Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
System Overview
Contents:
CHAPTER 1 SYSTEM OVERVIEW............................................................................................................ 1 1.PCS 7 SYSTEM ARCHITECTURE........................................................................................................... 1 1.1 A TYPICAL SYSTEM CONFIGURATION ....................................................................................................... 1 1.2 ES: ENGINEERING STATION ..................................................................................................................... 1 1.3 AS: AUTOMATION STATION ..................................................................................................................... 3 1.4 FIELD DEVICES ......................................................................................................................................... 4 1.4.1 PROFIBUS DP and PROFIBUS PA................................................................................................ 5 1.4.2 PCS 7 Engineering tools for field devices (PDM) ........................................................................... 6 1.5 PCS7 OS: OPERATOR STATION ................................................................................................................ 7 1.6 THE PLANT BUS AND THE TERMINAL BUS .............................................................................................. 10 1.7 FROM ENGINEERING TO PROCESS OPERATION......................................................................................... 12 2. PCS 7 SOFTWARE SYSTEM............................................................................................................. 12 2.1 BASIC DATA ........................................................................................................................................... 12 2.2 SOFTWARE LICENSING............................................................................................................................ 12 3. TOTALLY INTEGRATED AUTOMATION (TIA) ......................................................................... 13
APPENDICES ............................................................................................................................................... 15 APPENDIX 1: INSTALLATION OF PCS 7......................................................................................................... 15 1.1 Presupposed operating systems ........................................................................................................ 15 1.2 PCS 7 and Domains.......................................................................................................................... 15 1.3 PC station specification (minimal) ................................................................................................... 16 1.4 Installation of a Workstation for PCS 7............................................................................................ 16 APPENDIX 2: ESSENTIAL DOCUMENTS OF PCS 7 .......................................................................................... 16 APPENDIX 3: PCS 7 SUPPORT ....................................................................................................................... 16 APPENDIX 4: SOFTWARE AND HARDWARE FOR THE EXERCISES IN THIS MANUAL ......................................... 17
Terminal bus
Plant bus
Page 1 - 1
PCS 7 ES provides powerful engineering tools, for example: SIMATIC Manager: project creation, library creation, project management and diagnostics, etc. Multi-project: In the SIMATIC Manager, you can create projects (single projects) or multi-projects. A multi-project contains one or several projects and a master data library. Master data library: A master data library is associated with a multi-project. Different from other system or application specific libraries, a master data library is within a multi-project and collects all function types used in the multi-project. Component View: Used for adding and engineering new stations such as ES, AS and OS. Plant View: Used for design Plant Hierarchy (PH) of plants. Process Object View: During engineering, you create many objects. The Process object view contains all the engineering aspects of a project. You display these objects and edit them in the view. HW Config: Hardware Configuration Environment for an AS. Used for configuration of CPUs, communication processors, peripheries and field buses, etc. NetPro: Configuration Environment for communication between AS and AS, as well as, AS and OS. Configuration Console: With the Configuration Console, you can change the settings of PC Network adapters. Station Configurator: It displays the actual PC configuration found and set up for PCS 7 systems. SIMATIC NET: NetPro, Configuration Console, and Station Configurator are interfaces of the SIMATIC NET. SIMATIC NET is a platform to configure network and bus systems used in a SIMATIC project. CFC: Continuous Function Chart. Used for design of libraries, automation logic, interlocks, algorithms and controls, etc. SFC: Sequential Function Chart. Used for design of sequential controls, logic and interlocks, etc. SCL: Structured Control Language. Used for programming of algorithms and creation of function blocks, etc. IEA: Import Export Assistant. Used for generation of control models, process tag types and replicas. WinCC: Windows Control Centre. PCS 7 operator interfaces and visualisation. Graphics Designer: Design of plant pictures, graphic objects and animations. Web Navigator: With PCS 7 OS Web you get the facility to monitor and control the process via internet or intranet.
Page 1 - 2
Engineering of PCS 7 projects on an ES can be divided into two phases namely AS engineering and OS engineering. AS engineering covers the design of the plant hierarchy, function blocks, CFCs, SFCs, configuration of hardware and communication components. OS engineering covers the design of plant operating interface with operating functions and plant pictures, as well as the configuration of the archive and protocol (s. Capital 1.5) A lot of system functions from AS engineering are automatically available for OS engineering with the function: Compile OS.
The CPU, comprising of hardware and firmware, processes an S7 program, which is downloaded from the ES via the plant bus and programs. PCS 7 AS contains the CPUs, which are from Siemens SIMATIC S7 400 series. They can communicate with the field level via an internal PROFIBUS DP interface or via a/several CPs . A typical example of automation systems with a link to Distributed I/Os is shown in Picture 1.2.
Page 1 - 3
The S7 program, which is processed in the CPU, consists of a continuous processing sequence of the cascaded blocks. What are blocks? Which blocks are there in PCS 7? Block is an important concept in PCS 7. A summary of the blocks used in the system is listed in Table 1.1.
Block Organisation block (OB) System function block (SFB) System function Call (SFC) Function block (FB) Function Call (FC) Instance data block (instance DB) Data block (DB) Brief Description of Function OBs determine the structure and the processing sequence of the user program. SFBs and SFCs are integrated in the S7 CPU and allow you to access some system functions. FBs are blocks with a program and a "memory" to store variables. You can design your own FBs. FCs contain program routines for frequently used functions. FCs have no memory. Instance DBs are associated with blocks when an FB/SFB is called. They are created automatically during compilation. DBs are data areas for storing user data. Furthermore, the data that are not assigned to a function block, can also be defined as global DBs (shared data) and used globally by any blocks. SDB contains the data of HW configuration.
Table 1.1: Blocks of PCS 7 Note The abbreviation SFC is for the Sequential Function Chart (editor or charts). The System Function Call will not use the abbreviation. However, you will see objects such as SFC4, SFC265, SFB35, etc. in the PCS 7 system and they mean the system Functions (System Function Call / Block ).
Page 1 - 4
Page 1 - 5
Page 1 - 6
PCS 7 system also provides library functions to integrate devices into automation design. Picture 1.6 shows that the reading of a pressure transmitter is cyclic read into the CFC via the function block PA_AI and the value is displayed at OS.
Picture 1.6: Field devices integrated with the PCS 7 engineering tools
Page 1 - 7
Design of graphic objects (buttons, slides, trends, faceplates etc.). SFC Visualization: Automatic graphic map of SFC operation sequence in the OS runtime system. Design of data archives (variables and messages) and long-term data storage. Design of reports: Printing-out of system and process data. User administration: Allocation and control of authorisation accesses of users for different operational roles. Redundancy: Configuration of a second equivalent OS server that is coupled with the primary server. If one of the two server computers fails, the second server assumes the administration/maintenance of the entire system. After the server which failed is brought back into service, the contents of all message and process archives are copied and synchronised. Time Synchronisation: One OS acts in run-time as a time master and controls the time synchronisation of all other OS and AS connected to the plant bus and terminal bus with the current time. Lifebeat Monitoring: Lifebeat Monitoring is used to constantly monitor the individual systems (OS and AS) and visualises the results as screen displays in the OS runtime system. Asset Management: In addition to Lifebeat Monitoring automatically generated diagnosis pictures contributes to better maintenance of the plant and makes it available to provide the data to superordinate management systems. Connection to other applications. PCS 7 OS provides open interfaces for user solutions. This makes it possible to integrate PCS 7 OS into complex, companywide automation solutions, e.g. OPC or OLEDB.
It is possible to create 3 kinds of different OS projects. (1) Single-user project A single-user project is used for a stand-alone operating station. It is for small systems where server and client functions are combined on one PC. Depend on request engineering and operation can also be combined on a single station. (2) Multi-user project A multi-user project is used in the Server/Client environment. It is a project with an own database, for an OS server station, it is possible to supply OS client stations with the project data. (3) Client project A client project is also used in the Server/Client environment. It is a project without own database, for an OS client station, it is possible to connect themselves to an OS server station. OS projects will be downloaded to the corresponding stations after OS engineering.
Page 1 - 8
(1) OS server An OS server provides the connected OS clients with the process values in process pictures and passes the instructions of operators on to the function blocks in assigned Ass. An OS server can be accessed by up to 32 clients, named as Operate Station. Normally, OS server is not used to operate the plant. Depending on the license one OS server can access up to 85,000 process objects, which can be allocated on up to 32 ASs. If plants project needs several OS servers, OS servers are arranged according to plant hierarchies. One or more areas of the hierarchy are assigned to an OS server. This is fundamentally different from SCADA systems where OS servers are arranged according to archives, for example, message (alarms) server, process - trend (process variables) server, and picture (graphic objects) server. Picture 1.7 shows the distribution of PCS 7 OS servers according to the plant areas.
OS server 1
OS server 2
OS server 3
Reaction unit
Cleaning unit
Picture 1.7: PCS 7 OS servers (2) Redundant OS server Here, the redundancy is at the OS level. PCS 7 provides redundancy at all levels, for example, at the AS level, plant bus level and peripheral level, etc. Two OS servers can form a redundant pair of servers with one of them designed as standby server. Both server of this pair are functionally identical and are running in parallel during normal operation. Each server has its own process connections and data archives. The AS sends the process data and messages to both redundant servers. If one server fails, the clients will automatically switch from the failed server to the other active server. After the failed server comes back online, the redundancy will perform archive synchronisation for the down time. The archive gap caused by the failure will be filled by transferring the missing data to the server which was failed. This action equalises the servers. (3) OS client An OS client communicates with the assigned OS server via terminal bus. Clients have no direct access to the plant bus and ASs. They access project data on OS servers only via a so-called server package.
Page 1 - 9
Page 1 - 10
The following switches are predominantly used in SIMATIC PCS 7: SCALANCE X414-3E with two Gigabit-Ethernet ports for design of plant bus and OS-LAN (terminal bus) with redundant, optical Gigabit ring technology; permits maximum communications performance, especially with very large plants with comprehensive quantity frameworks and wide communication networks. SCALANCE X208 with 8 ports for transmission rates up to 100 Mbit/s, suitable for electrical Industrial Ethernet structures with linear, star or ring topology (ring together with SCALANCE X-400 as redundant manager). SCALANCE X204-2 with 2 optical and 4 electrical ports for transmission rates up 100 Mbit/s, suitable for optical Industrial Ethernet structures with linear or ring topology (ring together with SCALANCE X-400 as redundant manager). The plant bus and the terminal bus are best separately laid out in PCS 7. Normally, there are one or several switches per control cabinet, where the communication modules of AS, ES or OS are connected via a patch cable. CP443-1 is used as AS communication module. In the simple case, a standard network adapter is used as ES and OS communication module. For high performance CP 1613 is used in plant bus. For communication on the plant bus, the designed S7 connections of individual stations are downloaded based on MAC address or TCP/IP address. With PCS 7 you can configure the plant bus and the terminal bus as a redundant network. The following redundancy concepts can be combined with each other: Electrical or optical ring structure: One ring comprises of at least 2 switches, whereby one assumes the function of redundant manager. It tolerates an error, for example, an injury or breakup on a cable. Redundant ring: A complete backup structure of an existing ring is built. Two rings are coupled on the terminal bus. On the plant bus it is better to separate these two rings. Software SIMATIC S7 REDCONNECT (plant bus): If a fault-tolerant AS is in use, S7 REDCONNECT can switch between 2 or 4 designed connections automatically. Therefore a S7 connection fault-tolerant is created instead of a S7 connection. A further prerequisite is that a CP1613 as network adapter is necessary in each OS server or OS single station. Redundant connection of terminal bus: Every OS on the terminal bus is connected to a redundant ring structure with 2 network adapters. The two Intel Network adapters are combined into team with a TCP/IP address, so that the station can also be reached via the terminal bus in case of one Network adapter failed.
Page 1 - 11
Page 1 - 12
Picture 1.9: Industrial sectors and control systems SIMATIC PCS 7 system is the core of Siemens concept for totally integrated automation (TIA). Picture 1.10 shows the coverage of SIMATIC PCS 7 and relations to other Siemens systems. Industrial networks (Plant bus and PROFIBUS) and field devices are fully integrated into and covered by SIMATIC. The SIMATIC IT is the Siemens product at the Management Execution System (MES) level. Through SIMATIC IT PCS 7 systems can be connected to the enterprise level (ERP).
Page 1 - 13
Picture 1.10: SIMATIC PCS 7 coverage This manual focuses on the PCS 7 system engineering. In terms of physical levels of the automation systems, the manual has covered the OS server, OS clients, AS, and distributed I/O. Picture 1.11 shows an example of PCS 7 system components. There are more devices can be included and configured in PCS 7 systems. Everything to list would blow up/be too much for the frame of this manual.
Picture 1.11: PCS 7 system architecture Training documents and courses are also available from Siemens on all other topics, e.g. SIMATIC BATCH and PROFIBUS technology, etc.
Page 1 - 14
Appendices
Appendix 1: Installation of PCS 7
Note Refer to the PCS 7 PCS 7 Readme file for latest information on PCS 7 installation.
Windows XP Professional SP2 Windows XP Professional SP2 Windows Server 2003 Standard Edition SP1 Windows XP Professional SP2 Windows Server 2003 Standard Edition SP1 Windows Server 2003 Standard Edition SP1
Table 1.4: Windows installation You need at least one engineering station for the exercises in this book.
Page 1 - 15
Page 1 - 16
Note
Hardware
Automation system AS 414-3 with runtime license for 100 PO 6ES7 654-1QD58-0XX0 Automation system AS 416-2 with runtime license for 100 PO 6ES7 654-1JE58-0XX0 Automation system AS 416-3 with runtime license for 100 PO 6ES7 654-1KF58-0XX0 Automation system AS 417-4 with runtime license for 100 PO 6ES7 654-1LE58-0XX0 ET200M: I/O subsystem pull & plug With an IM 153-2 high feature ES (*1) 6ES7 654-0XX07-1XA0 SIMATIC PCS 7 ES/OS IL 43 BCE WXP With Basic communication Ethernet (BCE)
AS: Standard automation system with Industrial Ethernet connection via CP (selection)
Table 1.6: Software and hardware components required for the exercises (*1) Attention, that the license for plant bus communication (BCE, Basic Communication Ethernet) is only contained in SIMATIC PCS 7 ES/OS. (*2) Generally, for purpose of exercises and demonstration, there is a trial license for 14 days in every PCS 7 DVD.
Page 1 - 17