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www.siemens.com/simatic-pcs7

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

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

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 Process Control
Combination of “Automation engineering” + “HMI” + “Communication”
Automation System “AS” + Operator Station “OS” +
Bus

* Configuration centralized in the Engineering System “ES”, which contains

libraries tools and AS/OS blocks.
libraries, blocks

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 -SIMATIC Process Control System 7 based on the SIMATIC S7-400 CPUs.
-Other controllers (S7-200 & S7-300 ….etc) can be integrated in PCS7 but not
parameterized.

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 Overview
Select SIMATIC S7-400 components can be combined in the automation systems of
the SIMATIC PCS 7 process control system.
The following characteristics make the SIMATIC S7-400 predestined for use as a
SIMATIC PCS 7 automation system:
• modular and fan-free design,
• high degree of expansion capability and robust design,
design
• simple or redundant design,
• comprehensive communications capabilities,
• integral system functions and
• simple connection of central or distributed I/Os.
Various automation systems are available with a price/performance ratio which can
be tailored to your system requirements.
All automation systems are equipped with an onboard PROFIBUS DP field-bus
connection. Additional PROFIBUS communication modules can be fitted if required.
Design
The automation systems are delivered as preassembled and tested complete
systems without surcharge, and are mostly comprised of:
• Racks with 9 or 18 slots, which can be physically separate in the case of
redundant systems
• Standard CPU 414-3, 416-2, 416-3 or 417-4 as well as the redundant CPU 414-4H
or 417-4H
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 SIMATIC PCS7 BOX extends the product spectrum of SIMATIC PCS7 by adding a
cost-effective entrance-level product that unites SIMATIC PCS7 functionality for
automation, operation, visualization and engineering in one compact PC system. In
conjunction with the distributed I/Os on the PROFIBUS, SIMATIC PCS7 BOX
represents a complete SIMATIC PCS7 process control system.

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 Engineering Toolset

1-Hardware Configuration
2- Libraries (for modules, blocks,….)
3- CFC “Continues Function Chart” for function diagram
4- SFC “Sequiatial Function Chart” for process control
5- Graphic Designer
6- Faceplate Designer
7- SCL “Structured Control Language” for customized function block using (codes)
commands AWL file
8- Simatic Batch for Batch process
9- Simatic Route Control for route selections
10- F-System (yellow code) Fail safe system
11- PDM “Process Device Manager”

-From 1 to 4 is used for “AS” logic programming

-5
5 & 6 iis used
d ffor SCADA (M
(Monitor
it & C
Control)
t l)
-From 1 to 6 is a standard SW package rest is special ones

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 Block Libraries Depending on whether V4 (old project, old CPU) or V5
(new project, new CPU) is used, use the File Manager in the SIMATIC Manager to
hide the libraries you are not using. It can be advantageous to create a separate
library for each project in the same project directory. In the first instance, keep the
blocks there that will then be used in the project. If you upgrade the software at a
later date, you can first try to import to a copy of this library before using the blocks
in projects.
Create
C t PProject
j t U th
Use the SIMATIC Manager
M tto create
t the
th new project.
j t
The Manager handles all of the data generated during configuration.
Resources The resources include the stations in the project (with their hardware),
the S7 programs (with blocks in the user programs, chart containers containing
blocks imported via CFC), networks, as well as the OS.
Hardware Within the project, the AS hardware components (CPU, CP, and I/O
modules)
d l ) mustt bbe configured
fi d iin accordance
d with
ith th
the h
hardware
d structure.
t t Thi
This
configuration is loaded into the station and sets parameters for the modules.
Plant Hierarchy A hierarchy (with a maximum of five levels) is used to
display the system to be configured in the project. The hierarchy corresponds to the
AKZ system (comparable to a directory tree).
Assign Resources One AS and one OS can be assigned to each hierarchy
l
level.
l Th
The subordinate
b di t llevels l can iinherit
h it th
the assignment.
i t CFC and
d SFC charts,
h t OS
displays, reports and documents belonging to the assigned AS/OS are inserted in
the last level (as “leaves“ on the “branch“).
Software AS-specific or OS-specific tools are used to configure the software as
needed. From the AS, you double-click the object in the plant hierarchy to start the
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 Info Flow Sensors, transducers, and DP process signal converters record
process information. The AS processes this information and uses the same path to
pass it on to the actuator. In parallel, commands are sent from the OS to the AS. AS
information is displayed graphically on the OS.
ET 200M The IM 153-1 interface module converts the process signal converter
(I/O module) information into message frames for and from the AS.
DP bus The bus (PROFIBUS DP) transports the message frames between the
AS (DP master interface) and the ET 200M interfaces.
AS (S7 417-4) The DP master interface reads in the telegrams in the
AS. The driver blocks convert and process the message frames into process
values. That is, open-loop control algorithms and closed-loop control algorithms
convert the frames into commands and send the commands back to the distributed
I/Os the same way. At the same time, the values are monitored. When specified
events
t occur, messages are sentt tot the
th OS.
OS
System Bus The system bus can be MPI (Multi-Point-Interface), PROFIBUS or the
industrial Ethernet. The system bus serves to communicate between the AS-OS,
AS-AS, as well as the ES with the above mentioned nodes used for configuring and
startup purposes.
OS (WinCC) Data coming from the AS - embedded in process mimics - is displayed
graphically
hi ll as measured d values
l with
ith a titime-based
b d sequence, and
d as messages with
ith
classification. The plant operator's commands are passed on the relevant AS and
the response information displayed.
The configuration and startup steps shown on the following pages are
based on this procedure.
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 ES Software The system should be configured with a uniform, plant-
oriented approach. This is why the components shown in the slide above were
expanded and coordinated with each other. The optional package expands the
SIMATIC Manager and makes it possible to carry out the described task.
System Orientation The optional process control components provide the
PCS project planning engineer with an environment in which process automation
tasks, operating and monitoring tasks, communication between the components,
anddddocumentation
t ti can b be carried
i d outt iin a system-oriented
t i t d manner. Si
Since th
the
various SIMATIC components are managed in a system-related measuring point-
oriented hierarchy (project planning engineer assigns AS objects, OS objects and
documents to a specific system component), configuration, startup and
maintenance become significantly more efficient.
Import/export Interfaces to other configuration tools are provided. This is how PCS
engineering fits into the whole process engineering/production engineering
approach.
Division of Work
Work is divided when a project is handled on various networked PCS.
Project work can be divided into several secondary projects on non-
networked PCs. The divided work is then combined into one project.

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 Vertical Integration
The available software, database management and communication
allow vertical integration in all components and levels of the TIA product range.

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 Horizontal Integration All the components in all phases – from
material to end product storage – make horizontal integration
possible.

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 www.siemens.com/simatic-pcs7

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 1. Open the SIMATIC Manager
2. If the wizard does not start automatically, select the menu command File > 'New
Project' Wizard....
The PCS 7 "New Project" wizard opens.
3. In step 1(4) "Introduction", activate the option "Multiproject with project and
master data library" – this option is activated as the default setting.
4 Click the "Next" button
4. button.

Note: Click on the "Preview>>" button to display a preview of your current stage of
configuration. This preview corresponds to the appearance of the project in the
SIMATIC Manager .

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 5. In Step 2(4) "Which PLC will you use in your project?", select the CPU type you
are using in your project, for example a CPU 417-4. Below the list, you will see
detailed information on the selected CPU. When you make your selection here, you
should compare the type number and order number printed on the front panel of
your CPU with the type number and order number displayed in the list.
6. Click the "Next" button.
7. In step 3(4) "Which objects will be used in the project ?", make the following
settings:
- In the list box "Number of levels", select the entry "4".
- In the "AS objects" section, ensure that the check boxes "CFC chart" and "SFC
chart" are activated.
- Under OS objects, activate the "PCS 7 OS" check box.
The "Single
"Single-user
ser ssystem"
stem" option is a
automatically
tomaticall activated.
acti ated
8. Click the "Next" button.

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 9. In step 4(4), enter the project name “PCS7_ITC” in the "Directory name" box and
confirm the storage location.
10. Click on the "Finish" (Make) button.
The dialog box "Message Number Assignment Selection" opens when the project is
created and the check box "Assign unique message numbers CPU wide” is
activated."
11 Accept the current settings and click the "OK"
11. OK button.
button

The project is now created with these settings.

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 Once you have opened your project in the SIMATIC Manager, you can activate
various views:
• Select the menu command View > [Name of the desired view] in the SIMATIC
Manager:
- Component view (mainly for HW operation)
- Plant view (mainly for hierarchy of the system)
- Process object view (mainly for data
data, msg
msg, pics
pics, duplicate
duplicate… operations)
• If you have already opened several projects, select the menu command Window
> [Name of the project (name of the view)].
• You can display all the 3 view by the menu command Window > Arrange > [type
of arrangement].

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 In the component view:
1. Go to the tree structure and select the folder PCS7_ITC_MP/
PCS7_ITC_Prj/SIMATIC 400(1)".
2. Mark the "Hardware" object in the detail window and select the menu command
Edit > Open Object.
HW Config is opened and the hardware structure of your system is displayed.
Note
If the hardware catalog is not displayed, select the menu command View >
Catalog.
The hardware catalog opens and the "PCS7_V61" profile is active.

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 3. Select the following CP from the catalog: "SIMATIC 400/ CP-400/Industrial
Ethernet/ CP 443-1/ 6GK7 443-1EX11-0XE0/V2.0" or "..../ V2.3" and drag it to slot 5
of the rack.

The "Properties - Ethernet Interface" dialog box opens.

4 Activate the "Set MAC address/use ISO protocol" option.

4. option

5. In the "MAC address" box, enter the MAC address printed on the front of the CP.

6. Deactivate the "IP protocol is used" option.

This deactivates all the associated input boxes.
boxes

7. Click the "New" button to create a new network connection. The CPU will
communicate with the ES via this network connection.
The "Properties - New Subnet Industrial Ethernet" dialog box opens.

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 8. Apply all your selections and click the "OK" button. The "Ethernet(1)" entry is
entered in the "Subnet list box and is already selected.
9. Click the "OK" button to enter your settings. The dialog is closed.

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 10.Open the properties of the MPI in the CPU, choose its properties then assign it
to a MPI-Subnet and give it an MPI address. This is only for trying the program
without AS (controller) using the “PLCSim” connected to the WinCC (SCADA)

11. Select the menu command Station > Save and Compile.

12 Close HW Config
12. Config.

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 11. Select the following CP from the catalog: "SIMATIC 400/ CP-400/PROFIBUS/
CP 443-5 Ext./ 6GK7 443-5DX04-0XE0” and drag it to slot 6 of the rack.

The "Properties - PROFIBUS Interface CP 443-5 Ext" dialog box opens.

12. Assign it to a PROFIBUS-Subnet and give it the same address like the switch in
the CP
CP.

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 13. Select the following CP from the catalog: "SIMATIC 400/ CP-400/PROFIBUS/
CP 443-5 Ext./ 6GK7 443-5DX04-0XE0” and drag it to slot 6 of the rack.

The "Properties - PROFIBUS Interface IM 153-2" dialog box opens.

14. Assign same address like the switch in the IM.

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 15. Select the IM signal modules from the catalog (DI, DO, AI, AO, …etc), see next
slide

16. Select the menu command Station > Save and Compile.

17. Close HW Config.

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 In the component view
1. Select the object “PCS7_ITC_MP/ PCS7_ITC_Prj/ SIMATIC PC Station(1)" in
the tree.

2. Select the menu command Edit > Rename. (or right click on the PC station >
Rename)

3. Enter the name of the local computer as it appears in the network and press the
Enter key. The icon of the PC station is labeled with a yellow arrow in the
component

Note
If the PC station is not labeled with a yellow arrow, press the "F5" key. This
refreshes the screen display.

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 1. Select the folder “PCS7_ITC_MP/ PCS7_ITC_Prj/ [Name of the PC station]".
2. Mark the "Configuration" object in the detail window and select the menu
command Edit > Open Object.
HW Config opens and the components of the OS are displayed. HW Config is
opened with the settings you made during configuration of the PLC:
- The hardware catalog is open.
- The "PCS7
"PCS7_V61"
V61" profile is active
active.
3. Select the following CP from the catalog:
"SIMATIC PC-Station/CP-Profibus/CP 5611/SW V6.0 SP5...“. and drag it to slot 2 of
the rack. The "Properties” dialog box opens, close it.
4- Double click the CP 5611, Choose MPI in the interface type.
5 Click on properties to assign the CP5611 to the MPI network giving it the address
5-
defined in the PG\PC Interface.

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 1. Open the SIMATIC Manager. Select the PC station (from the component view)
and the select the menu command PLC > Configure. The "Configure" dialog
opens.

2. Select the required target computer in the "Available Computers" list. Click the
"Configure" button. The "Configure: <Selected Station>" dialog opens.

3. To perform the remote configuration and finalize it, follow the instructions
provided by the online help for the dialog section "Configure: < Selected Station>".
Result: The configuration data are transferred to the PC station. You have to
download the network settings to this PC station to activate the network
connections.

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 1. In the tree, select the object “PCS7_ITC_MP/PCS7_ITC_Prj/[Name of you local
computer]/ WinCC Application".
2. Mark the "Connections" entry in the detail window and select the menu command
Edit > Open Object. Net Pro opens.
3. Select the object "WinCC Application" for the SIMATIC PC station. An empty list
is displayed in the lower detail window. You need to enter the required connection in
this list.
4. To do this, mark the first line in the lower detail window and select the menu
command Insert > New Connection . The "Insert New Connection" dialog
opens.

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 5. Select the CPU you are using in your project in the tree. This is the
communication partner of the OS, i.e. the OS receives data from this automation
system.

6. In the drop-down list "Type", select the entry "S7 Connection" and activate the
check box "Display properties before inserting".

7. Click the "OK" button. The "Properties – S7 Connection" dialog opens and the
"General" tab is active.

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 8. Select the connection partner for the connection between the CPU and OS as
shown in the slide.

9. Click the "OK" button. The new connection is shown in the list. This new
connection is displayed if you select the CPU for the PLC.

10. Select the menu command Network > Save and Compile
10 Compile. The "Save and
Compile" dialog box opens.

11. Activate the "Compile and check everything" option in the dialog and click on the
"OK" button. When compiling is completed, the "Outputs for consistency check"
message window opens.

12. When the compiling was completed without error, close the window. If any errors
are shown, correct them using the error messages and perform the compiling again.

13. Choose the PC station in the NetPro and in the menu command > PLC >
Download selected stations.

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 In this course we are working with PLC-Sim as our AS
1- From the SIMATIC Manager menu > Options > Simulation modules to activate
the AS simulator.
2- Turn the simulator into Run_P.
3- Back to the NetPro and in the menu command > PLC > Download selected
stations.

Now we have configured the AS & OS with their network connections.

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 The plant hierarchy that normally abbreviates to PH, mirrors the hierarchical
structure of your plant: Plant, unit, function etc. The PH allows you to make a lot of
different settings and the most important of these are described below.
• Number of hierarchy levels: Your plant structure influences the number of
hierarchy levels. As a rule of thumb, the more complex the plant structure the higher
the number of hierarchy levels you require to reflect your plant structure. Hierarchy
folders with the default names are created when you work with the wizard.
• Selecting the hierarchy level(s) that contribute to the name of the plant designation
(also known as higher level designation): The higher level designation abbreviated
to HID is used at many points in the PCS 7 project, for example, messages
occurring during the process mode and tags contain this HID. This enables you to
quickly determine the association of a message or tag to a specific plant unit. s a
rule of thumb, the more hierarchy levels used to specify the HID and the longer
each individual part is,
is the longer and less easily recognizable the entire HID
becomes.
• Deriving the picture tree from the PH: The process pictures are arranged in a
certain hierarchy: This allows you to
change from an overview picture to a lower level picture showing only part of the
overview picture but with far greater detail. You can derive the tree of the process
pictures from the plant hierarchy so that they conform to the plant hierarchy
hierarchy.

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 1. Select the "color_gs_MP/color_gs_Prj" hierarchy level in the tree structure.
2. Select the menu command Options > Plant Hierarchy > Settings.
The "Customize Plant Hierarchy" dialog box opens where you can set all the
options for the Plant Hierarchy.
3. Enter the value "4" in the "Number of hierarchy levels" box.
This means that a maximum of 4 hierarchy levels are permitted.
4. For hierarchy levels 1 to 4, enter the value "10" in the "Max. number of
characters" field.
This limits the plant designation to 10 characters per hierarchy level.
5. Activate the "Include in designation" check box for the levels 1 and 2.
6. Activate the "OS area" option button for level 2.
7. Activate the "Base picture hierarchy on the plant hierarchy" check box.
8. Click the "OK" button to enter your settings.
The message "You have changed the "Included in HID" property. Do you also
want the changes to apply to existing hierarchy folders?" is displayed.
9. Click on the "Yes" button in the dialog.
This enters all your settings.

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 1. Rename the highest hierarchy folder to plant and delete all (units & functions in
it).

2. Start inserting hierarchy folders like shown in the slide.

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 1. In each hierarchy folder insert an CFC & Picture.

2. Rename the CFC to the hierarchy name.

3. Right click on the picture, choose Object Properties and select to “derive the
block icons” for the symbols in the picture to be taken from the CFC blocks while
compiling.
compiling

Repeat the above steps for all hierarchy folder.

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ITC 57/1
 www.siemens.com/simatic-pcs7

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 What is CFC?
CFC (Continuous Function Chart) is a graphic editor that can be used in conjunction
with the STEP 7 software package. It is used to create the entire software structure
of the CPU from ready-made blocks (or user defined blocks). When working with
the editor, you place blocks on function charts, assign parameters to them, and
interconnect them. Interconnecting means, for example, that values are transferred
from one output to
one or more inputs during communication between the blocks.

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 Generating Module Drivers
The module drivers in PCS 7 are special blocks for diagnostics and signaling errors
that occur during the signal processing. With the "Generate Module Drivers"
function, you can include these blocks in your charts automatically if the following
conditions are met:
The hardware is configured with HW Config and
the technological functions are configured in CFC
CFC.

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 The following slides is an example for SCL, target is to create reactor block

1- In SM > component view > project master library > sources > right click > insert >
SCL
2- In symbol table define reactor as FB600
3- open the SCL file then copy & paste the next code then compile to generate the
reactor FB

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 FUNCTION_BLOCK Reactor(* Simulation block with feedback signals
for PCS 7 course only *)

(* Block Attributes *)

TITLE ='REAC';
VERSION:'5.0';
//KNOW HOW PROTECT if no comment
//KNOW_HOW_PROTECT
AUTHOR:Siemens;
FAMILY:Training;
NAME:PLANT;

((* Variable Declaration *))

VAR_IN_OUT

V1_OP_CL: BOOL; //Filling1

V2_OP_CL: BOOL;; //Filling2
g
V3_OP_CL: BOOL; //Filling3
M1_ON_OF: BOOL; //Mixer motor
RS_COOL : BOOL; //Container empty and cold
SET_HOT : BOOL; //Container full and warm
V_RESET : BOOL;; //Valves closed,, motor off

END_VAR

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 VAR_INPUT

V1_FLOW: REAL := 100.0; //Flow V1 0..100%

V2_FLOW: REAL := 100.0; //Flow V2
V3_FLOW: REAL := 100.0; //Flow V3
CFV: REAL := 0.002; //Correction factor valves
V HOT FL:
V_HOT_FL: REAL ::= 0.0;
0 0; //Flow heating 0
0..100%
100%
TMP_ENV: REAL := 20.0; //Environment temperature
TMP_HOT: REAL := 120.0; //Heating medium temperature
T_LAG_SH: REAL := 10.0; //T_PT1-Shell[s]
T_LAG_IN: REAL := 30.0; //T_PT2-Inside[s] full reactor
SAMPLE T: REAL :=
SAMPLE_T: : 1.0; //Sampling time[s]

END_VAR

VAR_OUTPUT

OVERFLOW: BOOL := FALSE; //Overflow

LEVEL{S7_m_c:= 'true'} : REAL := 0.0; //Fill level in %
TMP_SHEL: REAL := 20.0; //Shell temp
TMP_INT {S7_m_c:= 'true'} : REAL := 20.0; //Internal temp
FB_V1_CL : Bool := 1;; //Valve1 closed
FB_V1_OP {S7_m_c:= 'true'} : Bool := 0; //Valve1 opened
FB_V2_CL : Bool := 1; //Valve2 closed
FB_V2_OP {S7_m_c:= 'true'} : Bool := 0; //Valve2 open
FB_V3_CL : Bool := 1; //Valve3 closed
FB_V3_OP
_ _ {{S7_m_c:=
_ _ 'true'}} : Bool := 0; //Valve3 open
p
MOTOR_ON_OFF {S7_m_c:= 'true'} : BOOL := 0; //Motor ON/OFF

END_VAR

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 VAR

STATE1 : bool := FALSE; //State

//State_AuxiliaryCells
AuxiliaryCells
STATE2 : bool := 0; //State_AuxiliaryCells
STATE3 : bool := 0; //State_AuxiliaryCells
STATE_M : bool := 0; //State_AuxiliaryCells
NIV: REAL := 0.0; //Fill level auxiliary cells
TMP SH IN:
TMP_SH_IN: REAL :=
: 20; //Shell temp
temp_Auxiliary
Auxiliary cell
TMP_IN_IN: REAL := 20; //Inside temp_Auxiliary cells
TMP_IN1: REAL := 20;
TMP_IN2: REAL := 20;
TMP_SH_HILF: REAL := 20;
T LAG IN HILF:REAL ::= 0.0;
T_LAG_IN_HILF:REAL
EXP_SHEL: REAL := 1.0;
EXP_IN: REAL := 1.0;
TIME1 : real := 0.0;
TIME2 : real := 0.0;
TIME3 : real := 0.0;;
TIME_MOTOR : real := 0.0;

END_VAR
BEGIN

// Cold reset;
IF RS_COOL
THEN
RS_COOL:=FALSE;
LEVEL:=0.0;
TMP_SHEL:=TMP_ENV;
TMP_INT:=TMP_ENV;
TMP_IN1:=TMP_ENV;
TMP_IN2:=TMP_ENV;
END_IF;

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 //Warm set;
IF SET_HOT
SET HOT
THEN
SET_HOT:=FALSE;
LEVEL:=100.0;
TMP_SHEL:=TMP_HOT;
TMP IN1:=TMP
TMP_IN1: TMP_HOT;
HOT;
TMP_IN2:=TMP_HOT;
TMP_INT:=TMP_HOT;
END_IF;

// Valve and motor reset;

IF V_RESET
THEN
V_RESET := FALSE;
V1_OP_CL := FALSE;
V2_OP_CL := FALSE;;
V3_OP_CL := FALSE;
M1_ON_OF := FALSE;
FB_V1_CL := TRUE; //Valve1 closed
FB_V1_OP := FALSE; //Valve1 opened
FB_V2_CL := TRUE;; //Valve2 closed
FB_V2_OP := FALSE; //Valve2 open
FB_V3_CL := TRUE; //Valve3 closed
FB_V3_OP := FALSE; //Valve3 open

STATE1 := 0;
STATE2 := 0;
STATE3 := 0;
STATE_M := 0;
END_IF;

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 // Valve and motor feedback signals;

IF V1_OP_CL
V1 OP CL <> STATE1
THEN
TIME1 := TIME1 + SAMPLE_T;
END_IF;
IF V2_OP_CL <> STATE2
THEN
TIME2 := TIME2 + SAMPLE_T;
END_IF;
IF V3_OP_CL <> STATE3
THEN
TIME3 ::= TIME3 + SAMPLE_T;
SAMPLE T;
END_IF;
IF M1_ON_OF <> STATE_M
THEN
TIME_MOTOR := TIME_MOTOR + SAMPLE_T;
END_IF;;
IF (TIME1 >= 4 ) AND (V1_OP_CL = 1)
THEN
FB_V1_OP := 1;
FB_V1_CL := 0;
STATE1:= 1;;
TIME1 :=0;
ELSIF (TIME1 >= 4 ) AND (V1_OP_CL = 0)
THEN
FB_V1_OP := 0;
FB_V1_CL
_ _ := 1;
STATE1:= 0;
TIME1 :=0;

END_IF;

ITC 66/1
 IF (TIME2 >= 4 ) AND (V2_OP_CL = 1)
THEN
FB V2 OP := 1;
FB_V2_OP
FB_V2_CL := 0;
STATE2:= 1;
TIME2 :=0;
ELSIF (TIME2 >= 4 ) AND (V2_OP_CL = 0)
THEN
FB_V2_OP := 0;
FB_V2_CL := 1;
STATE2:= 0;
TIME2 :=0;
END IF;
END_IF;
IF (TIME3 >= 4 ) AND (V3_OP_CL = 1)
THEN
FB_V3_OP := 1;
FB_V3_CL := 0;
STATE3:= 1;;
TIME3 :=0;
ELSIF (TIME3 >= 4 ) AND (V3_OP_CL = 0)
THEN
FB_V3_OP := 0;
FB_V3_CL := 1;;
STATE3:= 0;
TIME3 :=0;
END_IF;
IF (TIME_MOTOR >= 4 ) AND (M1_ON_OF = 1)
THEN
MOTOR_ON_OFF := 1;
STATE_M:= 1;
TIME_MOTOR :=0;
ELSIF (TIME_MOTOR >= 2 ) AND (M1_ON_OF = 0)
THEN

ITC 67/1
 MOTOR_ON_OFF := 0;
STATE M:= 0;
STATE_M:=
TIME_MOTOR :=0;
END_IF;
// Calculate filling level;
NIV:=LEVEL;
IF V1_OP_CL
V1 OP CL
THEN
NIV:=NIV + V1_FLOW*CFV;
END_IF;
IF V2_OP_CL
THEN
NIV:=NIV + V2_FLOW*CFV;
END_IF;
IF V3_OP_CL
THEN
NIV:=NIV - V3_FLOW*CFV;;
END_IF;
IF NIV>100.0
THEN
OVERFLOW:=TRUE;
NIV:=100.0;;
ELSE
OVERFLOW:=FALSE;
IF NIV<0.0
THEN
NIV:=0.0;
END_IF;
END_IF;
LEVEL:=NIV;
//Temperature response

ITC 68/1
 //Shell temp via PT1
TMP_SH_IN:= (TMP_HOT-TMP_ENV)*V_HOT_FL/100.0 + TMP_ENV;
EXP_SHEL:=1.0/EXP(1.0*SAMPLE_T/T_LAG_SH);
TMP_SHEL:=TMP_SH_IN+(TMP_SHEL-TMP_SH_IN)*EXP_SHEL;

//Internal temp via PT2

T_LAG_IN_HILF:=(T_LAG_IN/SAMPLE_T)*(LEVEL+10.0)/110.0;
EXP_IN:=1.0/EXP(1.0/T_LAG_IN_HILF);
TMP_IN1:=TMP_SHEL+(TMP_IN1-TMP_SHEL)*EXP_IN;
TMP_IN2:=TMP_IN1+(TMP_IN2-TMP_IN1)*EXP_IN;
TMP INT:=TMP
TMP_INT: TMP_IN2;
IN2;
END_FUNCTION_BLOCK;

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ITC 70/1
 In the HW-Config we can edit the symbols for each I/O card located in the ET200
station

ITC 71/1
ITC 72/1
 1- From the Plant view > ReacA > Create NK111 CFC & open it
2- From the PCS 7 library > drag & drop 2 “CH_DI” (for open close feedback), one
“CH_DO” (for control output) & one “VALVE” (for the valve control) + one “OR” block
for Control System Fault
3- Interconnect the blocks as shown in the slide to test valve of raw material 1 in
tank A
4 For the “Value”
4- Value of the channel drivers,
drivers right click > Interconnect to address >
choose the associated address
5- Rename the blocks as shown in the slide by double clicking each block

ITC 73/1
 1- From the Plant view > ReacA > Create NP111 CFC & open it
2- From the PCS 7 library > drag & drop one “CH_DI” (for running feedback), one
“CH_DO” (for control output) & one “MOTOR” (for the motor control) + one “OR”
block for Control System Fault
3- Interconnect the blocks as shown in the slide to test mixer motor in tank A
4- For the “Value” of the channel drivers, right click > Interconnect to address >
choose the associated address
5- Rename the blocks as shown in the slide by double clicking each block

Try download then discuss the I/Os of the valve & motor to understand their
operation.

ITC 74/1
 1- From the Plant view > ReacA > Open ReacA CFC
2- From the project master data library > drag & drop FB600 Reactor)
3- Open NK111 CFC
4- Connect FB open & close “SIM_I” in the NK111 CFC to FB_V1_OP & FB_V1_CL
in the ReacA CFC
5- Connect output from CO “value” in the NK111 CFC to V1_OP_CL in the ReacA
CFC
6- In the NK111 CFC, enable the simulation (SIM_ON) in the two FB blocks by
double click it and write “1”

Hint
Add an “AND”
AND block after the “value”
value of the “CO”
CO block connecting its output to the
Reactor “V1_OP_CL”
This is to help in IEA (Import Export Assistant) in next sildes

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ITC 76/1
 www.siemens.com/simatic-pcs7

ITC 77/1
 Creating/Editing Import Files with the IEA File Editor
IEA File Editor
The Import/Export Assistant (IEA) works with import/export files with a fixed format.
A plant planning tool such as SIGRAPH EMR supports this format. To be able to
create or edit import files even if you do not have a plant planning tool available, an
IEA data editor is installed with Import/Export Assistant, that keeps exactly to the
rules governing the structure of the import file.
The IEA Editor "s7jieaEx.exe" is a separate application, in other words it can also be
used outside the PCS 7 installation. It can be copied and made available to plant
planners.

Situations for using the Editor (based on the example of a "process tag" /
"model")
model )
The IEA File Editor is intended for the following situations:
You have created a process tag type/model and created the import file with the IEA.
With this import file, you want to create replicas of the model or process tags. The
number of rows in the import file must be increased according to the number of
replicas/process tags you want to create (for example by copying and editing).
Y have
You h created
t d a process ttag type/model
t / d l andd created
t d th
the import
i t file
fil with
ith th
the IEA
IEA.
You want to change this model, for example by including further I/Os and need to
extend the import file by adding these columns.
You do not have a tool for creating an import file and want to use the IEA File Editor
as a planning tool to structure the columns, column groups and rows of the import
ITC file and the corresponding values. 78/1
 Introduction
Using the wizard for process tag types, the process tag type is copied from the
master data library to the specified target projects as a process tag and the
corresponding data is then imported. This is based on an import file.
Depending on the entries in the import file, you can create any number of process
tags in one import action. As a result of the import, a process tag of this process tag
type is created in the target project for every row of the import file according to the
specified hierarchy path in the plant hierarchy.
Sources for Process Tag Types
You can store the following in the master data library:
Standardized process tag types from the control system library PCS 7 Library, for
example for motors, valves, PID controllers etc.
User created process tag types
User-created t pes from CFC charts

Process Tag Types

Process tag types are a very good function when you use numerous process tags
of the same type in a project. A CFC chart forms the basis of a process tag type.
When you use process tag types
types, you do not have to create a CFC chart for each
individual process tag. You can create a type of base CFC chart with all of the
generally used parameters and then duplicate this chart using the import/export
functions. In a way, you are creating an instance of a process tag type. With the
import/export function, you enter the required custom parameters for each process
ITC 79/1
 Requirement
A CFC chart has been created in the project or in the master data library that
contains the automation functions, parameters, and messages of the process tag to
be implemented according to a specified process tag description.

Procedure
1 Select the intended CFC chart in the SIMATIC Manager (any view).
1- view)
2- Select the menu command Options > Process Tags > Create/Modify Process
Tag Type...
Result: The wizard is started and the "Introduction" page is displayed.
The current master data library is displayed.
3- Click the "Next" button.
Res lt The dialog for cop
Result: copying
ing the chart to the master data library
librar as a
process tag type opens.
4- Confirm the dialog box with OK.
Result: The wizard changes to the "Which I/Os do you want to assign
to the process tag type?"

ITC 80/1
 5- In the left-hand window "I/Os in the chart of the process tag type", select the
flagged I/O for "Parameter" and "Signal". (By double-clicking or selecting
and clicking the "Arrow" button).
Result: The flagged I/O is adopted and displayed bold.
6- In the right-hand window "I/O points for parameters/signals", you can edit the
selected flagged I/Os.
The "Parameter/Signal" columns can be edited (using a drop-down list
b )
box),
"Process tag interface" and "Category" (using a drop-down list box).
The drop-down list box appears when you click the input field.
7- In the left-hand window, "I/Os in the chart of the process tag type", select the
messages of the relevant blocks. All the messages are displayed in the "I/O
points for messages" window.
8 Check
8- Ch k th
the selection
l ti and d click
li k on th
the "N
"Next"
t" b
button
tt and d th
then "Fi
"Finish".
i h"
Result: The new process tag type is stored in the master data library.
The CFC chart that was the origin of the process tag type is located in the S7
program and can continue to be used there or, if it is no longer required,
can be deleted.

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ITC 82/1
 Create a file for process tags

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ITC 84/1
 Automatic Creation of a Number of Process Tags

Requirement
To create process tags from process tag types, the relevant process tag types must
have an import file assigned to them.

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ITC 86/1
ITC 87/1
 Target

To create valves (NK112, NK113, NK121, NK122, NK123, NK131, NK132, NK133)
from the template file created from NK111

1- Select each row, Find & Replace

- NK111 with NK1xy (x=1,2,3 & y=1,2,3)
- ReacA with Reacx (x=A,B,C)
- V1 with Vx (x=1,2,3)

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ITC 89/1
 Automatic Creation of a Number of Process Tags

Procedure
1- Select the required hierarchy folder, project node or process tag library (hierarchy
folder in the master data library) or the process tag type.
2- Select the menu command Options > Process Tags > Import...
Result: The import dialog opens
opens.
After starting the function, the wizard searches for the process tag
types and corresponding import files (in all hierarchy subfolders as well)
and displays them. The import function will include all listed import files.
3- If you do not want to import certain files, you can select them and remove them
from the list with the "Remove" button. With the "Other File" button, you
can browse for a different import file and select it instead of the selected
file.
4- Start the actual import with the "Next" button followed by "Finish".

Result: Depending on the options selected, the complete list of import activities or
only the errors that occurred are displayed in the log window.
Th log
The l iis saved
d iin a llog fil
file and
d th
the name and
d path
th off th
the fil
file are di
displayed
l dbbelow
l
the log window. You can modify this setting with the "Browse" button.

ITC 90/1
 Now we can have 8 new valves, 3 valves in each reactor of the three reactors.

Exercise:
Create pump motor in ReacA (NP111), Using IEA create motor template as a
process tag to be used in creating the motors in the other reactors.

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 www.siemens.com/simatic-pcs7

ITC 92/1
 What is SFC?

SFC (Sequential Function Chart) is a sequential control system partitioned to

ensure step-by-step execution with control passing from one state to the next state
dependent on conditions. With a sequential control system, basic automation
functions, for example CFC charts are controlled based on state changes and can
be selectively processed. You create SFC charts in the SFC Editor.

ITC 93/1
 What are Sequence Path Elements?
An SFC chart consists of 1 to 8 and an SFC type of 1 to 32 sequencers each with a
sequence of sequence path elements. These elements include the following:
. Step
. Transition
And below a sequence (can be freely positioned):
. Text
The remaining elements are structures made up of different elements:
. Sequence
. Simultaneous sequence
. Alternative sequence
. Loop
. Jump

ITC 94/1
 Operating State Logic for SFC (SFC-OSL)
The current operating state of the SFC-OSL can be changed by the following
events:
. Commands (Start, Resume, Hold, ...) in the "MANUAL" or "AUTO" modes.
. External signals (inputs of the SFC, commands from another SFC, ...).
. Internal signals (commands from own sequencers, from the test mode or SFC
Visualization).
Visualization)
. Implicit state change.

ITC 95/1
 In ReacA, Create a SFC chart named ReacA. Use the SFC elements to apply the
following functions

1- Change all valves + mixer motor to automatic

2- Close the raw material valves NK111 & NK112 then open drain valve NK113
3- When tank level < 10 % close the drain valve
4- open the 2 raw material valves till tank level reaches 90 % close them
5- Start the mixer motor NP111 for 20 sec then stop it & open the tank drain NK113
6- When level < 10% close the valve

ITC 96/1