure.
Features such as
modularity and uniformity,
flexible adaptation to the plant structure,
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

30

SIMATIC ET 200M
Within the ET 200 range, the ET 200M is
the main distributed I/O system for process 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 diagnostics;
DO 32 x DC 24 V/0.5 A; AI 8 x 12 bit)
I & C I/O modules with increased
diagnostics capability
Ex input/output models
Closed-loop control and counter
modules
HART modules
Fail-safe modules
Up to 8 I/O modules can be connected
to one interface module. The I & C
I/O modules with diagnostics capability
also offer channel-based fault display,
internal module monitoring, monitoring of unsteady sensor signals, pulse
stretching, diagnostics alarm, holding
of last value or application of substitute
value on failure of CPU or load power
supply. They detect open-circuits, shortcircuits, load voltage failures as well as
module-internal faults, and automatically signal these events to the operator
station.
The ET 200M may also have a redundant design, and permits transmission
rates up to 12 Mbit/s. It can be used in
standard environments or in Ex zone 2.
The actuators/sensors can be located in
Ex zone 1 when using appropriate Ex
input/output modules. Hot swapping of
I/O modules is permissible in Ex zone 2
with appropriate permission (e.g. fire
certificate).

SIMATIC ET 200iS
The intrinsically-safe ET 200iS distributed I/O system with degree of protection IP 30 can be installed directly in
Ex zone 1 or 2 (EEx de ib [ia/ib] IIC T4),
the sensors/actuators also in zone 0 if
required. The ET 200iS is connected
using PROFIBUS DP. Using an isolating
transformer, this can also be introduced
as an intrinsically-safe bus into
Ex zone 1.
The ET 200iS has a bit-modular design:
flameproof power supply, interface
module for PROFIBUS DP, and up to
32 electronics modules. HART capability
is just as natural as hot swapping of individual modules without fire certificate.
Transmission rates up to 1.5 Mbit/s are
possible.
Incorporation into SIMATIC PCS 7 comprises CFC driver blocks, system diagnostics and time stamping. The
ET 200iS is easy and convenient to start.
Configuring of the electronics modules
and parameterization of the field
devices are carried out in the engineering system using SIMATIC PDM.
The range of electronics modules
includes a NAMUR digital input module,
a digital output module, and analog
input/output modules with and without
HART.
SIMATIC ET 200S
The ET 200S is a bit-modular distributed
I/O system with degree of protection
IP 20. It is approved for operation in
Ex zone 2, and has a design with
independent wiring, i.e. terminal
modules mounted as a carrier system
on a profile rail can be prewired and
tested without I/O modules. The
I/O modules are simply plugged on
later. The design supports hot swapping
of modules during runtime with fire
certificate.
The range of I/Os includes analog and
digital signal modules, technology
modules, motor starters up to 7.5 kW,
fail-safe digital input/output modules
and the fail-safe PM-E F power module.

Connection of I/O modules in hazardous area

SIMATIC ET 200X
The modular design with degree of protection IP 65/67 means that the ET 200X
is appropriate for local use. The ET 200X
consists of a basic module for connection to the PROFIBUS-DP and max.
7 expansion modules. The expansion
modules are mounted side by side using
integral connectors. All signal cables
and supply voltages required for the
inputs/outputs are looped through. The
modules can be replaced when servicing without having to dismount the
complete station.
In association with SIMATIC PCS 7, digital and analog input/output modules as
well as pneumatic interfaces for FESTO
valve manifolds CPV-10/-14 are primarily used as expansion modules in addition to an optional power module.

Connection of intelligent
field/process devices
Intelligent field/process devices are connected either directly via PROFIBUS or
via the HART interface modules in the
remote I/Os, also redundant if required.
With PROFIBUS, field/process devices
can be directly connected in the
Ex zones 0, 1 or 2. Communication
between SIMATIC PCS 7 and the intelligent field/process devices is carried out
on the basis of international standards
and specifications such as IEC 61158.
Field/process devices with a PROFIBUS
or HART interface can be parameterized, commissioned, diagnosed and
maintained throughout the plant using
SIMATIC PDM.
Intrinsically-safe operator panel
If required, an intrinsically-safe PC operator panel (add-on product) can be used
in potentially explosive atmospheres of
zone 1 or 2. The panel is connected to
an operator station, and distances up to
750 m are possible.

31

Process I/Os
Intelligent devices for automation in the field

Temperature measurements PDM

SITRANS T is used in conjunction with
a sensor to measure temperatures. Its
universal input stage means that all
common temperature sensors and
DC voltage sources can be connected:
Pt 100 resistance thermometers, thermocouples, resistance-based sensors/
potentiometers from 24 to 6000
and DC voltage sources from 17 to
1120 mV.

Siemens offers a complete range of

intelligent process devices particularly
appropriate for use together with the
SIMATIC PCS 7 process control system
for process automation at the field
level:
Field devices
Analyzers
Weighing systems
Drives
PDM

The process devices identified by

this symbol can be parameterized
using SIMATIC PDM.

Field devices
The field devices are available in versions with PROFIBUS DP/PA interface
and for communication using the HART
protocol.
Further information, technical data and
ordering data on these field devices can
also be found on the Internet:
www.siemens.com/fielddevices

32

Pressure measurements PDM

The SITRANS P transmitters are suitable
for flow and pressure measurements
(including absolute and differential
pressures) as well as for level measurements of corrosive and non-corrosive
gases, vapors and liquids. With its completely welded measuring cell, the
SITRANS P is completely vacuum-tight,
provides a high overload capability, and
has a long service life. The spans cover
the range from 1 mbar to 400 bar.
Flow measurements PDM
The SITRANS F US ultrasonic flowmeter
with the patented helical passage of
sound is used to measure the flow of
conductive and non-conductive liquids,
e.g. solvents, organic liquids and condensates.
The SITRANS F M electromagnetic flowmeter measures the flow of electrically
conductive media above 0.008 S/cm.
Homogeneous liquids can be measured,
also with solid particles such as slurries,
pastes and sludges. Flow velocities are
permissible up to 12 m/s.

Level measurements PDM

SITRANS LR 400 is a high-frequency
radar level meter for the process industry, featuring high accuracy and wide
measuring ranges.
SITRANS LR 300 is a level meter operating according to patented microwave
pulse technology, and provides longterm reliability even under difficult
operating conditions. The device can be
used on vessels subject to pressure,
with explosive or non-explosive media,
where large amounts of steam or dust
are produced, and at high temperatures.
Siemens additionally supplies various
ultrasonic level meters for many different applications. The range includes
compact devices for small measuring
ranges with liquids and sludges, devices
for medium and large measuring ranges
with solids and liquids, and a system for
monitoring and controlling pump stations.
Meters for capacitive level measurements
Mercap is an ideal capacitive level meter
for use under extreme temperature and
pressure conditions. The patented
active shield technology protects it from
dirt, deposits, steam and condensation.
The Pointek level switch is used to
determine predefined levels of bulk
materials, sludges and interfaces.

Positioner for pneumatic control

valves PDM
The SIPART PS2 electropneumatic
positioner controls the valve or damper
position on pneumatic linear or partturn actuators. The setpoint for the
valve position is defined by the control
system, and the actual value is returned
from the SIPART PS2 to the control system. A binary input can be used to block
the current valve position or to drive the
valve into a safety position.
Compact controllers PDM
The SIPART DR19 and DR21 compact
controllers designed for general process
engineering make it possible to increase
the availability at specific points at low
cost. They offer a wide range of prepared functions for process control
which can be simply called by users
without the necessity for programming
knowledge or additional aids. Using an
integral self-adjusting procedure, the
SIPART DR19 and DR21 can be rapidly
and simply adapted to the respective
task
The two compact controllers are connected to the SIMATIC PCS 7 automation systems via the PROFIBUS DP. The
SIPART DR19/21 function blocks
required for this are available as add-on
products for SIMATIC PCS 7. Each function block has its associated OS faceplate which shows the control and display elements of the corresponding
compact controller in the layout of the
controller block CTRL_PID.
Analyzers
Liquid analysis PDM
SIPAN means liquid analysis for pH,
conductivity and dissolved oxygen with
maximum convenience. The transmitters are powered via the PROFIBUS PA,
and the intrinsically-safe version is suitable for hazardous areas.

Gas analyzers PDM

ULTRAMAT 6 operates according to
the NDIR two-beam alternating light
principle, and measures IR-active gases
highly selectively.
CALOMAT 6 has been developed for
exact determination of composition and
concentration of process gases using
thermal conductivity.
OXYMAT 6 operates according to the
paramagnetic alternating pressure principle, and is used to measure oxygen in
gases.
Weighing systems
Weighing modules
Net weight and proportioning scales for
industrial processes can be configured
rapidly and efficiently using predefined
scales blocks.
For SIMATIC PCS 7, Siemens offers configuration packages with blocks for the
SIWAREX M and SIWAREX U weighing
modules as add-on products. These
blocks permit simple linking of the
weighing modules into the engineering
system, and also convenient operation
of the scales from the operator system.
The scales faceplate in the operator system also provides important diagnostics
information for the operating personnel.
Integral message response and maintenance functions such as the reading or
writing of all weighing parameters provide a high system availability, and thus
short down times.
Siemens-Milltronics weighing
systems
The range comprises:
Precision and torque scales for reliable and continuous weighing of bulk
materials
High-performance conveyor scales
for measuring ranges from 45 kg/h up
to 725 t/h
Low-maintenance bulk flow meter
with high reliability and repeatability
(even for difficult mixing and batch
functions)

Drives
Motor management PDM
The SIMOCODE-DP motor protection
and control device is primary used in the
motor control centers of the process
industry. It offers the following functions:
Comprehensive motor protection and
motor feeder monitoring
Integral, software-based control programs for all typical, switched motor
applications
Detailed motor and plant diagnostics
Integral PROFIBUS DP interface
In particular for applications in the
chemical industry, SIMOCODE-DP provides safe isolation and complies with
the NAMUR regulations.
Converters
The MASTERDRIVES converter range is
universal and modular. The power
range extends from 0.55 up to
2300 kW. All common international
power supplies from 200 to 690 V are
covered.
The MICROMASTER converter is a standard frequency converter in the power
range from 0.12 up to 90 kW, and can
be used for numerous drive applications
with variable speeds. The converter is
particularly suitable for applications
with pumps, fans and conveying equipment.
The add-on product "Drive ES PCS 7" can
be used to control, operate and monitor
the drives using the SIMATIC PCS 7 process control system. Parameterization,
commission and diagnostics of the
drives can be carried out with the addon product "Drive ES Basic" which can be
integrated in the SIMATIC Manager.

33

Migration solutions
TELEPERM M process control system to SIMATIC PCS 7

The TELEPERM M process control system from Siemens has proven itself
worldwide in many different sectors of
industry in the past 20 years. More than
15,000 installed systems have proven
their performance, reliability and userfriendliness in many years of use, even
under extreme operating conditions.
Many users now wish - or have - to
adapt their production to current market requirements, and therefore have to
expand or modernize their plants.
SIMATIC PCS 7, the successor generation for the process control system, was
introduced by Siemens in 1997 for new
plants and plant expansions, and offers
an open platform for modern, futureoriented and economical automation
solutions in all sectors.

34

The installed platform of the old process

control system is associated with large
investment costs for hardware and
application software, as well as valuable
and complex know-how of the operating and maintenance personnel.
The objective of migration is to modernize the existing platform step-by-step
without changing the system, simultaneously guaranteeing past investments
for as long as possible.
For this purpose, Siemens has been
offering optimized migration solutions
for the transition from TELEPERM M to
SIMATIC PCS 7 since 1996 already.
The range of migration products covers
hardware and software components as
well as services for conversion of the
application software, conversions on
site, or the migration of a complete system.

At the beginning, the main migration

requirement of customers was the stepby-step modernization and functional
expansion of individual components of
the existing TELEPERM M system:
Replacement of existing automation
systems by future-compatible automation systems under the premise of
importing existing application software and TELEPERM M I/Os.
Replacement of operation and monitoring systems by operator systems
on the basis of SIMATIC PCS 7
Integration of the distributed SIMATIC
process I/Os
Introduction of PROFIBUS as additional plant bus with a bridge as the
link to the TELEPERM M CS 275 plant
bus
Customers are increasingly deciding for
direct migration of TELEPERM M to
SIMATIC PCS 7. They are completely
selecting the proven system components of SIMATIC. They therefore profit
from the properties of a modern process
control system and the synergy effects
of TIA, and simultaneously have the
possibility for continuing to use the
existing TELEPERM M I/Os. Siemens supports this trend by means of new migration products as well as optimized services and in-house tools for hardware
and software conversion.
With the modern, pioneering SIMATIC
PCS 7 process control system, innovative migration solutions and services,
many years of know-how in process
control engineering and migration, as
well as worldwide servicing, Siemens
demonstrates its competence in the
process control engineering sector and
offers the security of a reliable partner.
You can find further information on
migration solutions on the Internet at
www.siemens.com/teleperm

SIMATIC PCS 7 on the Internet

We offer extensive information on the

SIMATIC PCS 7 process control system
on the interface at:
www.siemens.com/simatic-pcs7
In addition to the SIMATIC PCS 7 product range and add-on products from
Siemens and external partners, you will
also find:
Access to the catalog and online
ordering system (mall)
Current catalogs for SIMATIC PCS 7
and add-on products
System descriptions, product briefs,
presentation slides and references
Technical documentation such as
manuals or PCS 7 Update
FAQ sites with tips and tricks
Access to tools & downloads as well
as servicing facilities
Current training information
Newsletter for the complete range of
process automation
Range of services for process automation
Info Center for the process industry

Access to the process automation

portal with information on
TELEPERM M migration, process
instrumentation, process analysis or
sector-specific solutions

Service & Support our services for every phase of a project

Siemens offers comprehensive facilities
for service and support concerning
automation and drives in all phases of a
project: covering planning, commissioning, maintenance and modernization.
Online support
An information system accessible at all
times via the Internet, and covering
product support, Service & Support
facilities and support tools:
www.siemens.com/
automation/service&support

Technical support
Competent support for technical questions together with a wide range of specific services for our products and systems.
Tel.: +49 (0)180 50 50 222
Fax: +49 (0)180 50 50 223
E-mail: [email protected]
Technical consulting
Support during the planning and design
of your project: from detailed analysis of
current situation, definition of targets,
advice concerning products and systems, up to elaboration of the automation solution.

Field service
Commissioning, repairs and maintenance to guarantee the availability of
automation plants and systems.
Optimization and modernization
High-quality optimization and modernization facilities with the objective of
increasing productivity or reducing
costs.
Configuring and software engineering
Support during configuring and development with specific services ranging
from the configuring of an automation
project up to its implementation.
Repairs and spare parts
Comprehensive repair and spare parts
service during the operating phase
offers a high degree of operational
safety.

35

Further information

All information on SIMATIC

At the Internet address
www.siemens.com/simatic
you can reach the SIMATIC portal which
offers you access to all information concerning the SIMATIC range of products.
You can find further information documents in the online ordering form in the
support area of the portal under "Info
material". From there you can download
all SIMATIC catalogs,
customer periodicals such as advance
(products, systems, solutions for
Totally Integrated Automation) or
ProcessNews (info, news and trends
for process automation)
information documents and
technical descriptions
or order a printed copy if required.

Siemens partners worldwide

At the Internet address
www.siemens.com/
automation/partner

All names in this Product Brief assigned

a are registered trademarks of
Siemens AG.

you can find information on Siemens

partners worldwide for particular technologies, also for process automation
and SIMATIC PCS 7.

As far as possible, each location

includes partners for
technical support,
spare parts/repairs,
service,
training,
sales or
special consulting/engineering.

Siemens AG
Automation and Drives
Industrial Automation Systems
D-76181 Karlsruhe

www.siemens.com/simatic-pcs7
Order No. E86060-A4678-A131-A1-7600
Printed in the Federal Republic of Germany
315084 KB 0303 10.0 SR En

Siemens AG 2003
Subject to change without prior notice