s

Preface, Contents
Installation and Settings of the
operating system 1

SIMATIC 2
Installation PCS 7
3
Project structure
SIMATIC PCS 7 V6.1 4
Engineering Manual for the AS Engineering

Chemical Industry Configuration of the network 5

connections
Definition of Project Function 6
Blocks
Manual 7
OS Engineering
8
Archiving
9
Bulk Engineering
10
Integrated Asset Management
11
Compile and Download
12
Maintenance
13
References

Edition 03/2005
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to
prevent damage to property. The notices referring to your personal safety are highlighted in the manual
by a safety alert symbol, notices referring to property damage only have no safety alert symbol. The
notices shown below are graded according to the degree of danger.

Danger
! indicates that death or severe personal injury will result if proper precautions are not taken.

Warning
! indicates that death or severe personal injury may result if proper precautions are not taken.

Caution
! with a safety alert symbol indicates that minor personal injury can result if proper precautions are not
taken.

Caution
without a safety alert symbol indicates that property damage can result if proper precautions are not
taken.

Attention
indicates that an unintended result or situation can occur if the corresponding notice is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of
danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a
warning relating to property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning
and operation of a device/system may only be performed by qualified personnel. Within the context of
the safety notices in this documentation qualified persons are defined as persons who are authorized to
commission, ground and label devices, systems and circuits in accordance with established safety
practices and standards.

Prescribed Usage
Note the following:

Warning
! This device and its components may only be used for the applications described in the catalog or the
technical description, and only in connection with devices or components from other manufacturers
which have been approved or recommended by Siemens.
Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by ® are registered trademarks of the Siemens AG.
The remaining trademarks in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owner.

Copyright Siemens AG 2005 All rights reserved Disclaimer of Liability

The distribution and duplication of this document or the utilization We have reviewed the contents of this publication to ensure
and transmission of its contents are not permitted without express consistency with the hardware and software described. Since
written permission. Offenders will be liable for damages. All rights, variance cannot be precluded entirely, we cannot guarantee
including rights created by patent grant or registration of a utility full consistency. However, the information in this publication
model or design, are reserved is reviewed regularly and any necessary corrections are
included in subsequent editions.
Siemens AG
Automation and Drives Siemens AG 2005
Postfach 4848, 90327 Nuremberg, Germany Technical data subject to change.

Siemens Aktiengesellschaft
Preface

Purpose of the manual

Siemens has developed this manual, in addition to the standard PCS 7 V6.1
product documentation, as a guideline for chemical industry customers to benefit
from the Siemens experience in this industry.
The manual provides step-by-step instructions that can be easily followed.
However, the described procedures are not the only possible way to use the
system. Many settings depend on customer- or project-specific requirements,
constraints and environment. Therefore, Siemens cannot take any responsibility for
completeness and appropriateness of the contents.
In order to get a properly working basis, the installation and settings of the
operating system are described first in Chapter 1. Based on these preperations the
installation of SIMATIC PCS 7 is described on the following pages in Chapter 2.
Once you have a correctly installed system, you can start creating a PCS 7 project.
The procedure is described in Chapter 3. This chapter discusses in detail how a
typical project should be generated. It contains information about hardware and
software including the recommendations for the chemical industry. After this, the
engineering and settings of the automation stations are described (Chapter 4),
followed by information and recommendations on the networks, which are
discussed in Chapter 5. Since PCS 7 uses graphical editors to create the program,
the handling of function blocks in a project specific library and the usage in the
CFC editor are described in Chapter 6. This chapter also includes the usage of
sequential function charts SFC followed by the discussion and handling of the
message system. All needed aspects of the engineering and runtime of the
operator stations can be found in Chapter 7. The Master Graphics are described in
this chapter as well. Chapter 8 handles the archiving of SIMATIC PCS 7. In detail
Tag Logging, Alarm Logging and the central archive server are discussed there.
The topic “Bulk Engineering” with help of the “Import/Export Assistant” and the
“Process Object View” is shown in Chapter 9. There is pointed out how you can
use these functions and what are the benfits given by using these functionality. The
SIMATIC PCS 7 Integrated Asset Management is described in Chapter 10. After
the program has been created, it has to be compiled and downloaded to the
automation systems. This procedure is described in the Chapters 11 and 12.
Additionally, maintenance aspects are available in these chapters.
Finally, references can be found in the Chapters 13.

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

Training Centers
Siemens offers a number of training courses to familiarize you with the SIMATIC
S7 automation system. Please contact your regional training center or our central
training center in D 90327 Nuremberg, Germany for details:
Telephone: +49 (911) 895-3200.
Internet: http://www.sitrain.com

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 Installation and Settings of the operating system

Technical Support

You can reach the Technical Support for all A&D products
 Via the Web formula for the Support Request
http://www.siemens.com/automation/support-request
 Phone: + 49 180 5050 222
 Fax: + 49 180 5050 223
Additional information about our Technical Support can be found on the Internet
pages http://www.siemens.com/automation/service

Service & Support on the Internet

In addition to our documentation, we offer our Know-how online on the internet at:
http://www.siemens.com/automation/service&support
where you will find the following:
 The newsletter, which constantly provides you with up-to-date information on
your products.
 The right documents via our Search function in Service & Support.
 A forum, where users and experts from all over the world exchange their
experiences.
 Your local representative for Automation & Drives.
 Information on field service, repairs, spare parts and more under "Services".

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Installation and Settings of the operating system

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Contents

Preface iii

Contents vii

1 Installation and Settings of the operating system 1-1

1.1 Configuration hard disk....................................................................................1-1
1.2 Operating system............................................................................................. 1-2
1.3 First Settings on the computer.........................................................................1-4
1.3.1 Network............................................................................................................ 1-4
1.3.2 Audio................................................................................................................ 1-4
1.3.3 USB................................................................................................................. 1-4
1.3.4 SOM (Safecard on motherboard).....................................................................1-4
2 Installation PCS 7 2-1
2.1 Installation of PCS 7 V6.1................................................................................2-1
2.2 Hardware definition with Commissioning Wizard.............................................2-1
2.3 Station Configuration Editor.............................................................................2-2
2.4 Configuration Console......................................................................................2-2
3 Project structure 3-1
3.1 Hardware......................................................................................................... 3-2
3.1.1 Components (PC, OSM, AS, OLM, …. )..........................................................3-2
3.1.2 Architecture and Overview of example project.................................................3-2
3.2 Software........................................................................................................... 3-3
3.2.1 Create Multi Project......................................................................................... 3-3
3.2.2 Configuration of the ES project........................................................................3-9
3.2.3 Creating hardware configuration for the H-System (AS)................................3-14
3.2.4 Creating hardware configuration for the Standard AS....................................3-15
3.2.5 OS-Server,-Terminal projects, Redundancy..................................................3-16
3.3 Component view............................................................................................3-20
3.4 Plant Hierarchy structure and settings...........................................................3-21
3.5 General remarks............................................................................................3-24
3.5.1 Backup in engineering phase.........................................................................3-24
3.5.2 Engineering Rules..........................................................................................3-24
4 AS Engineering 4-1
4.1 Hardware configuration (HW Config)...............................................................4-1
4.1.1 Naming conventions for CPU, CPU-Program..................................................4-1
4.1.2 CPU Settings and Redundancy.......................................................................4-2
4.1.3 Profibus settings for CP443-5 Ext..................................................................4-10
4.1.4 Remote I/O Settings.......................................................................................4-14
4.1.5 Ex-I/O Modules.............................................................................................. 4-28
4.1.6 Industrial Ethernet settings CP443-1.............................................................4-28
4.1.7 Signal Names................................................................................................. 4-33
4.1.8 CiR download ability check............................................................................4-34
4.1.9 Modifying the System During Operation for H - Systems...............................4-35

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5 Configuration of the network connections 5-1

6 Definition of Project Function Blocks 6-1

6.1 Project Settings................................................................................................ 6-1
6.1.1 Copy blocks in the Master Data Library...........................................................6-1
6.1.2 Modification of the message class, priority and message text.........................6-2
6.1.3 Modification of attributes..................................................................................6-3
6.1.4 Preparations for programming with the CFC (Continuous Function Chart)......6-3
6.1.5 Driver Concept................................................................................................. 6-5
6.1.6 Messages of I/O- Periphery.............................................................................6-6
6.2 Graphical programming with CFC....................................................................6-7
6.2.1 Typicals............................................................................................................ 6-7
6.2.2 Run Sequence............................................................................................... 6-12
6.3 Graphical configuration with SFC...................................................................6-14
6.4 Message System............................................................................................ 6-14
6.4.1 Message Classes and Message Types.........................................................6-14
6.4.2 Message lists................................................................................................. 6-16
6.4.3 Message line format.......................................................................................6-17
6.4.4 Acknowledgement Concept...........................................................................6-18
6.4.5 Group displays of Messages..........................................................................6-20
6.4.6 Audio alarm indication....................................................................................6-21
6.4.7 Time stamping............................................................................................... 6-21
6.5 Create/import model in Master Data Library..................................................6-21
7 OS Engineering 7-1
7.1 Project Settings................................................................................................ 7-1
7.1.1 Redundancy Settings in the Server-Project.....................................................7-2
7.1.2 OS Terminal Project......................................................................................... 7-3
7.1.3 Computer properties........................................................................................7-4
7.1.4 Generating and loading the server data...........................................................7-5
7.1.5 Loading the server data to a Terminal Project.................................................7-5
7.1.6 Selection of a Preferred Server........................................................................7-7
7.1.7 WinCC- Communication Configurator..............................................................7-8
7.1.8 Project properties............................................................................................. 7-9
7.2 Operating and monitoring concept.................................................................7-10
7.2.1 User Interface................................................................................................ 7-10
7.2.2 Picture Tree Hierarchy...................................................................................7-11
7.2.3 Process Pictures............................................................................................7-13
7.2.4 Key Sets........................................................................................................ 7-13
7.3 OS Library...................................................................................................... 7-14
7.3.1 User defined Objects (UDOs)........................................................................7-14
7.3.2 Faceplates..................................................................................................... 7-17
7.3.3 Wizards.......................................................................................................... 7-25
7.4 Curves............................................................................................................ 7-30
7.5 Lifebeat monitoring.........................................................................................7-31
7.6 Time synchronization.....................................................................................7-34
7.7 Autostart functionality.....................................................................................7-39
7.8 Key lock for MultiTerminal..............................................................................7-40
8 Archiving 8-1
8.1 Tag Logging in WinCC.....................................................................................8-2
8.2 Alarm Logging in WinCC..................................................................................8-3
8.3 Central Archive Server (CAS)..........................................................................8-4
8.3.1 Configuring an Archive Server.........................................................................8-5
8.3.2 Server Data...................................................................................................... 8-7

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 Installation and Settings of the operating system

8.3.3 Storage Plus Viewer........................................................................................ 8-7

8.3.4 KPI and Advanced Reporting...........................................................................8-7
9 Bulk Engineering 9-1
9.1 Import/Export Assistant (IEA)...........................................................................9-3
9.1.1 Import............................................................................................................... 9-3
9.1.2 Export.............................................................................................................. 9-4
9.1.3 Example........................................................................................................... 9-5
9.2 Process Object View........................................................................................ 9-9
9.2.1 Example......................................................................................................... 9-10
9.2.2 Exporting and Importing I/Os and Messages.................................................9-12
10 Integrated Asset Management 10-1
10.1 Maintanance and diagnostic stations.............................................................10-1
10.1.1 Single Workstation System with Maintanance Station...................................10-1
10.1.2 Multiple Workstation System with MS Client on the ES.................................10-2
10.2 Diagnostic Structure.......................................................................................10-3
10.3 Diagnostic Screens........................................................................................10-5
10.4 Diagnostic and Maintanance Icons................................................................10-8
10.4.1 Diagnostic and Maintanance Icons in Block Icons.........................................10-8
10.4.2 Diagnostic and Maintanance Icons in Faceplate..........................................10-10
11 Compile and Download 11-1
11.1 Download CFC............................................................................................... 11-2
11.2 OS compilation............................................................................................... 11-3
12 Maintenance 12-1
12.1 Delta Compile and download in Run..............................................................12-1
13 References 13-1

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1 Installation and Settings of the operating
system

For each PC Station (ES, Server, Standby-Server and OS Terminal) the

appropriate installation procedure must be executed.

1.1 Configuration hard disk

Note:
! This is a recommended configuration for setup of hard disks and partitions in a
typical chemical project.

Backups should be made on media that are not affected by failure of the PC or the
harddisk containing the original date, for example, on CD, MOD or perhaps on a
network.

Drive Name Format Size (GB) Name Used for

1. C:\ NTFS 10 System Operating system installation and
PCS 7 installation
2. D:\ NTFS Rest Data PCS 7 project data
3. ... NTFS ... BACKUP Backup files

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1.2 Operating system
Within this procedure the operating system has to be installed on all PC-Stations.
 Windows 2000 Server / Windows Server 2003 for OS-Server and OS-Server
(stand-by).
 Windows 2000 Professional / Windows XP for ES and OS Terminal (Terminal).

Please follow the instructions in PCS 7 V6.1 description and the Readme-file
which are delivered with the PCS 7 CDs, refer to Process Control System PCS 7
PC Configuration and Authorization.

Here are a few additional remarks for the installation only.

 Language of the Operating system

Make sure that all PC Stations are installed with the same operating system
language (usually English or German).

 Regional Settings
Make sure that the regional settings of your PC are correct for the language
you want to work with.

 Computer Name
Special characters (e.g. “$”) are not allowed in the computer name.

 Screen Resolution
The best screen resolution for the LIBRARY Faceplates and pictures is
1280x1024. This is the recommended selection, especially for OS Single
stations and for OS Terminals.

 Power Options in BIOS

Switch off the power saving system (for all devices like hard disk, monitor etc.)
in BIOS and in the Control Panel.

 Installation Requirements
- WINDOWS 2000 incl. SP4 / Windows XP SP1
- Microsoft Hotfix Q828748 for Windows 2000 SP4
- Internet Explorer V6.0 incl. SP1
- Microsoft SQL Server 2000 incl. SP3

 WINDOWS Settings
Name: Customer name
Organization: Company name
Computer name Network administration
Administrator password: Network administration

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 Installation and Settings of the operating system

User login: User login name and password for the computer

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Installation and Settings of the operating system

 Using Virus Scanners

The following virus scanners have been tested for compatibility with
PCS 7 V6.1
- Trend Micro “Office Scan” (Program version: 5.02, VSApiNT version:
6510-1003, TmFilter version: 6510.0-1003, Pattern version: 557) and
“Server Protection” (Program version: 5.50.0.1237, Engine version:
6.510.1003, Pattern version: 557)
- Symantec AntiVirus Corporate Edition 8.1 (Workstation and Server)
- NAI Active Virus Defense Suite 11-25 Nodes Perpetual (McAfee Virus
Scan). When using the virus scanner McAfee, avoid an automatic “Pattern
Update”. You have to perform the pattern update manually.
The virus scan may not be active on OS and BATCH systems during the runtime.

For detailed information refer to Process Control System PCS 7 PC Configuration

and Authorization.

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 Installation and Settings of the operating system

1.3 First Settings on the computer

1.3.1 Network
 Unzip network card driver and install with setup.exe.
- Configure Full Duplex und 100MB/s.
 Rename LAN-Connection to ”LAN-Terminalbus”.
 Properties of the ”LAN-Terminalbus” are:
- TCP/IP is used.
- IP-Address e.g. 192.168.20.xxx (network administrator).
- Subnet-Mask 255.255.255.0 (CLASS C network).
 Create Workgroup "PCS 7“.
Alternatively a domain controller can be used in the network.

1.3.2 Audio
 If an “Audio”- folder is available for this machine insert driver with the device
manager in WINDOWS 2000. (Choose link to the "*.inf“- file)
Installation without setup-> Don’t use standard setup for installing the
AUDIO driver!

1.3.3 USB
 Install USB- support on SIEMENS IL40- Computers!

1.3.4 SOM (Safecard on motherboard)

 Used on SIEMENS RI45-Computers only!

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2 Installation PCS 7

2.1 Installation of PCS 7 V6.1

Please, always use the current installation instructions, which are delivered with the
PCS 7 installation CD. In general the language German must be installed, even if
you use English or another language only. Additionally you can install the language
needed.

For detailed information refer to Process Control System PCS 7 PC Configuration

and Authorization and Process Control System PCS 7 Engineering System
Configuration Manual.

2.2 Hardware definition with Commissioning Wizard

When you start your PC the first time after installation of PCS 7 the Commissioning
Wizard will be started automatically in order to ask you for the settings of the PC
Station. Enter these settings according to the hardware of your PC.
The configuration can be checked under:
Start  Simatic  SIMATIC NET  Settings  Configuration Console.

For detailed information refer to Process Control System PCS 7 PC Configuration

and Authorization.

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2.3 Station Configuration Editor
In the Station Configuration Editor, add the WinCC Application according to the
station type and give the correct station name.
The recommended indices for applications and hardware are listed in the following
table.

Index Object Type

1 WinCC Application
WinCC Application Terminal
WinCC Application Server (Stby)
2 CP1613 (if installed)

Typical configuration of an Engineering Station named ES.

2.4 Configuration Console

In the Configuration Console the access point “S7Online” must be setup to “PC
internal (local)”. To do this it is necessary to open “START > Simatic > SIMATIC
NET > Configuration Console” on the Engineering Station.

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3 Project structure

This chapter describes the installation of a PCS 7 project on the Engineering

Station (ES).
For general questions regarding PCS 7 Engineering please refer to the
Engineering Manual for PCS 7 V6.1.
As the project structure will be different from project to project (depending
on project size, number of objects, number of CPUs, Servers, OS Terminal
etc) this description can only be an example for one of many possible
solutions.
The description was made based on an example project with the following
configuration:
 2 CPUs (S7 417-4 / S7 417-4H)
 1 Engineering Station
 1 redundant Server-Pair
 3 OS Terminals.
To enable parallel Engineering and Runtime of the system we decided to create a
Multi-project named “Chemistry_MP“ which contains (5) PCS 7-Projects and a
Project Library.
 25_ES, including the ES
 20_OS, including the redundant Server-Pair
 21_MC, including the OS Terminal(s)
 01_PLANTA, including the CPU1
 02_PLANTB, including the CPU2
 Chemistry, the Project Library

Note:
! In this example all these projects are stored on the ES, but it would be possible, to
store these on different PCs to allow concurrent engineering.

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3.1 Hardware

3.1.1 Components (PC, OSM, AS, OLM, …. )

For configuring hardware components, please see also our Engineering manual
“PCS 7 - Configuration Manual Engineering System” at chapter 4 and followings.

3.1.2 Architecture and Overview of example project

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 Project structure

3.2 Software

3.2.1 Create Multi Project

Note
! USE ALWAYS A MULTIPROJECT in SIMATIC PCS 7 V6.1.
(Even if only a Single Project is required at the moment, this opens the option of a
later Multiproject use.)

Define a directory where all the PCS 7 projects will be stored in the future.
We don’t recommend using the default directories under “C:\SIEMENS\STEP7\
S7Proj”. We recommend creating a separate directory on drive “D:\”.
Use Options -> Customize to select the new directory under “Storage location for
projects”.
Use directory D:\PCS 7_Project to save your PCS 7 projects. The Wizard is always
used to create a new Project or Multiproject. The wizard creates a project structure
with Plant Hierarchy that has to be adjusted.
In the SIMATIC Manager create a new project by using File -> ‘New Project’
Wizard.
Select Type Multiproject.

Confirm with Continue

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Project structure

Select a 417-H System

and
deselect all OS objects in the next dialog window. This part of the project will be
manually created later in this description.

Confirm with Continue

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 Project structure

Change name: Chemistry

Change storage location to D:\PCS 7_Project

Confirm with Make

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Project structure

2. Change Project name for Plant A with the H-System.

New name: 01_Plant_A (Plant_A -> name of the Plant)
Select in Component view project folder “Chemistry_Prj”, press F2, and rename
the object.

Now it is necessary to rename the “SIMATIC H Station (1)” into “PlantA”. All other
user projects and Automation Stations (AS) will be inserted manually like described
in the next step.

3. Create new project for Plant A with a Standard CPU.

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 Project structure

4. Create new project for Master OS Server and red. OS Server.

5. Create new project for all OS Terminal Projects.

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Project structure

6. Create new project for the ES Station.

7. Project library
The Master Data Library is already generated by the ‘New Project’ Wizard and
is included in the project. The storage location is inside the project folder on the
D drive. This library “Chemistry_Lib” should contain all blocks and typicals used
in the project.

Once the projects are created, the Automation Stations (AS) and the PC Stations
according to the Hardware Configuration of the plant have to be created in the
Component view of the SIMATIC Manager.

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 Project structure

3.2.2 Configuration of the ES project

The object “SIMATIC PC Station” (ES, Server, Standby-Server and Terminal) has
to be configured according to the Hardware of the PC.
Always the first step is to configure the ES PC-Station and download it.
 Insert a new object SIMATIC PC Station for user project “25_ES”.

 Change the default PC Station name to network name of your ES.

For example: from ES5BLA (OLD NAME) to ES (name of your Engineering-
Station)
Here: The default name “ESBLA” has to be changed in ….

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Project structure

 …to the real name “ES” of the Engineering Station.

 Open the Hardware configuration of the PC Station and insert the appropriate
WinCC Application,….

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 Project structure

 …. and insert a CP 1613.

 Create and connect to the “Processbus” and give a MAC address.

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Project structure

 Download the configuration into the PC.

 Status should be “OK” in the Station Configuration Editor if download was

successful.

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 Project structure

 NetPro shows the connection to “Processbus”.

The usage of a CP1613 in an Engineering Station has the following benefits:

8. The OS-Project can be downloaded in all Server stations.
9. The function “OS Simulation” can be used also in case of a redundant
Automation System.

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Project structure

3.2.3 Creating hardware configuration for the H-System (AS)

 Insert a CP 443-1 and a CP 443-5 Ext in your project.
 In The properties, tab Operating Mode, choose DP master for the CP 443-5 Ext
 Add the IMs to the DP master system, like it is shown in the picture

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 Project structure

3.2.4 Creating hardware configuration for the Standard AS

 Insert a S7- 400 Station in the user project “02_Plant_B”.

 As well as a CP 443-1 and a CP 443-5 Ext

 In The properties, tab Operating Mode, choose DP master for the CP 443-5 Ext
 Add the IMs to the DP master system, like it is shown in the picture

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Project structure

3.2.5 OS-Server,-Terminal projects, Redundancy

 Example for the configuration of the SERVER_A user project.
Create inside the user project a new PC Station and open the Hardware
configuration. Create to connect the CP1613 a new “Processbus” and use unique
MAC addresses.

When saving the HW Configuration for the OS-Project the station is created on the
ES.
For the Standby-Server SERVER_B use WinCC Application (stby) instead of
WinCC Application and unique MAC addresses on the CP1613 cards. The rest is
identical to the Server Configuration.

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 Project structure

 Example for the configuration of an OS Terminal.

When saving the HW configuration the OS-Terminal project is created on the ES.
Configuration of redundancy for the master server “SERVER_A”. Rename the OS
object in “OS”.
 Choose the Master OS.

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Project structure

 Choose the path to the target OS Computer and the Standby OS.

Confirm with OK
 Choose the Stand-By OS.

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 Project structure

 Choose the path to the target OS Computer.

 Finish redundancy configuration by checking of the connection to the

“Processbus” of both OS-servers (NETPRO view).

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Project structure

3.3 Component view

Project component overview after the configuration of all PC-stations.

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 Project structure

3.4 Plant Hierarchy structure and settings

In the component view of the SIMATIC Manager, the Stations were inserted and
the physical plant configuration was defined. To map the plant topology in the
software structure, the plant view in SIMATIC Manager is used. The definition of
the plant hierarchy is one of the first steps in a project.
For the technological structure the plant designation system and the message
philosophy are very important.
Typical example for a chemistry plant.

The names of the hierarchy folders can be limited for maximum number of
characters. The names can be included completely or partly for the designation
system.

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Project structure

The settings for maximum number of hierarchy folders, maximum number of

characters, include in designation you will find if you select a hierarchy folder with
the right mouse button and use Options -> Plant Hierarchy -> Settings….

Note
! For a Chemistry plant, three hierarchy levels (area, unit, tag) are normally
used.
With the optional software package SIMATIC BATCH, four hierarchy levels
are normally used (area or line, unit, equipment module, control module).

If you check the “Derive picture hierarchy on the plant hierarchy” check box, the OS
picture hierarchy is derived entirely from the configured PH data. When it is
subsequently transferred to the OS, any picture hierarchy configured in WinCC
using the Picture Tree Manager is deleted and overwritten with the data generated
in SIMATIC Manager.

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 Project structure

Before a CFC or SFC can be inserted in the Plant view or the Process Object view
the hierarchy folder has to be assigned to a chart folder in AS. Select the hierarchy
folder and open the object properties. Use tab AS-OS Assignment to select the
chart folder for the assigned CPU.

Before Pictures can be inserted in the Plant view the OS assignment is also
required.
All elements you add to this hierarchy folder will be assigned to this AS/OS. If you
pass the selected assignments to the lower-level objects, the subordinated
hierarchy folders get the same AS/OS assignment.

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Project structure

3.5 General remarks

3.5.1 Backup in engineering phase

To enable independent Engineering for different Automation Stations, individual
PCS 7-Projects can be created for each Engineer.
There can be as many solutions as projects exist and one of the most important
steps at the beginning of the Engineering is to define the suitable project structure
that fits to your requirements.

3.5.2 Engineering Rules

Before you start creating your own PCS 7 project, it is usefull to follow engineering
rules in order to avoid double work:
 The PC names, OS Project names, and the Addresses (MAC Addresses,
TCP/IP Addresses, PROFIBUS Addresses) used in the description have to be
replaced by your PC Names etc.

 In PCS 7 V6.1 the whole Engineering has to be done on the Engineering

Station before the OS-Project is downloaded to the PCs. Don’t carry out any
engineering step on the Server or OS Terminal itself.
The only exception is the activation of the Time Synchronization for the Servers.
If the Engineering Station has no CP1613, this selection is not possible on the
ES and has to be executed out on the server itself.
 Don’t activate the OS-Project for Server on the Engineering Station if the
Redundancy is already activated. On the Engineering Station the OS-Project
can be activated in simulation mode with “Start OS Simulation”. In this case the
OS-Project is duplicated on the ES and the copy is activated.
 Don’t forget to take a backup of the complete project (or MultiProject) once in a
while, especially if more than one person is working on the project.
Recommendation: In the engineering phase a backup should be made
once a day.
 Use the Maser Data Library for the project and make sure that everybody
working for this project is using the blocks from this library.
 The time synchronization is very important for the Alarm Logging and Tag
Logging system. Make sure that there is only one (redundant) time Server in the
system and that all the Stations (PCs and CPUs) get the correct time. In PCS 7
V6.1 the CPU has always GMT!

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 Project structure

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4 AS Engineering

4.1 Hardware configuration (HW Config)

The following pages show the settings in the Hardware configuration for the
example project (“Chemistry_MP” ) and a typical chemical plant.
The screenshots in this description show the properties of a redundant CPU 417-4H
with CP 443-1/CP443-5 Ext. and a single CPU 417-4 with CP 443-1/CP443-5 Ext.
Other CPUs or CPs may have slightly different property windows.
Before following the manual it is necessary to create Rack, CPU, CP, Slaves and
make network connections.
More described details refer to Process Control System PCS 7 Engineering
System Configuration Manual.

4.1.1 Naming conventions for CPU, CPU-Program

Back in the SIMATIC Manager you see the elements of the Hardware
Configuration (CPU, CP) under each Automation Station. Below this you find the
program folder for the elements. For better identification we recommend to rename
the S7-Program folder for each CPU.
 Example for CPU naming conventions for a chemical plant:
Chemistry: name of the multiproject, perhaps name of the production factory
01_Plant_A: name of the part for a chemical plant in the production factory for the
complete PCS 7-project
PlantA: name of the SIMATIC-H-Station
S7(PlantA): name of the S7-program

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4.1.2 CPU Settings and Redundancy
CPU settings of Plant A with the H-System (Redundancy).

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 AS Engineering

Settings in the tab startup (all settings are standard).

Settings in the tab Cycle/Clock Memory.

Note
! A chemical plant redundant H-System is not allowed to stop, so it must be
configured with a relatively high “Scan Cycle Monitoring Time”
(maximum: 6000ms).

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AS Engineering

Size of process-image input/output area depends on the I/O-addresses of all DP-

slaves. Control of these parameters: View  Address overview….
 Settings of Maximum Communication Jobs (2400).

 Open the H-Parameters tab.

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 AS Engineering

Push “Calculate” and then “Recalculate”. The H-Parameters are always different
and depending from the maximum numbers of DP/PA slaves and PROFIBUS
communication speed.

 Change Settings Cyclic Interrupt Organization Blocks (OB30 to OB38).

Note
! The column “Process image partition” is very important to make sure the
applications uses current values.

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AS Engineering

Synchronization in the CPU as Slave.

 CPU-Settings of Plant B with the non-redundant Automation System

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 AS Engineering

 Settings in the tab startup (all Settings are standard).

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AS Engineering

 Settings in the tab Cycle/Clock Memory.

 Settings of Maximum Communication Jobs (2400).

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 AS Engineering

 Change Settings Cyclic Interrupt Organization Blocks (OB30 to OB38).

Note:
! See also remarks for the redundant Automation system described above.

 Time Synchronization of the CPU as Slave.

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AS Engineering

4.1.3 Profibus settings for CP443-5 Ext

Profibus-Settings of Plant A with the H-System (Redundancy)

Note:
! If you use more than one CP443-5 Ext. in a rack, you should then always assign
address 1 to all CPs as PROFIBUS Master address.

 Connect to the PROFIBUS network and change transmission rate to 1.5Mbps.

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 AS Engineering

 Change DP-mode to S7-compatible.

If a DP Slave forces DPV1 functionality, for example, if an interrupt must be
activated, you can not use this DP Slave on the DP Master in “S7 compatible”
operating mode.

 Standard Settings

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AS Engineering

 Profibus-Settings of Plant B with the non-redundant Automation System.

Note:
! If you use more than one CP443-5 Ext. in a rack you should then always assign
address 1 to all CPs as PROFIBUS Master address.

 Connect to the PROFIBUS network and change transmission rate to 1.5Mbps.

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 AS Engineering

 Change DP-mode to DPV1.

DPV1 contains enhancements geared towards process automation, in particular
acyclic data communication for parameter assignment, operation, visualization and
interrupt control of intelligent field devices, parallel to cyclic user data
communication. This permits online access to stations using engineering tools. In
addition, DPV1 has three additional interrupt types: status interrupt, update
interrupt and a manufacturer-specific interrupt.
On this interface you can maintain operation of currently connected DP Slaves that
does not support DPV1 functionality.

 Use Standard Settings.

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AS Engineering

4.1.4 Remote I/O Settings

Remote I/O settings of Plant A with the H-machine (Redundancy).
Here is a typical redundant configuration of a H-System 417-4H with the capability
of HCiR (High availability Configuration in Run).
 The name of a DP slave for a typical chemical plant represents his location.
For example: 2550C01CA04
25: short name of production factory
50: name of Control Room
C01C: name of rack and position
A04: slot of module
When a failure appears on the DP subnet a message will be generated on the OS
that provides information about the location of the failed slave.

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 AS Engineering

 The DP-Slave-Type for redundant systems can be chosen as IM 153-2

(6ES7153-2BA00-0XB0).
 The DP-Address for the PROFIBUS DP-slave can be chosen in DP slave
properties.
 The subnet for the DP-Slave can be chosen (Here: PROFIBUS (1)).
The connection to the redundant subnet PROFIBUS (2) will be made automatically
by the system.

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AS Engineering

 The network settings for profile (DP) and the transmission rate
(Standard 1.5 Mbps) must be chosen.

 The bus parameters and H-Parameters of the system will be calculated and
“Turn on cyclic distribution of the bus parameters” must be activated.

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 AS Engineering

Note:
! The bus parameters and the H-Parameters should always be the same for each
subnet-master system.

 The redundancy connection of the slave to the DP master system

(here: PROFIBUS(1) and (2) can be chosen in the tab redundancy.

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AS Engineering

 In NETPRO you can see the correct redundant network connection of the
CP443-5 Ext. to DP-PROFIBUS (1/2) of master system (1/2).

The typical configuration of I/O-module types for chemical plants will be described
in the following pictures.

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 AS Engineering

General rules
Channel specific settings will only be activated if the corresponding channel has
been connected. If channels are combined to channel groups (e.g. an 8-channel
AI-module consists of 4 channel groups which means 2 channels per channel
group) one group will be activated as soon as one channel is connected to a signal.
 Analog Input (6ES7331-7KF02-0AB0).
The module itself won’t generate process alarms. The measuring type depends if
the AI-module provides the measuring transducer (2- wire-MU) or if the measuring
transducer is externally provided (4-wire-MU).

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AS Engineering

 Analog Output (6ES7332-5HD01-0AB0).

It has to be configured project specifically, how the outputs should behave in case
of a CPU stop.
As an example, the following picture shows a setting OCV, that means the outputs
switch to no voltage, no current.

 Digital Input 16, floating point connection (6ES7321-7BH00-0AB0).

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 AS Engineering

 Digital Input 4,EX,NAMUR (6ES7321-7RD00-0AB0)

The module itself won’t generate process alarms.

 Digital Input 16, NAMUR (6ES7321-7TH00-0AB0).

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AS Engineering

 Digital Output (6ES7322-8BF00-0AB0):

Note:
! Wire break messages will be generated by activation of low power magnetic
valves, because the activation current is lower then the limit value for launching
the wire break monitoring.

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 AS Engineering

By using this type of valves the wire break monitoring must be deactivated. A wire
break monitoring can be provided by a user application in CFC with using feedback
signal and monitoring time.
 In order to optimize the cycle time you can choose a process image partition or
each single module. The configuration in a typical chemical plant for H-Systems
is:
All Digital Input/Output signals: PIP1.

All Analog Input/Output signals: PIP2.

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AS Engineering

Remote I/O Settings of Plant B with the Standard-machine

Here you see a typical configuration of a CPU 417-4 with the capability of CiR.
 You also have the name of the destination of a DP slave for a typical chemical
plant like a H-System.

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 AS Engineering

 The network settings for Profile (DP) and the transmission rate
(Standard: 1.5 Mbps) must be chosen.

 The bus parameters will be calculated by the system and “Turn on cyclic
distribution of the bus parameters” must be activated.

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AS Engineering

Note:
! The bus parameters should always be the same for each subnet-master system.

 The subnet for the DP-Slave must be chosen (Here: PROFIBUS(1)).

 In the option for operating parameters the slave configuration must be chosen
as “Replace modules during operation”.

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 AS Engineering

 In the option for time-of-day-synchronization the synchronization interval must

be set to 1.00 s.

 In NETPRO you can see the correct network connection of the CP443-5 Ext. to
DP-PROFIBUS (1) of master system (1).

Note:
! The typical configuration of I/O-module types for chemical plants
is the same for H-Systems.

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AS Engineering

4.1.5 Ex-I/O Modules

The Ex-I/O Modules are always project specific.

4.1.6 Industrial Ethernet settings CP443-1

Industrial Ethernet Settings of Plant A with the H-System (Redundancy)
For a redundant connection of CPU (here: PlantA) to “Processbus” the CP443-1 of
both racks must be configured.
Configuration of CP443-1:
 Insert correct MAC-address and make the connection to the Processbus.

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 AS Engineering

 Insert correct MAC-address and make the connection to the Processbus.

(It is not allowed to configure the same MAC-address like CP443-1).

 Configure transmission medium/duplex to “Automatic setting”.

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AS Engineering

 Activate SIMATIC time-of-day-synchronization.

Industrial Ethernet Settings of Plant B with the Standard AS-System

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 AS Engineering

For a connection of CPU (here: PlantB) to “Processbus” the CP443-1 must be

configured.
Configuration of CP443-1.
 Insert correct MAC-address and make the connection to the Processbus.

Note
! Generally, it is not allowed to give the same address for several process- bus
components.

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AS Engineering

 Configure transmission medium/duplex to “Automatic settings”.

 Activate SIMATIC time-of-day-synchronization.

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 AS Engineering

4.1.7 Signal Names

The hardware signals can be entered directly in the hardware configuration. For
example a typical chemical signal list is shown below.

They will be added to the Symbol table automatically and can further on used in
CFC.

There is also the possibility to import the hardware signal list from an excel file.

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AS Engineering

4.1.8 CiR download ability check

With CiR it’s possible to make modifications to the hardware configuration of a
single system while the system is running. That means, the CPU doesn’t need to
be stopped.

For a detailed description about CiR, e.g. what modifications can be performed
during operation and which modifications require a CPU Stop, refer to Process
Control System PCS 7 STEP 7 - Modifying the System During Operation via CiR.

In HW-CONFIG CiR can be activated as follows.

Select the subnet (DP-Mastersystem), chose “Activate CiR capability” from the
context menu (right mouse click on the subnet).
Symbols and placeholders for the CiR-Objects will be inserted.

Save and Compile the hardware configuration and download that to the Automation
System in STOP mode.

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 AS Engineering

4.1.9 Modifying the System During Operation for H - Systems

With HCIR it’s possible to perform plant modifications on H-Systems while the
system is running.

For a detailed description about HCiR, e.g. what modifications can be performed
during operation and which modifications require a CPU Stop, refer to Process
Control System PCS 7 S7 H Systems - Fault-Tolerant Systems

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5 Configuration of the network connections

After all the stations are defined, you have to configure the network connections for
the communication between the OS-Stations and the AS-Stations and for the
communication between the CPUs.
The settings for the network connections between the controllers are described in
Chapter CPU-CPU communication.
This description only refers to the communication between the OS Station and the
AS Station. For each connection between AS and OS Station, an S7-Connection
must be configured.
To define the connection, the CPs of the different stations must be linked to one
Ethernet bus.
The CP of the CPU is linked via “Processbus” to the Server OS Stations. For the
Process communication the ISO Protocol is used.
The OS Terminal are linked via “Terminal bus” to the Server Stations. In this
Network usually TCP/IP Protocol is used.
In a complete network this would look as follows:
Example with 2 CPUs, 1 redundant Server-Pair, 1 ES, and 3 OS Terminal:

In a Multiproject, the stations are often located in different user projects. Each
project has a network configuration that contains Ethernet connections to
“Processbus”.
To enable a network connections between different network configurations, the
buses must be merged.
In the SIMATIC Manager, you will find the merge function if you select the
Multiproject and use right mouse button option Multiproject  Adjust Projects.

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  Select Ethernet, and press execute, and the dialog window for Ind. Ethernet
merge/unmerge will open, and allow you to combine the Ethernet buses from
different networks.

 Under properties you will find the S7 Subnet ID (is always the same for all
Processbus-components).

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 Configuration of the network connections

After the network is merged, the network connections between OS Stations and the
CPUs can be defined.
 To add the S7 connection, select the WinCC Application of the OS-Project or
the CPU of the AS and use right mouse button for selection of “Insert New
Connection”.

 Select the CPU of the AS (or the WinCC Application of the OS) and press
“Apply”.

Confirm the Settings with OK.

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Configuration of the network connections

 Example for a naming of a redundant connection between CPU PlantA and

Server_A:
Type: S7 connection fault-tolerant
Name of partner ID: S7_connection_1 (here:Server_A)
Name of Local ID: 1 (here: CPU 01_Plant_A)
Active connection partner: NO

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 Configuration of the network connections

Type: S7 connection fault-tolerant

Name of Partner ID: 1 (here: CPU 01_Plant_A)
Name of Local ID: S7_connection_1 (here: Server_A)
Active connection partner: YES

 Example for a naming of a CPU-CPU connection between CPU PlantA and

CPU PlantB:

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Configuration of the network connections

CPU PLANT_A:
Type: S7 connection
Name of Partner ID: 4 (here: CPU 01_Plant_A)
Name of Local ID: 4 (here: CPU 01_Plant_B)
Active connection partner: NO

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 Configuration of the network connections

CPU PLANT_B:
Type: S7 connection
Name of Partner ID: 4 (here: CPU 01_Plant_A)
Name of Local ID: 4 (here: CPU 01_Plant_B)
Active connection partner: YES

Enter the network connections between all the OS Stations (Server, Standby-
Server and ES) and the Automation Stations, and then Download the
hardware configuration.
After the station configuration is finished and the network connections are
completed, the configuration data has to be downloaded to the CPUs and to the
OS Stations.
 For the download to the stations, always start with the Engineering Station. The
network configuration for the Engineering Station has to be exact in order to
enable the download to the CPUs and to the other PC Stations.
Check the configuration editor to be sure that everything is configured correctly.
 Download the Hardware Configuration to the Automation Station.
 Download the network configuration to the Automation Station.
 Download the configuration for the Server using access path “PC Internal local”.
Check the configuration editor on the Server Station to be sure that the
configuration is correct.
 Download the configuration for the Standby-Server using access path “PC
Internal local”
Check the configuration editor on the Server Station to be sure that the
configuration is correct.
 Download the configuration for each Terminal.
If the Engineering Station has no CP1613 you have to use access path
“TCP/IP” for the download of the configuration to the Terminal.
Check the configuration editor on the Terminal Station to be sure that the
configuration is correct.

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Configuration of the network connections

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6 Definition of Project Function Blocks

6.1 Project Settings

6.1.1 Copy blocks in the Master Data Library

 Copy all blocks from the PCS 7 Library V6.1 to Master Data Library
“Chemistry_LIB”.

Note
! All blocks used in engineering should be taken from the “Chemistry_LIB” Master
Data Library.

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6.1.2 Modification of the message class, priority and message text
 Opportunity of modification of the message class, priority, and message text for
each function block.
Choose the block  Special Object Properties  Message….

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 Definition of Project Function Blocks

6.1.3 Modification of attributes

 Opportunity of modification of the attributes for each function block, for example
“S7_m_c = TRUE” (Block is relevant for operator control and monitoring).
Mouse click on the connector inside the function block  Variable
Properties  Attributes…..

6.1.4 Preparations for programming with the CFC (Continuous Function

Chart)
Select the CPU S7-Program (e. g. PlantA). The S7-Program contains source
folder, block folder, and symbols.
For PCS 7 you have to insert one more folder for using charts, Insert New Object ->
Chart folder. Select the Chart folder and insert a new object type CFC.
Define reserved ranges for CFC blocks.
With a double-click on “CFC1” the CFC editor will open.

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Definition of Project Function Blocks

Under Options -> Customize -> Compilation you have to define the reserved
ranges:
 For example: DB: 1 to 60,
 For example: FC : 0 to 700.

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 Definition of Project Function Blocks

6.1.5 Driver Concept

Driver blocks are the interfaces between the I/O-Modules and the engineering
software. Via driver blocks, input/output signals as well as information about the
status (e.g. wire break) are provided for further use in the CFC editor.
PCS 7 V6.1 provides channel drivers (for the actual signal) and module drivers (for
diagnosis of Subnet, Rack, Module). Channel drivers have to be configured in
CFC.
Symbolic names for each channel (e.g. H4711 GO+) have to be configured in HW-
Config. Interconnecting the driver block and the symbolic name does the
assignment of a specific I/O-signal to a signal driver.
Module drivers are automatically generated by the system during the compilation of
the CFC charts. For that feature the option “Generate Module Drivers” has to be
activated. As an alternative way to generate module drivers do the following:
In SIMATIC Manager select the chart container where you want to generate
module drivers.
Over the context menu go to “Options > Charts > Generate Module Driver”.
The module drivers contain all settings that were set up via mode and diagnosis in
HW-Config.
With the input channel drivers “CH_AI” and “CH_DI” you get the possibility to set
substitute values over the parameter SUBS_ON = 1 in case of a failure of the
module (QBAD is set to 1). The substitute value itself can be configured with the
input SUBS_I.

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Definition of Project Function Blocks

6.1.6 Messages of I/O- Periphery

Through the use of diagnose capable I/O-Modules it is possible to generate a
various number of messages that contain the error status of the modules.
Specific settings based on a running chemical plant are described in the following.
 In the settings for the generation of Module Drivers activate the option “Enable
all” under the paragraph “Diagnostic Block Messages”.

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 Definition of Project Function Blocks

6.2 Graphical programming with CFC

6.2.1 Typicals
A typical, is a project specific interconnection between blocks, basically a
configuration of function blocks. It’s a template for a specific automation function
(e.g. Control Loop). In the following the most important Typicals for a chemistry
plant will be explained.

Analog Measurement (ANAMON):

Monitoring a measured value can be accomplished with an input channel driver
and the standard block MEAS_MON.
This typical can be expanded in order to monitor additional limit values.
A channel/module failure has to be connected from the input channel driver to the
CSF-Input of the MEAS_MON- Block.
Message class: AS-System message
Message type: Error
Message text: Error (additionally behind the event text in the column “Event“)
AS-Failure in column "Type"
Alarm / Warning: To report a limit value the block parameter Alarm high /
Alarm low/ Warning high / Warning low have
to be parameterized.
Example of that typical.

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Definition of Project Function Blocks

Fixed Setpoint Control (PIDCTRL):

Fixed setpoint control can be accomplished with an input channel driver and the
standard block CTRL_PID.
A channel/module failure has to be connected from the input channel driver to the
CSF-Input of the CTRL_PID - Block.
Message class: AS-System message
Message type: Error
Message text: Error (additionally behind the event text in the
column “Event“) AS-Failure in column "Type"
Alarm / Warning: To report a limit value the block parameter Alarm high /
Alarm low/ Warning high / Warning low have
to be parameterized.
Example of that typical:

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 Definition of Project Function Blocks

Cascade control (CASCADE):

Cascade control can be accomplished with an input channel driver and the
standard block CTRL_PID. In order to build this type of control two CTRL_PID-
blocks have to be connected in series.
A channel/module failure has to be connected from the input channel driver to the
CSF-Input of the CTRL_PID - Block.
Message class: AS-System message
Message type: Error
Message text: Error (additionally behind the event text in the field
“Event“) AS-Failure in field "Type"
Alarm / Warning: To report a limit value the block parameter Alarm high /
Alarm low/ Warning high / Warning low have
to be parameterized.

Ratio Control (RATIO):

Ratio control can be accomplished with an input channel driver and the standard
blocks CTRL_PID and RATIO_P.
The controlled variable will be controlled in a configurable ratio to another variable.
Message class: AS-System message
Message type: Error
Message text: Error (additionally behind the event text in the
column “Event“) AS-Failure in column "Type"
Alarm / Warning: To report a limit value the block parameter Alarm high /
Alarm low/ Warning high / Warning low have
to be parameterized.

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Definition of Project Function Blocks

Valve Control (VALVE_I):

Valve Control can be accomplished with an input channel driver and the standard
blocks INTERLOK und VALVE.
The outputs QBAD of the driver blocks has to be connected to the error input CSF
of the VALVE-Block.
Message class: AS-System message failure
Message type: Error

Example of that typical.

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 Definition of Project Function Blocks

Motor Control (MOTOR_I):

Motor Control can be accomplished with an input/output channel driver and the
standard blocks INTERLOK und MOTOR.
The outputs QBAD of the driver blocks has to be connected to the error input CSF
of the MOTOR-Block.
Message class: AS-System message failure
Message type: Error

Example of that typical.

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Definition of Project Function Blocks

6.2.2 Run Sequence

For all in CFC configured blocks, a Run Sequence has to be defined. The Run
Sequence defines in which cycle and on which event the block is supposed to be
executed.
The differentiation of the calling time and the calling cycle is managed by the
organization blocks (OB).
OB100: Restart
All blocks that have a startup behavior have to be placed in this OB (Driver blocks,
Control loops, ...).
Those blocks will be inserted in that OB automatically, as soon as they are inserted
in a CFC-chart.
OB100 is only called when the AS restarts.
OB32: 1 Sec.- Cycle
All blocks that have to be executed in a 1 sec cycle have to be placed in this OB.
The installation and the installation order have to be configured.

Note:
! For chemical plants the 1 sec cycle is usually the standard cycle.

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 Definition of Project Function Blocks

OB33: 500ms- Cycle

OB34: 100ms- Cycle

Blocks that need a faster execution than 1 sec. have to be installed in this OB. The
installation and the installation order have to be configured.
Blocks that need to be executed faster will be defined by the end customer or is
dependant on the project requirements.

OB80-88: Error-OBs
Based on certain states or errors Error-OBs are called. Error-OBs are generated
automatically when module drivers are generated. Therefore, they don’t need to be
configured manually.

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Definition of Project Function Blocks

6.3 Graphical configuration with SFC

SFC (Sequential Function Chart) allows the graphic configuration and
commissioning of sequential control systems. These are transferred to an
automation system and executed there. The sequential control system allows
status or event driven execution of production processes based on sequencers.
SFC provides charts and types with instances, standard SFC functions such as
steps, transitions, simultaneous sequences, alternative sequences, etc.
Block Icons for SFC and SFC-Types are automatically generated while compiling
the OS.
For detailed information on that topic refer to Process Control System PCS 7
Engineering System Configuration Manual

6.4 Message System

6.4.1 Message Classes and Message Types

Alarms and messages are divided in message classes and message types. Within
SIMATIC PCS 7 up to 18 message classes can be defined. A mode of
acknowledgement is specified for each message class. Within the message
classes, types of messages can be defined. The message class and message type
are used to specify the color of characters and the background color of a message.
Within one message class up to 16 message types can be defined. Messages
roughly divided in messages generated by the system and engineered messages,
informing about the state of the plant. The following table shows the recommended
message classes and types.

Message Class Message Type Acknowledgement Target group Color

Alarm High (1) New-value signal with

Alarm (1) Operator white / red
Alarm Low (2) single acknowledgement
Warning High (19) New-value signal with black /
Warning (2) Operator
Warning Low (20) single acknowledgement yellow
Tolerance High (37) Signals without white /
Tolerance (3) Operator
Tolerance Low (38) acknowledgement turquoise
Operator to
AS system AS- System (55) New-value signal with inform yellow /
messages (4) Peripheral Fault (56) single acknowledgement Maintenance black
personnel
Operator to
OS system New-value signal with inform yellow /
OS- System (71)
messages (5) single acknowledgement Maintenance black
personnel
Preventive New-value signal with Maintenance yellow /
Maintenance (89)
maintenance (6) single acknowledgement personnel black
Process message Process signal (106) New-value signal with white /
(7) Operator
single acknowledgement magenta

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Message Class Message Type Acknowledgement Target group Color

Operational Signals without white /

Process signal (122) Operator
message (8) acknowledgement magenta
Operator control Operator control Signals without
Operator white / blue
request (9) request (139) acknowledgement
Operator control Operator control Signals without white /
Operator
signaling (10) signal (156) acknowledgement magenta
Control Technology Signals without Maintenance white /
Maintenance (12)
(177) acknowledgement personnel magenta
Status message Status AS (253) Signals without white /
Operator
(16) Status OS (254) acknowledgement magenta

The SIMATIC PCS 7 standard message class “system” (17) and (18) are not used.
Messages belonging to these message classes are assigned to the signal classes
(4), (5) and (12).

Explanation of the message classes:

 Alarm, warning, and tolerance messages/signals inform about limit violation.

The limits are engineered in the user configuration CFC. The messages/signals
are intended for the operator.
 AS system messages inform about fault conditions in the I/O periphery and in
the system, such as broken wires, short-circuit, channel faults, module faults,
fault of access, loss of redundancy and failure of auxiliary power. When a
system-generated signal or message occurs, the operator shall inform the
maintenance support team without delay.
 OS system massages inform about OS system faults, e.g. faults occurring when
accessing a database, faults in server redundancy, faults in time
synchronization. When a system-generated field instrumentation signal or
message occurs, the operator shall inform the maintenance support team
without delay.
 Operational messages inform about the plant status during normal operation
(e.g. "Setpoint temperature reached").
 Operator control requests are messages, which, initiated by sequence control
systems or batch systems, prompt the operator to act.
 Operator control messages inform about manual action taken by the operator
(e.g. "User xy: Controller T4711: W was: 20 DEGC, W is now: 35 DEGC"), or
they are system-generated messages that make reference to events within the
systems (e.g. "Wrong password entered").
 Maintenance messages are system-generated messages that suggest that
engineering or configuration error has occurred. The messages are recorded in
the maintenance list only, and are intended for maintenance personnel.
 Status messages inform about system states which occur in regular operation
and are documented (e.g. "Login by chip card")
In order to avoid a message flood, the following methodology is part of SIMATIC
PCS 7 message concept: accumulative messages suppress follow messages.

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Example: An I/O module with eight channels can signal a broken wire for each
channel. If the I/O module has no power supply, only this message is signaled and
the broken wire messages are suppressed. If the I/O module is removed, only this
is signaled and the message of lost power supply is suppressed.

6.4.2 Message lists

SIMATIC PCS 7 categorize messages received in message lists depending on
state and type. The following message lists are implemented:
 Message line
The last non-acknowledged message is shown in the line above the process
overview area.

 New List:
All unacknowledged messages.
 Old List:
All acknowledged messages that are still active from the process.
 Gone List:
All messages marked as 'Gone' (special message property).
 Operator Input List:
All operator control messages (e.g. the setpoint of a controller is set to xxx).
 Control System List
All messages which refer to control system.
 Journal List
The journal list shows all messages (coming, acknowledged and gone
messages).

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6.4.3 Message line format

The following message blocks are used in all message lists.
 OneLine: Date (8 characters, format tt.mm.jj)
Time (8 characters, format hh.mm.ss)
Source (32 character, e.g. T8111/R)
Event (64 character, e.g. temperature K801 to high)
Message class (5 character, e.g. AH)

 New List: Date (8 characters, format tt.mm.jj)

Time (8 characters, format hh.mm.ss)
Source (32 character, e.g. T8111/R)
Event (64 character, e.g. temperature K801 to high)
Status (incoming K, outgoing G, incoming and outgoing KG)
Charge Name
 Gone List: Date (8 characters, format tt.mm.jj)
Time (8 characters, format hh.mm.ss)
Source (32 character, e.g. T8111/R)
Event (64 character, e.g. temperature K801 to high)
Status (incoming K, outgoing G, incoming and outgoing KG)
Charge Name
 Old List: Date (8 characters, format tt.mm.jj)
Time (8 characters, format hh.mm.ss)
Source (32 character, e.g. T8111/R)
Event (64 character, e.g. temperature K801 to high)
Status (incoming K, outgoing G, incoming and outgoing KG)
Charge Name
 Journal List: Date (8 characters, format tt.mm.jj)
Time (8 characters, format hh.mm.ss)
Source (32 character, e.g. T8111/R)
Event (64 character, e.g. temperature K801 to high)
Message Duration (8 characters)
Message class (5 character, e.g. AH)
 Operation- Date (8 characters, format tt.mm.jj)
List: Time (8 characters, format hh.mm.ss)
Source (32 character, e.g. T8111/R)
Operation (72 character, incl. operator)

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6.4.4 Acknowledgement Concept

SIMATIC PCS 7 is based on a centralized acknowledgement concept. If a
message gets acknowledged on an OS- Terminal this particular acknowledgment
gets transferred to the function block in the AS over the OS-Server. From there the
acknowledgement will be centrally send to all connected OS-Stations.
 Messaging with single acknowledgment (for message classes 1, 2, 4, 5, 6, 7).

For message class 5 (OS Process Control Message) an additional option, called
Message without status “went out”, has to be activated.

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 Message without acknowledgment (for message classes 3, 8, 9, 10, 12, 16).

For message classes 10 and 16 an additional option, called Message without

status ”went out”, has to be activated.

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6.4.5 Group displays of Messages

A typical chemical plant is engineered with a hierarchical group display structure. A
single message from a process picture can be traced via the group display over all
levels.
The highest level in SIMATIC PCS 7 is always the overview area. This overview
provides the operator with group display messages for each area.

These messages are only valid in the corresponding area. All group displays for
one area are connected logically with an OR function and including all lower
hierarchy level automatically.
By mouse click on the group display, the operator will be forwarded directly through
the whole hierarchy down to the process picture where the alarm occurred.
The group display contains the following information.
A Alarm (white on red) flashing
W Warning (black on yellow) flashing
S Failure (yellow on black) flashing
O Operator control request (white on blue) non-flashing

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6.4.6 Audio alarm indication

Failures and errors in the process are indicated within the message list as well as
in form of sounds. The audio indication can be done with the signal module. One
signal module has been installed per OS-Server. The connection between the
signal module and the horn module in the control room is done via a terminal strip
with common horn relays. In that way, an occurring alarm can be audibly indicated
directly to the operator in the control room. The acknowledgement of the horn is
done with the horn-button in a process graphic of any OS-Terminal.
The distribution of message classes to the particular channels of the signal device
is done with the Alarm Logging Wizard:
 All classes can be used for audio alarm indication.

6.4.7 Time stamping

Inside a SIMATIC PCS 7, project messages are created on different areas and
locations. The origin impacts the time stamping of the message. Independent from
the origin all messages are archived and shown in the same way. AS and I/O
messages are delivered as single messages over process bus to the OS-Station.
The message contains the time stamp for this message. The OS-Station shows in
all messages lists the messages with the time stamp from the origin automatically
in the right order.
To have always the correct time stamp available, it is necessary to setup a time
synchronization between all components of the SIMATIC PCS 7 project.

For detailed information on that topic refer to Process Control System PCS 7
Operator Station Configuration Manual, chapter 11 time synchronization.

Origin Configuring the Location of Meaning in PCS 7

message text generation of
time stamp
Operator Station (OS) In WinCC-Editor In the Operator OS System Messages
"Alarm- Logging" Station
within the OS
Automation System In the instances of the In the Automation Process Messages and AS
(AS) function blocks (e.g. System System Messages from
CTRL_PID or the SIMATIC Stations
MEAS_MON) within
the CFC-Charts
Distributed Periphery In the instances of the In the ET200M Selected events for the
(ET200M) function block through the first value acquisition in
IM_DRV within the IM153-2 case of a plant failure
CFC-Charts (10ms accuracy)

6.5 Create/import model in Master Data Library

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For information on this topic refer to Process Control System PCS 7 Engineering
System Configuration Manual.

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7.1 Project Settings

The OS-Project for a Single-User System or a Multi-User System has already been
defined with the SIMATIC Manager. However, the following settings have to be
made in the OS-Project, which means you have to start WinCC Explorer. This has
to be done directly from the SIMATIC Manager by selecting the OS with right
mouse button and Open Object.

Importnt Note:
! The following steps must be executed from the beginning of the engineering
phase and in the engineering language that will be used for the project. If you
change the language later, the language dependent settings have to be made
again.

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7.1.1 Redundancy Settings in the Server-Project
After the Server-Project and the Standby-Server-Project have been configured in
the SIMATIC Manager the Server-Project must get the corresponding Standby-
Server-Project assigned to it as well.
 Open the Server-Project and set up the redundancy as follows:
- Activate Redundancy,
- Select the Redundant Partner Server,
- Select the options according to your requirements.

Note:
! A serial connection between both servers is required. This connection allows the
servers to check their current status.

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7.1.2 OS Terminal Project

The following settings have to be performed in the OS-Project of each
OS-Terminal.
With the OS Project Editor the following settings are made for the user interface.

Tab Function
Layout Monitor configuration and specification of buttons to enable the plant
operator to switch between individual areas and servers.
Message Settings for message lists and area assignments.
Configuration
Areas Specification of areas that the plant operator can access from the overview
area.
Runtime Definition of the maximum number of windows that can be opened when
Window faceplates and curves are called.
Basic data Selection of objects that have to be replaced after a change. The following
objects can be selected:
 Pictures,
 Faceplates,
 Scripts.
General  Settings for the OS Project Editor for the “Download Changes”
function.
A complete download operation is required with the “complete
configuration” setting.
 Settings for the protocols that are replaced when the project editor is
executed.

In the tab “Layout” choose the correct screen resolution. It may be SIMATIC
Standard 1280*1024 or, if selection for server is required, SIMATIC Serverview
1280*1024.
Also select the Number of horizontal and vertical area keys and the number of
servers under the button <Detail> (Picture Tree) as well as the monitor
configuration of your PC.

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Example for the Layout of an OS Terminal.

The settings in the other folders can be modified later.

7.1.3 Computer properties

The computer properties must be checked and adapted to the requirements of the
plant. Most of the settings are likely not be entered at the beginning of the
engineering phase and need to be adapted later on (sometimes after
commissioning).

Note:
! The Computer Name for all OS Projects is the name of the Engineering Station.
During the download of the OS-Project to the individual PCs the name is
automatically replaced by the Name of the PC Station.

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7.1.4 Generating and loading the server data

To make the server data available for the Terminal, a server package must be
created in the Server-Project and be loaded to the Terminal-Project.
In PCS 7 V6.1 server data are automatically created during the compilation of the
OS-Data.

7.1.5 Loading the server data to a Terminal Project

To load the Server Data to an OS-Terminal, open the Terminal-Project on the
Engineering Station and right-click “Server data”. Select the option “Loading…”.
 In the "Open" – Dialog, select the Server-Project and within that the computer
name (in this case this is the name of the Engineering Station). There you find a
folder “Packages”.
 In the folder Packages select the package-file (.pck) and click on "open".
The Server data will be copied into folder "packages“ and is available on the
OS-Terminal.

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To select the standard server right-click on “Server data” and select the option
“Standard server…”. Select the standard server for the component “Alarms”.

Once the Server data is loaded and configured the package gets automatically
updated during compilation of the OS-Data.

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7.1.6 Selection of a Preferred Server

To distribute the load for the servers uniformly it is useful to connect one part of the
Terminal to one Server and the other part to the Standby-Server.
Therefore a Preferred Server must be configured under Serverdata -> Configure ...
Example:

The following standard is used by chemical plants.

Terminal_01, Terminal_03, … to SERVER_A.
Terminal_02, Terminal_04, … to SERVER_B.
When the preferred Server is stopped, all connected Terminals automatically
switch to the Partner-Server. Once the preferred Server runs again, Terminals
automatically switch back to the preferred Server.

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7.1.7 WinCC- Communication Configurator

For the optimization of OS-Terminal- / OS-Server-Monitoring a tool called “WinCC
Communication Configurator” exists.
You’ll find that tool under Start > Simatic > WinCC > Tools > Communication
Configurator. The following settings have to be made.

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7.1.8 Project properties

Adaptations for the project itself can be performed under properties of the OS-
Project.
The folder “General” contains the Project Type (Client-Project, Multi-User-Project
or Single-User-Project).
By generating a new OS-Project of type “WinCC Application“ a “Multi-User-Project”
will be created automatically.
In PCS 7 V6.1 it is not required to change this setting to Single-User Project since
the Engineering Station automatically has a Server license installed.

Note:
! If you still prefer to change this setting it is possible to select type Single-User
System. Don’t delete the startup list!

In the tab “Update Cycles” the time values for the update cycles have to be
defined. The default value of this is 2000 ms. You have to adapt this value
according to your requirement, e.g. 1000 ms.
For more detailed information Refer to Process Control System PCS 7 Operator
Station Configuration Manual Standard PCS 7 V6.1 OS Manual.

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7.2 Operating and monitoring concept

7.2.1 User Interface

The SIMATIC PCS 7 user interface is divided in three parts.
 Overview Area: The overview area represents the technological plant view
generated automatically from the Engineering Station. The Operator is using
this overview area for choosing process pictures and for navigation.
 Working Area: The working area shows the process picture.
 Key Set Area: The Key Set Area is used for operation, navigation to alarm
windows, SIMATIC Batch windows, and SFC visualization windows.

sub-navigation
window
Overview
Area

Working
Area

Key Set
Area

The SIMATIC PCS 7 user interface is a field proven operator interface for a safe
operation - even in critical situations.

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7.2.2 Picture Tree Hierarchy

Overview

Level 1

Level 2

Level 3
....

A hierarchal structure of the plant can be setup in up to 8 levels. The navigation

between the process pictures will be provided by buttons. The assignment for the
process pictures to the navigation will be defined in SIMATIC Manager during AS
engineering. The display name for the OS area can be modified in the SIMATIC
Manager. Inside the object properties for a hierarchy folder the OS area name can
be defined. Usually the same name like for the plant view is used, no additional
settings are necessary.

Note:
! In a typical chemistry plant only the overview and level 1 and level 2 are used.

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The WinCC Picture Tree Manager will be generated automatically during the OS
compilation because of the settings in the SIMATIC Manager.

Corresponding from the plant view all overview buttons are displayed.

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7.2.3 Process Pictures

 Design of the functions
This functionality will be provided with user objects. The operation is done by
Faceplates coming from the OS Library.
 Design of the pipes
For a typical chemistry plant the following settings are recommended.
Color: black: Product
yellow Gas, N2
dark red Steam, Heater
green Water
blue Air
thickness: thick Main product lines (line thickness 4)
thin miscellaneous pipes (line thickness 2)

 Design of the vessel

Display a vessel inside the graphics with black line color and grey background
color. The forms of the vessels are defined by the RI- flow chart. The vessel
volume must be show with a static variable on the vessel. The level indicator will be
shown with a bar object.

 Picture navigation, Pipe begin Pipe end

Pipe interruptions are signaled with an arrow object on the end. If the arrow symbol
is a reference to another process picture, the arrow must be fully filled with color.
Example of process picture for chemical plant:

7.2.4 Key Sets

The files “@buttons11”, “@buttons12” contains all in SIMATIC PCS 7 used
buttons. These files are automatically generated and included in each OS-Project.

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7.3 OS Library

7.3.1 User defined Objects (UDOs)

User defined objects (UDOs) support the automatic generation of block icons in
your OS-Graphics. The ability of exporting and importing of UDOs with MS Excel
makes project engineering easier.
When you modify an UDO centrally in the template graphic, and you want this UDO
to be updated in your graphics where this UDO has already been used, the Wizard
“Update of the picture objects” will update this UDO automatically.
The template graphic for UDOs is located in the WinCC picture
"@@PCS7Typicals.PDL".

The UDOs were designed for a screen resolution of 1280 x1024 and 1024 x786
pixels. Depending on the adjusted screen resolution in the project, the correct
template graphic will be copied into the project automatically.

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The following UDOs are available in the Mastergraphics Library V6.1.

UDO- types Belonging AS block

Controller CTRL_PID, CTRL_S, DOSE,
FMCS_PID, FMT_PID
AnalogValue GroupSignal ELAP_CNT, MEAS_MON, SWIT_CNT
AnalogValue RATIO_P, OP_A, OP_A_LIM,
OP_A_RJC
BinaryValue GroupSignal DIG_MON
BinaryValue OP_D, OP_D3, OP_TRIG
Motor MOTOR, MOT_SPED, MOT_REV
Valve VALVE, VAL_MOT
Other INTERLOK, SFC_PLAN, SFC_TYP

 CTRL_PID: PID-Control
PID automatic controller for the setting up of standard automatic controller
circuits: Fixed set point control, cascade control (single/multiple cascades),
ratio control, and synchronization control.

 CTRL_S: PID-Step-Control
The CTRL_S controller is a step controller for process control systems in which
integral-action actuating elements (for example, motor driven valves) are used.
The valves controlled by means of two binary control signals.

 DOSE: Dosage
The DOSE block is used for upsizing or downsizing batches in single-
component dosing with weighting devices and also for dosing using volumetric
measuring devices. The dosing value is monitored against the setpoint value
for exceeding or falling below tolerance and the results supplied to two
corresponding outputs at the end of dosing.

 FMCS_PID: Controller
The block “FMCS_PID” is used to interface the FM 355 controller block.

 FMT_PID: Temperature Controller

The block “FMT_PID” interfaces the temperature controller module FM 355-2.

 ELAP_CNT: Hour Meter

The block is used to measure the operating hours of units.

 MEAS_MON: Analogue measured value monitoring

Is used for the monitoring of a measured value (analog signal) on the pairs of
limit values warning limit (high/low) and alarm limit (high/low).

 SWIT_CNT: Switching cycle counter

The block is used to count unit switching cycles.

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 RATIO_P: Ratio control

The block is used to create a ratio, e.g. in a ratio control. It is also used as a
percentage adjuster (for example, speed ratio control), or to influence the
reference input variable of a cascade.

 OP_A: Local control of analog values

Basic operator control block for processing analog values of an AS block,
without limit monitoring and operator enable functions.

 OP_A_LIM: Local control of analog values(limiting)

The operator control block OP_A_LIM processes the analog value of a block.
Operator control outside the operating limits is limited to respective violated
limit value.

 OP_A_RJC: Local control of analog values(rejecting)

The operator control block OP_A_LIM processes the analog value of a block.
Any operation outside the operation limits will be discarded.

 DIG_MON: Digital value monitoring

The block is used to monitor a digital measuring point with chatter suppression.

 OP_D: Local control of digital values(2 buttons)

The block is used to control the digital value of a block by means of two
pushbuttons.

 OP_D3: Local control of digital values(3 buttons)

The block is used to perform a logical one-of-three digital value operation. If
one of the operator inputs I1, I2 or I3 is set, the corresponding output is set to 1
and the other outputs are reset, in as far as the operation is permissible.

 OP_TRIG: Local control of digital values(1 button)

The block is used to implement a single pushbutton control.

 VALVE: Valve Control

The block is used to operate control valves (open/close fittings) by means of
control signals (open/close). The position of rest of the valve can be the closed
or opened state. The two position feedback signals (open/closed) are
generated by the limit switches and can be monitored.

 VAL_MOT: Valve Control

The block is used to control motor driven valves by means of two control
signals. The valve can be stopped at any position. The two position feedback
signals are generated by the limit switches (open/closed).

 MOTOR: Motor with 1 control signal

The block is used to control motors by means of a control signal (on/off). The
motor speed feedback can be monitored optionally. This motor feedback signal
is provided by a contactor relay.

 MOT_REV: Motor with 2 directions of rotation

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The block is used to drive motors with 2 directions of

rotation(clockwise/counterclockwise). A maximum of 2 feedback signals, which
are generated by auxiliary contactors, are monitored.

 MOT_SPED: Motor with 2 speeds

The block is used to control two speed motors (slow/rapid). The two feedback
signals output by the contactor relays can be monitored.

 INTERLOK: Interlocking
The INTERLOK block is used to implement a standardized interlock display
which can be called on the OS. The block can be assigned a maximum of 10
input signals, which can each be inverted as required.

7.3.2 Faceplates
The faceplate is the graphical display of all elements of a technological block in the
automation that are intended for operator control and monitoring. The faceplate
block is displayed in a separate window on the OS and is called by left click on the
block icon.
The following faceplates are available in the Mastergraphics Library V6.1.

 CTRL_PID: PID-Control
Block Icon Faceplate

 CTRL_S: PID-Step-Control
Block Icon Faceplate

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 DOSE: Dosage
Block Icon Faceplate

 FMCS_PID: Controller
Block Icon Faceplate

 FMT_PID: Temperature Controller

Block Icon Faceplate

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 ELAP_CNT: Hour Meter

Block Icon Faceplate

 MEAS_MON: Analogue measured value monitoring

Block Icon Faceplate

 SWIT_CNT: Switching cycle counter

Block Icon Faceplate

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 RATIO_P: Ratio control

Block Icon Faceplate

 OP_A: Local control of analog values

Block Icon Faceplate

 OP_A_LIM: Local control of analog values(limiting)

Block Icon Faceplate

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 OP_A_RJC: Local control of analog values(rejecting)

Block Icon Faceplate

 DIG_MON: Digital value monitoring

Block Icon Faceplate

 OP_D: Local control of digital values(2 buttons)

Block Icon Faceplate

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 OP_D3: Local control of digital values(3 buttons)

Block Icon Faceplate

 OP_TRIG: Local control of digital values(1 button)

Block Icon Faceplate

 VALVE: Valve Control

Block Icon Faceplate

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 VAL_MOT: Valve Control

Block Icon Faceplate

 MOTOR: Motor with 1 control signal

Block Icon Faceplate

 MOT_REV: Motor with 2 directions of rotation

Block Icon Faceplate

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OS Engineering

 MOT_SPED: Motor with 2 speeds

Block Icon Faceplate

 INTERLOK: Interlocking
Block Icon Faceplate

Detailed Information of the Faceplates can be found in the “PCS 7 Programming

Instruction for Blocks” Manual.

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7.3.3 Wizards
The following wizards are available for the UDOs:

Wizard name Register in the Dynamic Wizard

Connect picture block to tag structure Standard Dynamics
Import picture objects Picture Functions
Export picture objects Picture Functions
Update picture objects Picture Functions

Wizard "Connect picture block with tag structur".

This wizard is used for connecting the UDOs with a measuring point.
After the "welcome" side the dialog appears for the selection of a measuring point.

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Wizard "Update picture objects"

Changes on the UDOs in the template picture are taken on with this standard
wizard in the plant pictures.
In the choice dialog for the template picture "@PCS7Typicals.pdl" must be
selected.

Wizard "Export picture objects"

With this standard wizard the projected UDOs are exported into a file. The file is
stored in the csv-format and can be edited with Microsoft Excel into tabular form.

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Wizard "Imort picture objects"

The UDOs deposited in the csv file are integrated with this standard wizard in
WinCC pictures. The tabular form of the import file must the described structure in
the wizard "export picture objects" correspond.
In the choice dialog for the template picture "@PCS7Typicals.pdl" must be
selected.

Create UDOs over SIMATIC Manager

The UDOs can be created in the SIMATIC Manager in the WinCC pictures.
Therefore, WinCC pictures must be generated in the technological hierarchy (TH).
The pictures gets its properties via the selection of "Derive the block symbols from
the technological hierarchy"

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OS Engineering

Following the UDOs can be created in the WinCC pictures using the command
"Create/Update Block Icons" or over the dialog "Compile"

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Restriction
An update of the UDOs with the above mentioned commands is possible, though
the adjusted authorization levels are lost in the WinCC pictures and are replaced
by the authorization levels adjusted in the template picture.
The Measuring point gets its designation inscribed at creating / updating. Therefore
this must be corrected manually, the fastest way is by using the import / export of
the pictures and correction in MS Excel. After a new update of the UDOs from the
SIMATIC Manager, the process must be repeated. Therefore, the update should be
started with the wizard "Update picture objects "
In the property dialog, the block icon can be specified as the number of the object
type that is created for this block in the picture.

In the upper example the Object type @CTRL_PID/1 for the CTRL_PID block
would be created.

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7.4 Curves
A graphic, that contains curves, can have up to 6 single curves. Each curve will be
connected to a tag from the Process Value Archive.
The graphic consists of a description of the curves in the lower area (Color symbol,
Name, Display Area, current value, unit) and the actual formatted curve.
A typical layout for a chemical plant curve looks like.

 Up to 6 curves will be put together to one group. The following colors apply:
Curve 1 Black Curve 4Green
Curve 2 Red Curve 5Yellow
Curve 3 Blue Curve 6Turquoise
 A common time axis is used. The format is hh:mm:ss. The timeframe is 2 hours.
For each curve a value axis will be created. The scaling is done in steps of 10
units. That means, one scaling unit is equal to the display range divided by 10.
Each value axis will be labeled with the corresponding unit.
 Display: Current value of the I/O Driver Block.
 The following symbols won’t be displayed in the symbol bar:
Open Help System
Open Configuration Dialog
Open the dialog for selecting tags or archives
 Calling the graphic: A curve will be selected via the current value of an UDO.
Through this action the graphic with 6 curves will be opened.

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7.5 Lifebeat monitoring

Normally, Lifebeat Monitoring will not recognize just one interrupted connection to
the H-System. Only when both connections fail, will the interrupted connection be
displayed in Lifebeat Monitoring.
With the following configuration you can monitor both connections to a H-System.
1. Open the OS-project.
2. Choose the unit "Industrial Ethernet" in the variable container > SIMATIC S7
PROTOCOL SUITE.
- With the right mouse button, click on "Industrial Ethernet" and choose a
new connection in the dialog that opens.
- Now enter "S7(PlantA)_1" as name.

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- In "Properties" enter the Ethernet address, rack number and slot of the
first CPU.

3. Enter another connection in this channel as described in step 2.

- As name, please enter " S7(PlantA)_2".
- In "Properties" enter the Ethernet address, rack number and slot of the
second CPU.
4. In the WinCC-Explorer, choose Lifebeat Monitoring and open it.

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5. Enter the data as shown in the following figure.

6. Click on the Update button to refresh the display for the configuration graphic
"@Config.pdl".

7. Close the dialog.

Note:
! For PlantB, which is a single CPU, add another device to the Device List in
Lifebeat Monitoring and select the corresponding named connection.

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7.6 Time synchronization

The time synchronization in a chemical plant has the following purpose.
 Synchronization of all PCS 7-Components such as CPUs, Servers, Terminals,
and Engineering Stations.
The following pictures show the settings for time synchronization.
In this example the Server PCs (Primary and Standby) will be the time Master:
The Primary Server is connected to an external DCF77 clock for receiving the
exact time.
The software “DCF77 Service” makes the synchronization for the Primary Server.
Example of configuration of “DCF77 Service” for Primary Server.

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The time synchronization for the “Processbus” is accomplished through the servers
over the CP1613.The following parameters must be chosen for both servers.

Note:
! If the Engineering Station has no CP1613 the Settings for Time,
synchronization cannot be executed on the ES. The settings for the time synchronization
must then be performed on both Servers after the Download of the OS Project
In this case the CP1613 of the server that has started up first works as Master.
If the Master server fails or is turned off the redundant partner takes over the master
functionality.

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The CPUs of the AS are running as time Slave and receive their time over the
system bus.
The following settings have to be made in HW-CONFIG for each CPU.

The WinCC-Terminals get their time from both servers.

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Therefore, the following settings have to be made in the Editor "Time

Synchronization" in each Terminal-project.

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Activate daylight savings time on each computer.

(Setting: "Start > Settings > Control Panel > Date/Time" tab "Time Zone").
Required Time Zone for Germany: GMT + 01:00

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7.7 Autostart functionality

In order to get a server to reboot and restart after a failure automatically, the
Autostart functionality has to be activated.
This has to be done with the following settings.

Enter the path to your OS-Project and click on “Add to AutoStart”.

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7.8 Key lock for MultiTerminal

Over the properties-dialog of the computer in WinCC Explorer you can lock certain
keys. The key locks can be set in the tabs “Parameter” and “Graphics-Runtime”.
Keys, such as "Ctrl+Alt+DEL" or "Alt+F4", can be disabled for the operator.

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8 Archiving

In a PCS 7 system, you can archive various types of data that accumulates during
process mode. This data includes process values such as measured values,
messages and alarms.
PCS 7 allows you to create archive tags for process values designated for this
purpose. These process values must be designated in the SIMATIC Manager as
being relevant for archiving using the “Archive” attribute. This attribute can only be
set for block I/Os intendend for operator control and monitoring. PCS 7
automatically creates the required archive tags when the “Compile OS” function
executes, assuming you have set this option.
As default, archiving is performed locally on the various OS servers. If you also use
a central archive server, further archiving routines are performed centrally on this
archive server.
As an additional tool for archiving data from PCS 7, you can also use Storage Plus.
These software package requires a seperate license.
The picture below shows the separat parts of the archiving.

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8.1 Tag Logging in WinCC
Archiving process values is done by the tool “Tag Logging”. Curves are archived
over a time range of 6 months.
The following Archive configuration has to be set up in "Tag Logging" and is typical
for a chemical plant.
Tag Logging Fast and Slow:
 Archive size: Timeframe over all segments: 6 months.
 Maximum size over all segments: 7 Gbyte.

The Process Value Archive contains stored values of variables that have been
created in the Process Value Archive.
The Process Value Archive is configured as a cyclic archive. Storage location is the
hard drive.
Example of typical configuration for chemical plant:

Cycle Time Archiving Time

in Sec. in Sec.
Temperature 30 30
Level 10 30
Pressure 2 30
Flow 2 10

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8.2 Alarm Logging in WinCC

The occurred status changes of alarms and messages will be written to
configurable Message Archives. Archiving messages can be done through Long
Term Archives.
Messages will be stored in a long-term archive. All required settings have to be
made in the Alarm Logging Editor of WinCC.

Long Term Archives

Example of a typical configuration for a chemical plant.

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8.3 Central Archive Server (CAS)

The central archive server is used for long-term archiving diverse plant data from
PCS 7 in a central database. The central archive server enables you to manage
swapped-out SIMATIC BATCH measured values and messages from the OS
archives, OS reports and BATCH data. These data are provided regardless of the
PCS 7 runtime system.
The figure below shows a plant configuration with a central archive server.

Note:
! You need to install additional Microsoft components for the central archive server. These
components are on the PCS 7 Toolset DVD in the folder Microsoft\MS_for_CAS.
Install the appropriate language version for the installed operating system.

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8.3.1 Configuring an Archive Server

1. Select the object (name of the project here CAS_1) in the tree structure and
then select the Insert Station  SIMATIC PC Station

2. Select the newly inserted PC Station in the tree structure and select the
“Configuration” object in the detail window and open HW Config
3. Select the PCS 7_V61 catalog and insert the “SIMATIC PC Station\HMI\WinCC
Application CAS” component

4. Insert further components, for example, network adapters

5. Select the “Store and compile station” menu command and close HW Config
6. Select the “(OS)” object of the archive server in the tree structure of SIMATIC
Manager
7. Select the Edit  Object Properties menu command

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Archiving

8. Enter the name of the archive server in the “Name” input box
9. Change to the “Target OS” tab and enter the destination path of the archive
server

10.Click the “Apply” button and go to the “CAS options for central archive server”
tab

11.Enter the time period in the “Save time frame in days” input box for which the
archive data will remain available in the interim archive of the archive server
before it is transferred to the long-term archive
12.Make the settings for the long-term archive
13.Click “OK” this applies the settings

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8.3.2 Server Data

If you use a central archive server in your project, you must distribut the server
data as follows:
 The archive server requires the server data of all OS servers for which it
archives data
 The OS clients require the server data of all OS servers from which they require
data
 The OS clients also require the server data of the archive server so that they
can read out the process value from the archives from the archive server, and,
for example, display them in online trends
How to load the server data is shown in the chapter 7.1.4.

8.3.3 Storage Plus Viewer

OS clients can only display the messages archived locally on the OS server. To
display messages that are already stored on the central archive server, you require
the seperate software package “Storage Plus Viewer”.
In the Storage Plus Viewer, you define views of the database of the archive server.
The data is published over the Internet Information Server and can then be viewed
over an Intranet.

8.3.4 KPI and Advanced Reporting

Only with the CAS it is not possible to realize KPI or the advanced reporting.
If the functionality of KPI and the advanced reporting is claimed in your project you
are able to implement that with SIMATIC IT Historian.
For detailed information refer to SIMATIC IT documentation.

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9 Bulk Engineering

The picture below shows an example with data from CAD/CAE as interface. These
data are used by IEA (Import-Export-Assistant) to generate many process tags
automatically.

 Standardized technological libraries with tested blocks and charts (typicals)

 Import plant data (e.g. process tag list or I/O list) from the higher-level
CAD/CAE world

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  Automatic generation of controller configuration based on the imported process
tag list and the typicals
- Creation of the plant hirarchy
- Editing of saved process tag charts
 Automatic derivation of the OS picture hierarchy, automatic interconnection of
blocks and placement in pictures
 Commissioning of individual process objects with the convenient graphical tools
CFC, SFC
 Export of optimized parameters back to CAD/CAE world during commissioning

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9.1 Import/Export Assistant (IEA)

9.1.1 Import
You can use the import/export assistant to create process tags of process tag
types and import data of the import files to the process tags. The process tag type
is copied as process tags from the project library to the specified target project.

Import options:
 You have selected a process tag. The corresponding process tag type will be
included.
 You have selected a project or hierarchie folder. The process tag types of the
sublevel process tags will be included.
 You have selected a process tag type. This process tag type will be included.
 You have selected a project library or one of its hierarch folders. The sublevel
process tag types will be included.

With the IEA, you can create replicas of models and import the data from the
import file to the replicas.

Import options:
 If you have selected a hierarchy folder that is a model, only this model is
selected for import
 If you have selected a top hierarchy folder (or the project node) and there are
models in the lower levels, all models are selected.

Import dialog
1. Select the required hierarchy folder, project node or process tag library
(hierarchy folder in the project library) or the process tag type.
2. Call menu command Options > Process tags > Import or Options > Models >
Import
3. Customize the import settings
4. Click “Finish” to initiate the import

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9.1.2 Export
Furthermore you can use the IEA to export process tag data. All accessible project
of the multiproject are taken into account. If you have selected the master hirarchy
folder (or the project node) that contains the sublevel process tags, all process tags
will be included in the export and the data are exported. Each process tag type is
assigned an export file, each process tag of the process tag type is assigned a row
in the corresponding export file.
With the IEA, you can export the data of replicas of the models.

Export options:
 If you have selected a hierarchy folder that is a model, only this model is
selected for export
 If you have selected a top hierarchy folder (or the project node), and there are
models at the lower levels, all the lower level models are selected for export and
the data of the replicas are exported.

Export dialog

1. Select the required hierarchy folder of the required model.

2. Call menu command Options > Process tags > Export. The process tags are
now searched for and listed
3. Select the export files intended for export
4. Click “Finish” to initiate the export

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9.1.3 Example
This example shows how to generate n additional motor tags automatically in
PlantB > reactorB of the multiproject.
 Open the Process Object View

Generate 3 additional motors via import

 Right click Motor_I and choose Process Tags > Import

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 Select import file “MOTORS_00”

 Open “MOTORS_00” and make settings

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 Finish the import and you will see following result in process object view

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Built up a OS display in the new generated hierarchy.

 Insert a new picture “Picture_IEA” and execute the function “Create/Update
Block Icons”

 The block icons are inserted into the picture. Each of the 3 motors is
represented by a different symbol icon.

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9.2 Process Object View

You use the process object view when you require details of process tags and CFC
charts and want to edit their attributes and aspects. Working with the process
object view is ideal when you want to assign to say parameters, comments or
interconnections for large volumes of objects. With the process object view all data
of the basic control throughout can be displayed in a process control-oriented view.
Project-wide means that the data of all projects in a multiproject is acquired. All
editable aspects are consistent and presented in a practical form for the user.
The process object view contains 6 tabs for the various aspects of the object.
 General:
This displays all the subordinate ES objects (process tags, CFCs, SFCs,
pictures, reports, or additional documents) with their general information for the
plant unit currently selected in the left-hand window.
 Parameters:
This displays the connecting points which were explicitly selected in the
process object view for editing (S7_edit = para) for all the process tags and
CFCs displayed in the "General" tab.
 Signals:
This displays the connecting points which were explicitly selected in the
process object view for editing (S7_edit = signal) for all the process tags and
CFCs displayed in the "General" tab.
 Messages:
Here the corresponding messages are displayed for all the process tags and
CFC charts displayed in the "General" tab.
 Picture objects:
This displays any picture interconnections which may exist in WinCC for all the
process tags and CFCs displayed in the "General" tab.
 Measured value archives:
This displays any archive interconnections which may exist in WinCC for all the
process tags and CFCs displayed in the "General" tab.

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Jumps to CFC, SFC, HW Config and WinCC Explorer allow editing of aspects that
cannot be edited directly in the process object view (such as module parameter
assignments, picture contents).

9.2.1 Example
The following shows how to check / adapt all limits of measuring range in a project.
 Select the complete project and then filter the process tag types using tab
“General” > filter by column “Process tag type” > display “Analog Messung”

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 Filter the process tag connector using tab “Parameters” > filter by column
“process tag connector” > display “MO_PVHR”

As the result the measuring range high limits of all Process tags from type
‚AnalogMessung‘ are displayed. Now you are able to check and adapt the several
values faster.

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9.2.2 Exporting and Importing I/Os and Messages

By exporting and importing attributes, you have the following options with the
information from parameters, signals, and messages:
You can:
 Export them to a file
 Edit them with standard applications (EXCEL, ACCESS)
Open the import/export file with EXCEL but not by double-clicking on the csv
file.
- First start the EXCEL program.
- Then select the relevant file with the "File > Open..." menu command.
The content is now arranged in columns according to your headers.
 And read them in again (import).
These functions are particularly advantageous of you want to edit greater amounts
of data. You do not have to open the individual charts with CFC in order to edit the
I/Os, since the I/Os of all the charts of the hierarchy folder are read in
automatically.
Those charts which are positioned in the selected and in all the subordinate
hierarchy folders are edited (corresponding to the selection in the process object
view).

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10 Integrated Asset Management

SIMATIC PCS 7 with the diagnostic and maintenance functions provides the
monitoring of the various components of a PCS 7 plant, and display of the status in
the process mode. This status is shown with defined symbols, which are the basis
for the NAMUR/PNO definition.
When diagnostic and maintenance functions are used, a Maintenance Station must
be created.

10.1 Maintanance and diagnostic stations

A maintanance station provides diagnostic and maintanance functions. The basis
for a maintanance station (MS) is always an OS that provides this additional
maintanance functionality. The maintanance station can be operated on an OS
server as an MS server and/or on an engineering station as an MS client.
With SIMATIC PCS 7 V6.1 two types are possible for the Asset Management.

10.1.1 Single Workstation System with Maintanance Station

The engineering station, operator station and maintanance station are on one
computer.

Note:
! In this configuration, the OS must configured as a multiple workstation system. You make
this settings when you create the project with “New Project” PCS 7 wizard.

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10.1.2 Multiple Workstation System with MS Client on the ES
The MS client is installed directly on the ES and the MS server is on a separate
computer.

This installation is advisable because all the data of the PCS 7 project required by
the MS client is already available. With this setup, you can avoid the manual
transfer of the PCS 7 project data to a separate MS client and subsequent adaption
if you want to monitor SNMP components. With this plant configuration, the manual
jobs that must be done after each update of PCS 7 project are also unneccessary.

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 Integrated Asset Management

10.2 Diagnostic Structure

In the following the procedure for setting up of the diagnostics screens in the plant
hierarchy is described.
1. Select the name of the Multiproject in the tree structure
2. Select the menu commend Options  Plant Hierarchy  Settings, the dialog
“Select the project to be used as a template” is opened

3. Select the project whose to be used as a template for the plant hierarchy and
click OK
4. In the dialog field “Customize Plant Hierarchy” select the option “Derive
diagnostics screens from the plant hierarchy”

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Integrated Asset Management

5. The next dialog “Define maintanance station” shows all OS stations, which are
available in the Multiproject. Select the OS server that you want to define as a
diagnosis server and cklick OK

After having created the diagnosis structure for the first time, you will find the
following hierarchy by default:

First hierarchy Second hierarchy Third hierarchy Fourth hierarchy level

level level level
(Multi)project Diagnostics Overview picture –
“Overview”
PLC objects Overview picture – “PLC objects”
Network objects Overview picture – “Network
objects”
PC stations Overview picture – “PC stations”

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10.3 Diagnostic Screens

To generate diagnostics screens, the module drivers must have been generated
and interconnected with the signal-processing blocks in the CFC charts after all the
configuration operations, such as hardware configuration, CFC and SFC charts,
OS configuration, etc., have been completed. These module drivers are blocks with
special functions in PCS 7 that are required for the diagnostic functions.
There are two ways to generate the module drivers:
1. When you compile the AS: Activate the option “Generate module drivers” in the
compilation settings. This performs the automatic generation of the module
drivers during the compilation.

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2. When you execute the function “Create/update diagnostics screens”: When this
function is executed, PCS 7 checks whether changes have been made to the
hardware for which no module drivers have yet been generated. If that is the
case, all CPUs for which no module drivers have yet been generated, are
displayed one after the other in a dialog field where they can be selected for the
function “Generate module drivers”.

For the generation of the diagnostics screens, SIMATIC PCS 7 offers a fully
automatic function that generates all diagnostics screens with the corresponding
diagnostic block icons in the required plant hierarchy.

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By executing the function "Create/update diagnostics screens", corresponding sub-

folders and their diagnostics screens are created for all objects of the plant
configuration with diagnostics capability.

Select the menu option “Options > Plant Hierarchy > Create/update diagnostics
screens” or, via the context menu with the right mouse button, “Logic Hierarchy >
Create/update diagnostics screens”, as shown in the picture under 2. above.

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10.4 Diagnostic and Maintanance Icons

For all PCS 7 components, uniform icons are displayed that indicate the
maintanance and diagnostic status.

10.4.1 Diagnostic and Maintanance Icons in Block Icons

In the following you will find a list of all diagnosis and maintenance icons that are
used in the block icons. These icons were generated according to NAMUR and
PNO recommendations and they are strictly used in the PCS 7 Maintenance
Station.

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10.4.2 Diagnostic and Maintanance Icons in Faceplate

In the following you will find a list of all diagnosis and maintenance icons that are
used in the faceplates. These icons were generated according to NAMUR and
PNO recommendations and they are strictly used in the PCS 7 Maintenance
Station.

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11 Compile and Download

Before you can download the program into the CPU, it must be compiled. It will be
complied into a machine language. During compilation, the program will be
checked for errors and warnings.
You can compile the complete program or changes only.

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11.1 Download CFC
First the hardware definitions and the network configuration have to be downloaded
into the CPU (if this hasn’t been done before).
The S7 Program has to be downloaded from the CFC. PCS 7 takes care of the
right order of the loading procedure.

Note:
! Do not download the blocks in SIMATIC Manager directly!

You will be asked for a complete download or to download only the changes.
Changes in the interfaces of a function or function block will require a full compile
and a partial download of the program.
This results in a CPU stop.

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 Compile and Download

11.2 OS compilation
In the step ‘Compile OS’, according to the selected scope of the compilation the
Picture Tree, SFC visualization, Server package, and the block icons can be
generated/updated along with the variable transfer.
In order to make the object variables available in the tag management of WinCC
the OS Compile must be executed. You can find this function in the SIMATIC
Manager under Options > OS > Compile.
First select the program icon to assign the S7-Program to an operator stations.

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Compile and Download

Check for network connections! Named connections are required.

Select each S7-Program and press “Named Connection”

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 Compile and Download

Select the subnet type “Named Connections”.

Finally select the transfer data and the scope of compilation.

Note:
! Don’t forget to deselect the picture tree, if you created the picture tree manually in
the OS-Project. Otherwise it will be overwritten!

Now press “Finish” to start the compilation.

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Compile and Download

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12 Maintenance

12.1 Delta Compile and download in Run

After new plant objects or pictures were added and the function has been tested on
the Engineering Station, we want to update the Servers and the Terminals to make
the new function available for the process. This requires a project download to the
OS PCs.
If there was no structural change, and as long as an OS Compile for changes is
possible, the OS Stations can remain in Runtime mode during the Project
Download. After a complete OS compilation, the destination Project has to be
deactivated during the Download procedure.

Note:
! The modifications in the OS-Projects for the Server, Standby-Server, and
Terminals are never performed directly on the OS Stations. Any modification has
to be carried out on the Engineering station and then being downloaded are
different OS Stations.
The update procedure can be performed manually (step by step) or automatically
using the “Compile and Download Objects” Dialog in the SIMATIC Manager.

Manual update procedure:

1. Compile the CPU-Program (from CFC).

2. Compile the OS Project(s) .
If you have an OS-Project for the ES and one for the Server you have to start
the compilation for both OS-Projects.
At the end of the OS Compile procedure the Server Data is automatically
updated by the system and the updated package is automatically loaded into
the Terminal Projects.
3. Now you can carry out the Project-Download from the Engineering Station to
the Server Station. The Download is executed from the SIMATIC Manager by
selecting the OS-Project and pressing Download Button.
4. Wait for the “Download successfully completed” – Message before you
continue.
5. Now you can carry out the Project Download from the Engineering Station to
the Standby-Server Station. (Same procedure as for the Main Server).
6. After the “Download successfully completed” – Message the Project Download
is finished!

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 7. If it is necessary to update the Terminals as well (may not always be required),
use the same procedure for each Terminal.
“Make” Dialog: Compile and Download Objects.

The Picture shows the required Selection to update the Servers (Primary and
Standby Server) and one Terminal.

Note:
! Even if only the OS Project for Server is selected for Compilation and Download,
the Standby-Server is getting updated as well

Structural changes (e.g. a new variable was added for an existing object) require
the stop of the runtime system during the project download. This is still no problem
because of redundant Servers but the download procedure is slightly different:
1. To actualize the Tag Management an OS Compile has to be performed.
The OS Compilation must be executed on ES.
At the end of the OS Compile procedure the Server Data is automatically
updated by the system and the updated package is automatically loaded into
the Terminal Projects.
2. After that you must close the OS-Project on the Server Station. First close the
WinCC Explorer (if it is not already closed) and second the Runtime.
The Standby-Server will be MASTER, the Terminal will be switched to the
Standby-Server.

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 Maintenance

Important
After closing the WinCC Project on the Server Station, you have to wait for at least
2 minutes. During this time the project is still “used”.

3. Now you execute the Project-Download from the Engineering Station to the
Server Station. The Server-Project on the Engineering Station must remain
closed. The download is started from the SIMATIC Manager.
4. Wait for the “Download successfully completed” – Message before you
continue.
5. After both Servers are running again, the Redundancy Manager starts
actualizing the Server data. If necessary wait until the procedure is finished.
6. Now you can close the OS-Project on the Standby Server Station. First close
the WinCC Explorer (if it is not already closed) and second the Runtime.
The Server will be MASTER, the Terminal will be switched to the Server.

Important
After closing the WinCC Project on the Standby-Server Station, you have to wait
for at least 2 minutes. During this time the project is still “used”.

7. Now you can execute the Project-Download from the Engineering Station to the
Standby-Server Station. The Download is carried out from the SIMATIC
Manager.
8. After the “Download successfully completed” – Message the Project Download
is finished!

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Maintenance

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13 References

Use always the current documentation of the used version of SIMATIC PCS 7.
The references in the table below refer to PCS 7 V6.1.

1. Process Control System PCS 7 PC Configuration and Authorization

Edition 01/2005
A5E00353686-01

2. Process Control System PCS 7

Engineering System
Configuration Manual
Edition 01/2005
A5E00346923-01

3. Process Control System PCS 7

Operator Station
Configuration Manual
Edition 01/2005
A5E00347064-01
4. Process Control System PCS 7
STEP 7 - Modifying the System During Operation via CiR
Edition 09/2004
A5E00266885-02
5. Process Control System PCS 7
S7 H Systems - Fault-Tolerant Systems
Edition 12/2004
A5E00267695-01

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