To immediately start processingeven without a plant and control componentsand to directly experience the results of your efforts as well

as gather practical
PA Module P01-00 experience, an interactive, simulation-supported learning environment is provided for the modules. It consists of the following components:
SIMIT Model: This model is used to simulate the process with tanks, pumps and valves as well as sensors and actuators. The local operator panel for the plant is also
SIMATIC PCS 7 Introduction MODULE PROCESS CONTROL ENGINEERING included in the model.
It has to be noted, however, that the model is used to generate sensor and actuator signals. The display should not be mistaken for a visualization interface. Operator
OVERVIEW control and monitoring is takes place with PCS 7 OS in the project.
The module Process Control Engineering deals with current topics for managing technical facilities by using a process control system. To this end, a process control lab SIMATIC PLCSIM: Here the automation system is simulated. The functionalities are configured mainly in Module P01. This means that changes within the automation
facility consisting of two reactors and several tanks for input materials and products has to be automated and visualized. In addition, a process system simulation is regardless of whether these are hardware configuration or software changes (SFC, CFC)become effective only after reloading them to the simulation.
provided to make processing the project possible even if hardware is not available. By combining the process model (SIMIT model) and control model (PLCSIM with its implemented and loaded functionality), the entire system can be simulated and
tried out as shown in Figure 3.
STRUCTURE OF THE INDIVIDUAL CHAPTERS
All chapters of the module follow the same basic pattern (Figure 1). SUMMARY
After introducing the Training Objective, first the Theory on which the training objective is based is described in Brief. Then, different aspects of the Theory are The modules P01 and P02 provide sufficient training material, exercises and instructions to conduct a course of one to two weekly semester hours. Depending on the
described in greater depth. A bibliography provides references for pursuing the topic further. Step by step instructions make it possible for the reader to immediately depth of coverage of the material, 30 to 60 work hours are to be scheduled (including exercises, homework, pre and post preparation). This corresponds to 1 to 2
put the theory into practice at the engineering station (ES) of the process control system PCS 7. Each chapter concludes with Exercises that lead deeper into the topic credits within the scope of the European Credit Transfer and Accumulation Systems (ECTS).
of the respective chapter. For Module P03, supplemented by the instructors own material, a course consisting of one weekly semester hour can be planned.
Objective
Theory in brief
Theory
Step by step instruction
Literature
Exercises

Figure 1: General Structure of Individual Chapters

RELATIONSHIP OF THE CHAPTERS
The sequence of the chapters is based on the usual sequences when planning a process control system. Based on the step by step instructions and the exercises, a
complete basic automation is prepared for the sample process in the control system. However, it was provided for that all chapters and exercises can be used
independently. All intermediate results attained in the course of the module are available as project files. This means it is possible to start/continue at any point, and
trainees can compare their own solutions with the sample solutions.

Module P01:
Reading the chapter P01-01 Process Description is recommended regardless of prior knowledge, since it introduces the process plant that is to be automated.
In the chapter P01-02 Hardware Configuration, the structure of the automation components (automation station and remote IO) is implemented after the project has
been set up. In the exercise, an additional automation station is integrated based on the AS RTX Box.
The chapter P01-03 Plant Hierarchy introduces an essential structural element of PCS 7. The automation of complex systems can thus be broken down into smaller
partial tasks (refer to P01-04 to P01-06). In addition, the plant hierarchy provides a possible structure to visualization (P02-01) and serves as a basis for re-usable
elements and structural units (P01-07). The standardized design of the plant hierarchy also serves as a basis for recipe control (P03-03).
Chapters P01-04 to P01-08 describe different aspects of automation.
Chapter P01-04 Individual Control Functions introduces the reader to the utilization of existing software objects (function blocks, templates) for real objects. As an
example, we implement the control of a pump motor with a function block of the PCS 7 Advanced Process Library in a Continuous Function Chart (CFC for short).
In this chapter, the result can be tested for the first time in a plant. If no plant is available, the simulation mentioned below can be used.
The chapter P01-05 Functional Safety introduces interfacing the lock on the software-side for the intended use of the plant. The previously implemented control of a
motor is restricted by means of given supplementary conditions in a way that no serious danger can arise for the plant or for persons.
The chapter P01-06 Control Loop deals with the topic Control Loop. The temperature control of a reactor is used as an example for implementing a PID controller.
The chapter P01-07 Importing Plant Design Data shows the capability of re-using individual control functions and/or entire structural units.
This is illustrated with an example of a CFC and a container as a template that are used to generate additional CFCs and additional containers. To work through this
chapter, extensive knowledge of the system (P01-01) and its structure (P01-03) is necessary.
The chapter P01-08 Sequential Control introduces the Sequential Function Chart (SFC for short). With the SFC, the master recipe is realized. The exercise in this
chapter concludes the first module, and as complex exercise it also includes the contents of the previous chapters. The exercise examples of these chapters are set up
in a way that they complete the engineering of the system piece by piece. Nevertheless, each aspect can be learned individually using the available project files.
Module P02:

Module P02 is based on the results of module P01.

The chapter P02-01 HMI Generation shows the reader how to configure a graphic user interface. Building on the results of the first module, the operator station is
configured, and the plant units configured so far are visualized through PCS 7 OS.
The chapter P02-02 Alarm Engineering deals with the implementation of an alarm system. Using a function block available in the PCS 7 Advanced Process Library,
monitoring a fill level is implemented.
The chapter P02-03 Archiving and Trend Reporting provides an overview of archiving process data, messages, batch logs and OS reports. Using a process value as an
example, archiving and displaying archived values are implemented in OS runtime under PCS 7.

Module P03:
Module P03 is based largely on the results of modules P01 and P02.
The chapter P03-01 Advanced Layout of UIs addresses the function of chart characteristics. Additional OS elements are introduced to adapt detail displays individually
to the segment displayed and to provide meaningful information for the detail level. Using the reactor as an example, ActiveX Controls and User Defined Objects are
generated. This chapter is based on P02-01 and P02-02.
The chapter P03-02 Vertical Integration with OPC shows the integration of automation systems into higher-level programs of the plant control level. The required
fundamentals for the setup and the method of functioning of OPC as well as the options for integration by means of PCS 7 are explained. Using a Microsoft Excel table
as an example, polling an OPC server that was set up previously is demonstrated.
In the chapter P03-03 Batch Control with Recipes, using the Batch Control Center for generating and updating recipes is described. Using a mixing process as an
example, a recipe is implemented with batch. Based on another approach for batch, a project template is provided for the known plant. As a basis for this chapter,
the reader has to be familiar with the process description (P01-01) and the plant hierarchy (P01-03).

SIMULATION

PA Module P01-01
SIMATIC PCS 7 Process Description
PROCESS DESCRIPTION
CLASSIFICATION OF PROCESS ENGINEERING PLANTS
To effectively automate process engineering plants, structuring the plant as well as describing its intended utilization is necessary. It is helpful in this case to subdivide
the plant into classes of process engineering plants that are similar regarding the requirements for automation engineering. According to [1], the number of
fundamentally different products and the physical structure of the plant can be used for classification.
If the same product is always manufactured in a plant, it is called a single product process cell. If the environmental conditions change or the composition of the
educts fluctuates, only the parameters of the process sequence or the settings are to be varied in these plants to always get the same product. In a multi-product
process cell, on the other hand, different products are manufactured either according to different processes or according to the same process but with clearly
different parameters.
From the view of automation, the single train process cell represents the simplest physical structure of a plant. The intermediate steps of the product traverse the
units in a fixed sequence. A multi train process cell consists of several parallel single lines; however, no product transfer is intended between them. Only material
quantities and finished product inventories are used jointly by the single lines. A multi train-multi path process cell also consists of single lines, but in contrast to the
simple multi train plant, product exchange between lines is possible. Here, the paths can either be fixed, dynamic with a fixed connection, or dynamic with a flexible
connection.
PROCESS CELL DESCRIPTION
In this instruction module, the laboratory plant shown in the adjacent Figure 1 is being automated.
The core of the plant consists of 2 reactors that are loaded with different educts. In the reactors, different products can be made at the same time. For that reason,
the plant can be classified as multi-product plant and multi train-multi path plant. It consists of several units that are permanently connected to each other.
Depending on the production process, it is possible to wire the lines between the units dynamically. This requires complex automation. In the following chapters of
this training module we will learn, however, that by taking into account a few simple principles and rules, the complicated automation system can be assembled quite
effectively and efficiently by combining existing blocks of the PCS 7 process control system.
Figure 1: Multi product and multi train-multi path process cell at TU Dresden as playground for modern process control engineering
The P&ID is not sufficient to specify all requirements for process control engineering. To ensure safe plant operation, the controller has to do the following: monitor
process intervention and, if needed, suppress user input, switch actuators on or off, mutually lock functions and/or take the plant to a safe state. For the plant
described above that is equipped with meters according to Figure 2, the following monitoring and locking functions are required and implemented step by step with
PCS 7 within the instruction modules:
Actuators must be switched only if the main switch of the plant is switched on and the Emergency Off switch is enabled.
Containers must not overflow; this means there is either a sensor that signals the maximum level, or the maximum level (here: 1000ml) is known numerically and is
evaluated by means of the measured level.
Pumps must not take in air; this means there is either a sensor that signals the minimum level, or the minimum level (here: 50ml) is known numerically and is
evaluated by means of the measured level.
Pumps must not attempt to take in liquid when a valve is closed or pump liquid against a closed valve.
The temperature in the two reactors must not exceed 60C.
The heaters of the two reactors must only be operated if they are covered with liquid (here: a minimum of 200ml in the reactor).
The agitators of the two reactors should be operated only if they are in contact with liquid (here: a minimum of 300ml in the reactor).
RECIPE
According to [1], a recipe is a specification for manufacturing a product according to a procedure. It describes what is needed to carry out a procedure. For the plant
described above, the following recipe applies which is implemented within this instruction module with PCS 7:
1. First, 350ml are to be drained from educt tank =SCE.A1.T1-B003 into the reactor =SCE.A1.T2-R001 and, at the same time, 200ml are to be drained from educt tank
=SCE.A1.T1-B002 into the reactor =SCE.A1.T2-R002.
2. When reactor =SCE.A1.T2-R001 is filled, the liquid is to be heated to 25C with the agitator switched on.
3. When reactor =SCE.A1.T2-R002 is filled, 150ml of educt A from educt tank =SCE.A1.T1-B001 is to be added to the reactor =SCE.A1.T2-R002. When this is completed,
the agitator of reactor =SCE.A1.T2-R002 is to be switched on 10s later.
4. When the temperature of the liquid in reactor =SCE.A1.T2-R001 has reached 25C, the mixture is to be pumped from reactor =SCE.A1.T2-R002 to reactor
=SCE.A1.T2-R001.
5. The mixture in reactor =SCE.A1.T2-R001 is now to be heated to 28C and then drained into product tank =SCE.A1.T3-B001.
LITERATURE
[1] DIN EN 61512-1 (Status 2000-01): Batch Oriented Operation.

The first unit provides the educts for the reactors. It consists of three educt containers. Their instrumentation is identical. To ascertain whether the container is empty
or full, the level is monitored by two sensors. With a valve at the outlet and a pump, the educt can be dosed for the second unit. The educt is refilled by means of a
valve at the inlet.
The second unit consists of two reactors that have the same dimensions as the educt containers but are equipped with other automation resources. Each reactor is
provided with an agitator and a heater. The level is continuously measured by an ultrasound sensor, and the temperature with a PT100 element. The educts are
drained into the reactor by means of the three valves at the inlet. With a pump at the outlet, the reaction product can either be transferred to the other reactor,
drained into the product tank of the third unit or the rinsing water can be returned to the rinse water container. An additional valve at the inlet allows for the reactor
being cleaned with rinsing water from the fourth unit.
The third unit contains the finished products and consists of two containers with two sensors that display the minimum and the maximum level. While the reactors
can be loaded by all educt containers, the product containers are assigned exactly to one reactor. With a valve at the inlet of the product container, the path from the
reactor to the product container is released. A valve each at the outlet of the product containers serves to remove the finished product from the plant.
The fourth unit consists of a rinse water container. It also is equipped with two sensors to indicate the minimum and maximum level. With a valve and a pump at the
outlet, the rinsing water can be transported to the reactors of the second unit, and by means of the valves at the inlet back again from the reactors.

PIPING AND INSTRUMENTATION DIAGRAM

Although a textual description of a plant explains the essential relationships, it is not very suitable to communicate the joint tasks of process engineering, electro-
technical engineering and automation engineering, because a textual description is prone to misunderstandings even where small plants are concerned, but above all
in the case of large plants with hundreds of devices and several tens of thousands of measuring points.
In the course of time, the Piping & Instrumentation Diagram (P&ID) has developed into a central planning tool for that reason. The P&ID documents the structure and
function of the process system for process as well as automation engineering. Figure 2 shows the P&ID of the experimentation plant that is to be automated in this
instruction module.
Containers, valves and pumps as well as functional requirements of process control engineering are represented by standardized symbols in the P&ID. The piping
between the elements is indicated as solid lines, the flow of information as dashed lines. For the sake of clarity, all units are shown in a P&ID in Figure 2.
A container or a process control function is associated with a certain unit by means of an identification system. This identification system provides clarity for persons
as well as the computer. As long as people work closely together, they can easily distinguish between educt container B001 and the product tank B001 based on the
context. This distinction becomes more difficult when communication takes place across several departments, when employees are processing many projects
simultaneously and when computers are involved. The complete designation for the first educt container B001 is therefore =SCE.A1.T1-B001. This means tank B001 in
factory SCE, plant A1, unit T1 can be clearly distinguished from a similar plant or unit.

PIPING AND INSTRUMENTATION DIAGRAM

Although a textual description of a plant explains the essential relationships, it is not very suitable to communicate the joint tasks of process engineering, electro-
technical engineering and automation engineering, because a textual description is prone to misunderstandings even where small plants are concerned, but above all
in the case of large plants with hundreds of devices and several tens of thousands of measuring points.
In the course of time, the Piping & Instrumentation Diagram (P&ID) has developed into a central planning tool for that reason. The P&ID documents the structure and
function of the process system for process as well as automation engineering. Figure 2 shows the P&ID of the experimentation plant that is to be automated in this
instruction module.
Containers, valves and pumps as well as functional requirements of process control engineering are represented by standardized symbols in the P&ID. The piping
between the elements is indicated as solid lines, the flow of information as dashed lines. For the sake of clarity, all units are shown in a P&ID in Figure 2.
A container or a process control function is associated with a certain unit by means of an identification system. This identification system provides clarity for persons
as well as the computer. As long as people work closely together, they can easily distinguish between educt container B001 and the product tank B001 based on the
context. This distinction becomes more difficult when communication takes place across several departments, when employees are processing many projects
simultaneously and when computers are involved. The complete designation for the first educt container B001 is therefore =SCE.A1.T1-B001. This means tank B001 in
factory SCE, plant A1, unit T1 can be clearly distinguished from a similar plant or unit.

SAFETY INTERLOCK AND PROTECTION FUNCTIONS


PA Module P01-02
SIMATIC PCS 7 Hardware Configuration
HARDWARE CONFIGURATION
TRAINING OBJECTIVE
In this chapter, the students learn how an automation system works. They will be able to configure the selected hardware in the hardware configuration of PCS 7 and
check it for consistency. Important settings will be parameterized so that from this data the process control system PCS 7 automatically sets up all blocks necessary
for communication between sensors, actuators and the control level in the automation stations.
THEORY IN BRIEF
When the hardware is configured, the 'real components for recording measured values as well as for reading out signals that influence the process are inserted and
arranged in the tabular representation of the configuration. As shown in Figure 1, this process describes at which slot or in which sequence which input/output
module is placed. In addition, during this process the input and output signals are assigned to a defined memory location in the process image and the modules are
parameterized. If fieldbuses are used, unique station addresses are specified as well.
When storing and compiling the settings that were made, the internal consistency is checked (do all modules match, have addresses been assigned twice, etc.). As
soon as the configuration is consistent within itself, the blocks necessary for the communication of the process data are set up without user assistance and can then
be loaded to the automation stations (AS) of the control system. These now have all the information to initially determine whether the installed configuration
corresponds to the one that was configured. They then make sure that the process data are available at the ASs in the desired scanning frequency for further
processing. For most users it is not apparent that extensive provisions are made in case an error occurs, such as the automatic transmission of suitable messages and
alarms.
THEORY
DISTRIBUTED ARCHITECTURE OF PROCESS CONTROL SYSTEMS
Scalable process control systems such as PCS 7 cover a large range of processes. Applications include small laboratory systems with only a few sensors and actuators
as well as systems that have a hundred thousand process tags. To cover this broad spectrum, special structures are required. A typical component structure that can
be easily expanded looks like this:
On the process management level, an operator system (OS) consisting of one or several operator stations is used. By means of these OSs, the control operators can
operate and monitor the system.
On the control level, one or several automation stations (AS) are located on which the control functions and closed loop control functions are carried out in real
time. These systems are to do their job regardless of OS failures. They consist of at least one power supply (PS) and a CPU as well as communication modules (CP), if
necessary.
On the field level, the states of the technical processes are recorded or the process is specifically influenced by means of sensors and actuators.
While all components can run on a single computer system in a labas seen in Figure 2, distributing the components is advisable when the size of a test center is
extensive to handle the complexity. Depending on the requirements, different bus systems that possess the necessary real time properties for process data
communication, for example, are used to exchange data between these components.
Figure 2: Scalable structure of the process control system PCS 7 [2]
PROCESS IMAGE
The automation programs are processed on the automation stations (AS) in the central processing unit (CPU) as in any other computer. The control programs are
processed cyclically. If signals from the process are processed, the program does not directly access the connected input and output modules; instead, a so-called
process image is generated where all signals are entered at once and stored at the beginning of the cycle.
There are two reasons for this: First, accessing the process image requires considerably less time because it is stored in the internal memory of the CPU. Second, it
ensures that the input information was collected within a defined time windowregardless of the execution time of the control program. This data consistency is
attained by entering the signals of the input modules once for each cycle in the process image of the inputs (PII). Next, the program is processed, and the results are
written to the process image of the outputs (PIQ).
Once the entire program is processed, the data is written from the PIQ to the output modules and only then read out to the process. The process image of the inputs
is then updated once again as shown Figure 3.
CONNECTION TO THE PROCESS
The process signals recorded by the sensors, such as temperature, pressure, level and flow rate, are converted into an electrical signal with transducers. If the
measuring device is not connected directly via fieldbus, the signal is usually converted into an electrical standard signal. It can then be recorded on the side of the
automation system by a standardized signal module.
Because process industry systems are to record a handful or up to several thousand measured values, it must be possible to select, clearly assign and parameterize
the measuring module when automation is planned. This means the required signal modules are initially arranged virtually in the hardware configuration. At the
same time, memory is assigned (as mentioned previously) in the process image to the signal modules. As soon as a signal module is included in the configuration,
sufficient memory is automatically assigned in the process image. This automatic assignment can then be changed manually; however, the size of the CPU memory
area must be taken into consideration.
Depending on the type of signal, different signal modules are used. For binary signals, DI (Digital Input) and DO modules (Digital Output) are used. The individual
signals are organized bit by bit; this means each input/out signal is assigned one bit of the process image. However, signal modules usually record 8, 16 or 32 signals
at once.
For analog signals, AI (Analog Input) and AO modules (Analog Output) are used. Analog modules are usually organized in words (16 bits). Each analog input or output
signal is assigned 16 bits of memory (as seen in Figure 4). To do this, the analog input module converts the analog process signal into a digital one. Depending on the
resolution, only the higher order positions are assigned and '0 is written to the lower order positions. Analog output modules convert the digital output value into an
analog signal. Regarding analog signals, modules are distinguished not only according to the number of signals but also according to their resolutions, for example,
2x12 bits, 8x13 bits or 8x16 bits.
DISTRIBUTED IO
In case sensors and signal sources are located far away from the automation system, wiring can become very extensive and complex. In addition, electro-magnetic
interferences can limit reliability. The use of distributed IO devices makes sense for such systems:
The automation system is at a central location.
One or several IO devices (input and output modules) process distributed on site.
Data is transferred between the periphery and the automation system [1] by means of PROFIBUS DP (distributed IO). To this end, the AS and the periphery have to
be equipped with corresponding communication modules.
A SIMATIC ET200M was selected as the distributed IO device for the system described in the previous chapter. The IO modules of the proven S7-400 automation
system are connected to an interface module (IM 153-x) that ensures communication to the AS. Figure 5 shows a typical configuration. On the right, several digital
and analog input and output modules are connected to the interface module IM 153-1. The process signals coming from the field are connected directly to the
routing level placed under the input and output modules; from there, short cables lead to the modules which means wiring faults to the field can be quickly
corrected.
Figure 5: Distributed I/O device ET200M (Source: Laboratory Plant TU Dresden)
In the hardware configuration, the SIMATIC ET200M is connected directly to a PROFIBUS DP line of the AS as seen in Figure 6. The hardware configuration
automatically recommends addresses that are not yet used in the selected subnet. The slots of the ET200M are assigned to input and output modules as described
below.
STEP BY STEP INSTRUCTIONS
TASK
In this chapter, the PCS 7 project for the multi-purpose plant is to be set up with a wizard.
Next, the included S7 station is configured. In the example, a SIMATIC S7-400 is used with a CPU 414-3 DP and a CP443-1 communication processor for interfacing to
an Ethernet by means of the TCP/IP protocol.
The IO signals for controlling the actuators in the plant and for recording the input signals are connected using the ET200M. This modular field device is connected to
the CPU by means of the PROFIBUS DP fieldbus.
The PC station as master computer with the PCS 7 software and WinCC for visualization has to be configured as well. You can use any PC or laptop with a standard
Ethernet interface for this purpose.
The master computer as operator station (OS) with the CPU as automation station (AS) is interfaced to an Ethernet by means of the TCP/IP protocol.
The project is also developed on the master computer. This makes the master computer the operator station (OS) as well as the engineering station (ES).
Figure 7: Plant configuration for multi-purpose plant
Note: The abbreviations Engineering Station (ES), Operator Station (OS) and Automation Station (AS) should be committed to memory, because these terms are used
frequently in the PCS 7 software and in this document.
Note: Depending on the available hardware, the CPU414-3DP can be replaced with another CPU, a PC based SIMATIC PCS 7 AS RTX or the SIMATIC PCS 7 Box PC.
Figure 8: Various plant configurations with SIMATIC PCS 7 Box, SIMATIC PCS 7 AS RTX and SIMATIC S7-400 CPU 414-3DP as controller (from left)
Note: In the following chapters, the simulation software S7-PLCSIM is used for testing the programs. This means you can basically configure any controller.
TRAINING OBJECTIVE
In this chapter, the student learns the following:
Creating a PCS 7 project
Generating the hardware configuration for an S7 station
Generating the hardware configuration for a PC station with WinCC
Networking the S7 station and the PC station
PROGRAMMING
1. The central tool in PCS 7 is the SIMATIC Manager. Here, it is called with a double click. (SIMATIC Manager)
2. To create a PCS 7 project, the use of a wizard is recommended because it sets up both the S7 station and the PC station in one step.
(File 'New Project' Wizard)
3. We are going to create the project as a multi-project. This means a master library is created in addition to the S7 station and the PC station. The library ensures that
the same version of blocks and chart templates (process tag types) is always used within a project. (Next)
4. Next we select the configuration of the AS with the CPU used, the power supply and the communication processors for PROFIBUS and Ethernet. Because PCS 7
stations are usually ordered as an entire station (bundle), the bundles can be selected based on their order numbers here. (CPU: AS414-3 Bundle: 6ES7***
Number of communication modules CP443-5: 0 Next)
Note: The number of additional communication modules for PROFIBUS is included here in an additional selection.
Because the bundles listed often do not correspond always match the available S7 stations exactly, individual components may have to be added or exchanged later
in the hardware configuration.
5. We now select the number of hierarchy levels for the plant hierarchy (refer to chapter Plant Hierarchy) and an OS object.
(3 PCS7 OS Single station system Next)
6. In the window below, the storage location and directory name (also project name) are specified and the project is finished.
(Storage location: any Directory name: PCS7_SCE Finish)
7. After the project is finished, it is opened and displayed in the Component view as well as the Plant view. We can switch between the views in the menu under View.
(View)
Note: Additional information about the Component view and Plant view is provided in the chapter below 'Plant Hierarchy'. In this chapter, only the Component view
familiar from STEP7 is used.

8. Next we select the SIMATIC 400 station in the Component view open the hardware configuration with a double click.
(Component view SIMATIC 400(1) Hardware)
9. To make the settings for Ethernet networking, we select the PN-IO interface with a double click in CP 443-1. (PN-IO)

10. Here, we can assign a device name and the properties for the Ethernet interface. (Properties)

11. In the parameters, we enter an IP address and a subnet mask and set up a new subnet. (Parameters 192.168.0.1 255.255.255.0 New)

12. Then we accept the subnet and the settings. (OK OK OK)

13. Next, we configure the ET200M as a field device on the PROFIBUS. To this end, we first have to set the matching profile, then select the matching interface
module in the catalog in the folder PROFIBUS DP/ET200M, and drag it to the CPUs master system.
(PROFIBUS-DP ET200M IM 153-2 HF PROFIBUS(1): DP master system(1))
Note: To exactly select the correct interface module, the order numbers have to be noted. They are printed on the interface module and in the footer of the
hardware catalog after you have selected a component.
If you do not have your own hardware available, it is best to adhere to the representation shown here.

14. In the following selection, assign the PROFIBUS address for the interface module. (3 OK)
Note: The address set here must also be on the interface module in binary code using a switch block.

15. Now, we enter the IO modules from the folders below the interface module used. This is done by dragging these modules to the respective slot within the
ET200M. The IO addresses of the individual modules should be set in their properties as shown here.
When your configuration is complete, accept it by using the button ' for saving and compiling.
(PROFIBUS-DP ET200M IM 153-2 DI-300 DO-300 AI-300 AO-300 Set addresses )
Note: To exactly select the correct modules, the order numbers have to be noted. They are printed on the modules and in the footer of the hardware catalog after
you have selected a component. If you do not have your own hardware available, it is best to adhere to the representation shown here.
Note: You can facilitate the search for the correct modules by utilizing the search dialog on the very top of the catalog. Simply enter the order number you are looking
for; then you can browse the entire catalog up and down.
Note: Slot 3 remains free. It is reserved for the extension module with a multi-tier configuration.
Note: To use the specified symbol table, it is important to set the specified IO addresses.

16. Next, in the SIMATIC Manager we select the SIMATIC PC station in the Component view and open the configuration with a double click.
(Component view SIMATIC PC Station(1) Configuration)
17. Within the PC station, the Ethernet interface must be entered first. To this end, we drag the CP Industrial Ethernet in version V8.1 from IE General to the first free
slot in the PC station.

In the window that is displayed next, we connect this interface with the Ethernet network already set up in the S7 station, and enter the IP address and the subnet
mask. (SIMATIC PC Station CP Industrial Ethernet IE General SW V8.1 Ethernet(1) 192.168.0.2 255.255.255.0 OK)

18. An Ethernet interface and the WinCC application are now entered in the PC station. We accept this configuration be clicking on ' for saving and compiling. ()

19. To check and compile the network in our project, we now open the Ethernet network with a double click in the Component view in SIMATIC Manager. (
Component view SCE_PCS7_Prj Ethernet(1))

20. The NetPro tool provides a nice overview of the components and networks in our project. We see that both stations are connected to each other over Ethernet
and the ET200M is interfaced with the SIMATIC S7-400 by means of PROFIBUS. We accept these network settings by clicking on the button for saving and compiling.
()

21. In the next window, we select Compile and check everything.

(Compile and check everything OK)
22. The result of the compilation is displayed in a window. ()
EXERCISES
The exercises provide an opportunity to implement what we have learned from theory and the step by step instructions. To this end, the existing multi-project from
the step by step instructions will be used and expanded.
Note: The exercises can be carried out without having to first work through the step by step instructions completely and correctly. To get to the required processing
level, the project archive provided can be unzipped and opened using the function 'Retrieve. (File Retrieve).
The project archive for the step by step instructions is called: PCS7_SCE_0102_R1503_en.zip
The following exercises are recommended especially for users of the PCS 7 trainer package, because an AS RTX Box is to be integrated here. The AS RTX Box is also an
automation station and can handle the identical tasks as the configured S7-400.
For that reason, this exercise is not mandatory for execution of the overall project.
EXERCISES
1. With a right mouse click on the project, add the new AS by selecting "Add new object" and then "Preconfigured station ". In the dialog field that opens, select the
"PCS7 BOX" as CPU and then the "AS RTX" with order number 6ES7654-0UE13-0XX0. Follow the dialog without making any other settings.
2. Because the AS RTX Box is a PC based automation station, you should have a second SIMATIC PC station in the project. The stations should now be assigned
plausible names; for example, SIMATIC S7-400(1) is named AS1, SIMATIC PC Station(1) is named OS and SIMATIC PC Station(2) is named AS2.
3. Now, network the AS RTX Box (=AS2) with the Ethernet(1) and with a new PROFIBUS master system PROFIBUS(2). To this end, you have to open the configuration
of the AS2. So far, your AS has only one interface to PROFIBUS, "CP5611-CP5621". For this reason, add an IE General. Assign parameters to the Ethernet interface
exactly as described in the step by step instructions. To parameterize the PROFIBUS interface, you have to open the Properties and add a new PROFIBUS network.
4. For the new AS to actually be able to handle the tasks of the AS1, you now need the identical ET200M. You have two options for adding the ET200M including the
IO cards. The first option corresponds to the configuration as provided in the step by step instructions. The second option is copying the generated ET200M and
inserting it with a right mouse click on the PROFIBUS(2) line.
 If, when structuring the plant, the physical model according to DIN EN 61512-1 is used (refer to Figure 3) which is largely identical to the U.S. standard ISA-S88.01-
PA Module P01-03 1995, PCS 7 enables the setup of a type-defined hierarchy.
Only the four lower levels of the model (process cell, unit, equipment module and control module) are specified in greater detail. They refer to certain types of
SIMATIC PCS 7 Plant Hierarchy facilities. Such a type is a group of process and control facilities that were combined for a certain purpose.
If the type-defined hierarchy is to be used in PCS 7 according to the standard ISA-S88.01, the uppermost folder of the plant hierarchy has to represent the process cell
level.
Below the process cell level, the hierarchy folders can then be type-defined as unit, and below that as an equipment module.
PLANT HIERARCHY Folders or levels that are not type-defined are designated as neutral and can be used for further structuring, or represent the level of the control modules.
TRAINING OBJECTIVE Type definition is the basis for working with the PCS 7 BATCH module. It should be noted that only one process cell can be defined for each project.
The students learn to structure an automation project according to technical aspects. A project structure, called Plant Hierarchy (PH), is implemented by setting up Figure 3: Physical model according to DIN EN 61512
hierarchy folders. In the folders of this plant hierarchy, CFCs and SFCs are then stored for the automation systems, displays and reports for the operator stations as 1. Enterprise
well as supplementary documents (such as unit descriptions, process tag sheets, planning documents from other applications such as Word, Excel, etc.). A well- 2. Site
planned plant hierarchy facilitates locating objects and is the prerequisite for the reuse of generic solutions as well as automatic generation mechanisms. 3. Area
THEORY IN BRIEF 4. Process cell
Figure 1: From plant model to plant hierarchy 5. Unit
The plant hierarchy essentially has three functions: 6. Equipment module
It maps a hierarchical name scheme that can be used to break down a complex system into partial tasks that can be solved with acceptable effort. 7. Control module
It is used for the structured storage of documents and objects in this hierarchical name scheme.
It allows for the automatic generation of the picture hierarchy for operator control and monitoring. LITERATURE
THEORY [1] Online Help PH Siemens
STRUCTURING ACCORDING TO DIN EN 81346-1 [2] DIN EN 81346-1 (Ed. 2010-05): Industrial systems, installations and equipment and industrial products - Structuring principles and reference designations.
To specify, plan, create, maintain or operate a system effectively, the system as well as the information about it is usually broken down into units. Each of these units [3] DIN EN 61512-1 (Ed. 2000-01): Batch control
can be subdivided further. This successive subdivision into units and the organization of these units is called Structuring.
Two general rules apply in this case: STEP BY STEP INSTRUCTIONS
Rule 1: A technical system has to be structured based on 'is part of relationships, applying the concept of Aspects of objects. TASK
Aspects act as filters for an object that is used to emphasize relevant information. Standard aspects focus on the following: In this chapter, a folder hierarchy will be created and documented in the plant view (plant hierarchy) corresponding to the Multi-Purpose Plant project and the
Function aspect: What is the objects task, or what is it actually doing? associated nomenclature.
Product aspect: What are the means the object uses to perform its task? TRAINING OBJECTIVE
Location aspect: Planned or actual location of the object In this chapter, the student will learn the following:
Plant view of the PCS 7 project
Figure 2 shows that the 'object for filling' 'is part of' the object for manufacturing Product 1 under the function aspect. Basic settings for the plant hierarchy
Rule 2: Structuring is carried out either from top to bottom (top down) or from bottom to top (bottom up). Creating and renaming folders in the plant hierarchy
For the top down method, we usually:
1. Select an object These instructions are based on the project 'PCS7_SCE_0102_Ueb_R1304.zip.
2. Select the suitable aspect PROGRAMMING
3. Determine the sub-objects in the selected aspect if there are any: Steps 1 to 3 can be repeated iteratively for the defined sub-objects as often as required. 1. To set up the plant hierarchy in a PCS 7 project, we have to switch to the Plant view.

For the bottom up method, we usually: (View Plant View)

1. Select the aspect we want to work with
2. Select the objects that are to be considered together 2. For the automatic compilation runs for the OS (operator system) to be executed correctly later, a few basic settings have to be made for the plant hierarchy.
3. Introduce a higher level object for which the selected objects are parts in the selected aspect. (Plant Hierarchy Settings)

As for the top down method, steps 1 to 3 can also be repeated iteratively here as often as necessary for each added higher level object. If an aspect is retained in the
entire structure, the structure is called aspect-related according to the standard, which means function-oriented, product-oriented or location-oriented. A process
engineering system is structured under the function aspect (function view). A function-oriented structure is based on the purpose of a system. The purpose of a
technical system is to perform a technical process whereby input variables (energy, Information, material) are processed into output variables (energy, information,
material) taking into account specific parameters. Figure 2 shows an example.
Figure 2: Function of the reactor and its sub-functions
Structuring on this basis provides a system that can be used during all phases of the life cycle: planning the plant, automating the plant, operating the plant.
STRUCTURE OF THE PLANT HIERARCHY
The plant hierarchy can be taken directly from the plant structuring that was carried out when the plant was planned. It has to be taken into account, however, that
this structure is mapped 1:1 when deriving the picture hierarchy from the plant hierarchy.
While planning a process plant, the planning engineer creates a reference identification system that allows for the unique identification of an object in an observed
plant. This reference identification system is based on structuring according to an aspect (for process plants, according to the function aspect).
In PCS 7, the reference identification system is called Higher Level Designation System (HID). The structure of the plant is implemented PCS 7 with a folder structure.
By nesting the hierarchy folders, complex plants can also be mapped. By setting the number of levels, the depth of the structure can be specified project-wide. The
maximum structural depth is limited to 8 levels.
DERIVING THE PICTURE HIERARCHY AND OS AREAS FROM THE PH
The OS picture hierarchy for the plant operator on the operator station can be derived completely from the configured data of the plant hierarchy. This takes place
automatically during a generation run which generates an operating screen for each level. In this screen, associated operator symbols are set up for all automation
blocks, if available, that are used in the charts of this level. In addition, the corresponding group alarms and navigation hierarchies are set up. It is possible to connect
individual areas of the plant structure in the plant hierarchy to OS areas. In the case of large plants, plant operators can thus be assigned only certain plant areas. In
the process mode, plant operators only see and operate those areas for which they have the corresponding user permissions. Plus only those messages that are
relevant to this area are displayed. As a rule, a unit corresponds to an OS area in the plant hierarchy.
In the general settings of the plant hierarchy we specify the hierarchy level that is to be the OS area level for the plant hierarchy. For each hierarchy folder of this
level, an area identifier is defined. The standard setting for the area identifier corresponds to the name of the hierarchy folder in the plant hierarchy. As soon as a
hierarchy folder is provided with an area identifier, all lower level hierarchy folders and objects also receive the area identifier. The representation of the hierarchy
levels always starts with the hierarchy level that is defined as OS area.
AS-OS ASSIGNMENT
For each hierarchy folder, an operator station has to be assigned to an automation system in the plant view. This AS-OS assignment has the following consequences
for the Component view:
All CFCs and SFCs that are inserted in the plant view are stored in the chart folder of the assigned automation system.
All displays and reports that are inserted in the plant view are stored in the folder of the assigned operator station.
TYPE DEFINITION ACCORDING TO ISA-S88.01
3. The following settings are made and accepted with OK (OK)
The number of hierarchy levels is set to 3, matching the project hierarchy. The hierarchy then maps our plant as follows:
Process cell (Level 1)
Unit (Level 2)
Containers/Equipment modules (Level 3)
24 as the maximum number of characters in each level will be relevant to the automatic generation of variable names for the OS.
In our project, levels 1 and 2 generate plant identifiers.
The names have a separator / between the names of levels 1 and 2.
The OS area specifies the level from which the process images are integrated in the picture hierarchy.
For the picture hierarchy to be generated automatically, it is important to set the checkmark at 'Derive picture hierarchy from the plant hierarchy.
4. Accept the changed properties also for the hierarchy folders that have already been set up. (Yes)
5. The object properties are now set for each hierarchy folder. Here, for example, for the folder of the first level. (Process cell(1) Object Properties)
6. In the subheading General, the name, the author and above all a pertinent comment are entered. (General)
7. The subheading 'Control and Monitoring Attributes' indicates whether the name is part of the plant designation. The system enters the name automatically based
on the settings for the plant hierarchy. (Control and Monitoring Attributes)
8. In the subheading 'AS-OS Assignment' a hierarchy folder is assigned to an automation system (AS) and to an operator system (OS). In our project, two ASs (AS1 =
CPU 414-3 DP and AS2 = AS RTX Box) and one OS are available for selection. The system enters the latter automatically. We select AS1 as the AS. All properties are
accepted with OK.
(AS-OS Assignment AS1 OK)
Note: The subheading 'S88 Type Definition' is not relevant at this point. It will be needed when batch processes are implemented.
Now make the corresponding changes for all three hierarchy folders:
9. The folder hierarchy now looks like this. By moving the mouse over a folder, the comment is displayed. (educt_tank B001)
10. We need more folders for our project. To this end, right-click on the hierarchy under which you want to create a new folder. Then select 'Insert New Object' and
'Hierarchy Folder'.
(A1_multipurpose_plant Insert New Object Hierarchy Folder)
11. The name of this folder and the comment are also entered. (T2_reaction unit reaction)
EXERCISES
In the exercises, we apply what we learned from the theory and from the step by step instructions. The existing multi-project from the step by step instructions
(PCS7_SCE_0103_R1304.zip) will be used and expanded.
TASKS
1. Implement the entire plant hierarchy of the multi-purpose plant according to the diagram below.

2. Add pertinent comments to the individual levels of the plant hierarchy.

Note: If you prefer to use AS2 as the automation system instead of AS1, you can make that change in the uppermost folder of the hierarchy, and accept it for all
subfolders.
 provides a variety of efficient and tested individual drive functions as block types in the control engineering libraries. Table 2 summarizes the individual drive
PA Module P01-04 functions in the PCS 7 Advanced Process Library [2].

SIMATIC PCS 7 Individual Drive Functions Table 2: Individual drive functions of the PCS 7 Advanced Process Library

Individual drive function Usage Object name

MotL Control of motors by means of a FB 1850
INDIVIDUAL DRIVE FUNCTIONS control signal (on/off) and a
TRAINING OBJECTIVE feedback signal
After working through this module, the students will be able to define and classify the term 'individual drive function' within the scope of object-oriented software MotRevL Control of reversible motors FB 1851
structuring. They understand the concept, the structure as well as the functional method of individual drive functions; they know typical individual drive functions (clockwise/counterclockwise) and up
and their implementation in PCS 7. to two feedback signals
THEORY IN BRIEF MotSpedL Control of two-speed motors FB 1856
The objective of object-oriented software structuring is to simulate the structure of the real plant as clearly as possible by modularizing the user software accordingly. (slow/rapid) and up to two feedback
To this end, at least one function block is provided for each field device type. This function block in turn provides the entire control logic, the necessary protection and signals
monitoring functions as well as suitable operator control and visualization options. The user program utilizes this block to implement the desired operating behavior VlvL Operation of control valves with one FB 1899
of a machine or a process. control signal (open/close) and two
Motors and valves are control engineering equipment that is not controlled directly, in the sense of object-oriented automation, but is initially modeled as function position feedback signals
block types. Such function block types are called Individual Drive Functions (IDF). They enable control, monitoring and operation of the control engineering (open/closed)
equipment by providing corresponding connections for actuating and control signals as well as for parameter assignment and monitoring functions. The technical VlvMotL Control of motor-driven valves with FB 1900
implementation of the control is achieved through an instance of the function block type and is hidden from the user. Figure 1 shows the transition from the real two control signals and two position
motorin this case a pumpto a block of the corresponding individual drive function. feedback signals (open/closed)
Figure 1: Transition from real motor to blocks of the individual drive function
In principle, control engineering equipment can be operated in four different operating modes. The device is in one of the following modes:
Shut down PROTECTIVE MEASURES
Manual mode When control engineering devices are activated, different protective measures have to be taken. The devices themselves have to be protected from faults, and the
Automatic mode controlled process has to be taken to a safe state in case of a malfunction and must be maintained in this state until the fault is rectified.
Local mode Device faults (for example, cable break, and axis break) cannot be prevented by the control engineering side, but the effects can be minimized through redundancy
concepts. Process faults (for example, container overflow, dry run of a pump), however, are to be prevented directly through the control. To this end, corresponding
The individual drive function must always be in exactly only one operating mode. The operating modes mentioned can either be equivalent or arranged hierarchically interlocks are implemented. If the individual drive function detects a dangerous process state based on the current input values, the controlled device is taken to a
using priorities. In addition, individual drive functions provide functions that protect against device and process faults. To this end, different interlocks as well as safe state (refer to the chapter Functional Safety). The device is kept in that state for the duration of the dangerous process state. Usually, interlocks are specified
execution time monitoring for the device and for the controlled process are implemented. using an interlock matrix.
Function blocks, referred to as block types in PCS 7, represent pre-assembled program parts for processing recurring functions. They can be inserted in CFCs where To detect a device error that occurred, the individual drive function often performs an execution time check. By using certain sensor information from limit sensors in
they can be parameterized as instances, interconnected, and adapted to the project requirements. The block type in this case specifies the characteristic for all valves, for example, the individual drive function checks whether the actuating signals that were read out have the required effect. If over a certain period of time the
instances of this type. In control engineering libraries, PCS 7 offers a variety of high performance and tested individual drive functions as block types. They each model measured values contradict the actuating signals that were read out, there is a fault. If such a runtime error is detected, the higher level control system is alerted and
a control engineering device and make the entire control logic available. In addition, functions are offered for the following: the controlled device is deactivated. The device remains inactive until the runtime error is removed and the alarm was acknowledged. Simple, binary circuit breakers
Operator control and Monitoring of the individual drive function are often used to detect device faults.
Controlling signals OPERATING MODES
Monitoring and Alarming Control engineering devices are generally not operated exclusively automatically. From time to time it is necessary handle the control manually from the control desk,
Operating State Selection or to activate the device directly on site; for example, when repairs have to be made. For this reason, we distinguish between four basic operating modes
Interlocks. Shut down: The device is not active.
Automatic mode: The individual drive function is activated automatically by a higher level program.
Faceplates with different views allow for seamless integration into a corresponding process control system. Manual mode: The operator activates the individual drive function directly by means of a graphical user interface of the control system.
Individual drive functions enable the efficient development of high performance, high quality solutions. They modularize and type-define recurrent functionalities. Local mode: The operator operates the device on site; for example, by using the operator panel.
This means functionalities can be reused and centrally modified which speeds up the development process considerably.
THEORY The individual drive function must always be in exactly one operating mode. There are different concepts as to how switching the operating mode connected with
OBJECT-ORIENTED SOFTWARE STRUCTURING this requirement can be realized safely and unambiguously. Basically, these concepts can be differentiated as the equality of the operating modes and an operating
The objective of object-oriented software structuring is to simulate the structure of the real plant through corresponding modularization of the user software as mode hierarchy. In the latter case, the possible operating modes are clearly prioritized in addition. A selected operating mode is changed in this case exactly when the
clearly as possible. To this end, a separate program is created for each field device in the plant. At least one function block is provided for each field device type. device is not active (operating mode Shut down) or when the requested new operating mode has a higher priority than the one that was selected previously.
This block implements the entire control logic for this field device type. In addition, it makes necessary protection and monitoring functions available as well as FUNCTION BLOCK TYPES IN PCS 7
suitable control and visualization options. This means it encapsulates the entire functionality that is necessary in connection with the corresponding field device type. Function block types are referred to as block types In PCS 7 and represent pre-assembled program parts for processing recurring functions. They can be inserted in
The user program utilizes this block to implement a desired control for a machine or for a process without having to access the knowledge of the internal data and CFCs where they can be parameterized, interconnected, and adapted to the project requirements.
operations of the function block. The block type specifies the characteristic for all instances of this type. To this end, the block types used for a project are stored in a master data library. When the
CHANNEL FUNCTIONS (DRIVERS) block type stored there is changed, the changes are accepted directly by all instances. This concept of type definition supports efficient engineering through
In addition to handling the field devices through separate reusable blocks, it is often advisable to abstract IO interfacing also by using channel blocks (drivers). reusability and central changeability of functions that recur frequently.
Although it is always possible to access the process image directly by using symbol names or addresses, the multitude of possible parameters for configuring the
channel have to be set at a different location. This quickly results in confusing programs. PCS 7 provides a number of drivers (channel blocks) that evaluate the status Block identifier
signals of the modules and support testing and commissioning of automation programs through simulation modes. In the analog drivers according to Table 1, internal Block type
digital variables are mapped to the physical addresses and display variables by means of the parameters VLRANGE and VHRANGE. PCS 7 can generate the necessary Run feedback
drivers automatically by using channel blocks. Channel blocks are therefore often used in the templates of the PCS 7 libraries. Control output
Table 1: Listing of different channel blocks to abstract IO interfacing Figure 2: Block of the individual drive function MotL

Channel blocks Block Connector, Parameter An individual drive function in PCS 7 models a control engineering device and provides the entire control logic. Figure 2 describes the basic structure of the
Digital output PCS7DiOu PV_Out corresponding motor block using the individual drive function Motor_Lean as an example.
Digital input PCS7DiIn PV_In In addition, the block provides the following functions:
Analog output PCS7AnOu PV_Out, Scale Operating, Monitoring, Signaling
Analog input PCS7AnIn PV_In, Scale Process values and setpoints can be operated and monitored by means of the display and control area. Operator authorizations and maintenance releases can be
controlled. General and instance-specific messages provide information about the device and process status.
INDIVIDUAL DRIVE FUNCTIONS
As control engineering devices, motors and valves are of crucial importance in factory and process automation. A large number of commercial types with specific Controlling Signals
operational and signaling behavior are available. In the sense of object-oriented automation, such devices are not controlled directly but initially modeled as function Control signals can be read out in the static or the pulsed mode. The signal status, which means the quality of the actuating signal, is monitored. Internal and external
block types. They are then always controlled indirectly by an instance of the corresponding function block type. Function blocks for motors and valves are called setpoints as well as simulated values can be specified. In addition, ramps or dead zones can be set.
Individual Drive Functions (IDF). Individual drive functions enable control, monitoring and operation of control engineering devices by providing corresponding Monitoring
connections for actuating and control signals as well as for parameter assignment and monitoring functions. The technical implementation of the control, such as The block can monitor limits and generate corresponding warnings or alarms if the limits are violated. In addition, feedback from actuating signals can be monitored.
starting performance, activating the drive, or device monitoring, for example, is implemented through the function block instance and is hidden from the user. PCS 7 Interlock Functions
The block enables a simple switch-on release, interlock without reset as well as interlock with reset. It implements a motor protection function that can switch off the
motor in case of thermal overload. In addition, a quick stop is available for motors; it has the highest priority in all operating modes and states. If there is an interlock,
the device is automatically taken to a de-energized state and thus to a defined safety position.
Operating State Selection
The operating modes mentioned above: local mode, automatic mode, manual mode and shutdown are available for all individual drive functions in PCS 7. They are
prioritized in the descending mode in the sequence mentioned. Automatic and manual mode have the same priority. In addition, it is possible to take the block into
another operating mode by means of configurable input parameters, regardless of the currently pending control (forcing of operating modes).
Display Blocks with Different Views
Display blocks provide for each block type a corresponding block symbol and, depending on the use case, corresponding views. Typical display blocks are, for
example, the block symbol itself, the parameter view of motors and valves, or the limit view of motors.
This list clearly shows the complexity and the functional scope of a customary individual drive function. The number of available inputs and outputs is correspondingly
large regarding these blocks. For example, the individual drive function MotL has more than 53 connections. To keep the complexity of the program design low
nevertheless, it is possible to hide inputs or outputs that are not needed. Moreover, the individual drive functions in PCS 7 use a uniform and integrated scheme for
designating the inputs and outputs.
The individual drive functions in PCS 7 provide a large functional scope and guarantee constantly high quality and reliability of the algorithms used. All block types are
tested extensively and have proven themselves industrially. This considerably reduces the effort for developing efficient high quality solutions.
LITERATURE
[1] Seitz, M. (2008): Speicherprogrammierbare Steuerungen (PLCs) Hanser Fachbuchverlag.
[2] SIEMENS (2014): Process Control System PCS 7: Advanced Process Library (V8.1). A5E33257529-AA.
STEP BY STEP INSTRUCTIONS
TASK
As the first program, we are creating in the Continuous Function Chart (CFC) a pump motor for draining the liquid from Reactor R001. The pump motor has an output
for activating the pump and an indication to check whether the pump is actually running.
Table 3: Assignment list
Figure 3: Excerpt from P&ID flowchart
When creating the program, a pre-assembled chart 'Motor_Lean from a PCS 7 library is used. It is copied to the master data library belonging to the project and
adapted there. Then the program is loaded to the PLC simulation and tested.
TRAINING OBJECTIVE
In this chapter, the student will learn the following:
Creating and importing symbols with the symbol table
Using master data libraries
Creating and editing CFCs
Compiling and downloading the project centrally
Testing the program by means of the control functions in the CFC
These instructions are based on project 'PCS7_SCE_0103_Ueb_R1503_en.zip'.
PROGRAMMING
1. Before starting with programming the individual drive functions for the pump motor, we have to create the symbols for the global variables. To this end, we select
the Component view in SIMATIC Manager, highlight the folder 'S7-Program(1) and open the symbols of the symbol table with a double click.
(SIMATIC Manager ViewComponent viewAS1 CPU 414-3 DP S7-Program(1) Symbols)
2. We now can specify the symbol and the comment for each address in the symbol table.
3. If available, the content of the entire symbol table can be imported in *.dif format. (Symbol Table Import). In this case, the imported table is integrated in the
existing table.
4. Now we select the source file in the 'Data Interchange Format' (*.DIF)
(P01-04_symbols_R1501_en.dif Open)
5. Before closing, the completed symbol table has to be saved.
(Save )
6. In extensive libraries, PCS 7 provides a variety of prepared blocks and also pre-assembled charts, called templates. We want to use exactly such a template for the
pump motor. To this end, we open the PCS 7 AP Library V81.
(File Open Libraries PCS 7 AP Library V81 OK)
7. To drag this template from the library to the project, go to the Plant view of the project. (View Plant View)
8. With Drag&Drop, Motor_Lean (library, templates) is moved to Process tag types (master data library).
(PCS 7 Library Blocks+Templates Templates drag Motor_Lean to Plant View SCE_PCS7_Lib Drag process tag types)
9. Now we are making a change centrally for all process tags of the type 'Motor_Lean. This is done be opening the CFC 'Motor_Lean in the master data library with a
double click. (Motor_Lean)
Note: CFC stands for Continuous Function Chart and is a graphic programming language for describing continuous processes. In the CFC, pre-assembled blocks are
placed, parameterized and interconnected. This way, the programmer creates an overall software structure for controlling a machine.
10. A CFC consists of chart partitions with 6 sheets each. In the overview, all six sheets are displayed with gray sheet bars. In the sheet bars, the incoming signals are
shown on the left and the outgoing signals on the right of the sheet. By double-clicking a sheet, its view can be changed.
(Overview Double click on first sheet)
Note: Using the tabs in the lower bar, we can switch between the chart partitions (maximum A to Z). Here only chart partition A is initially provided.
11. We now are making a change in the 'MotL block with the process tag type 'Motor_Lean. To this end, its properties are opened with Object Properties. (MotL->
right-click -> Object Properties)
12. You do not want to change the general properties such as operator control and monitoring; therefore, we change to the I/Os. (I/Os)
13. The connections are represented in a table together with a variety of properties that can be set. The most important properties are introduced below. In the
'MotL' block, we are only deleting the Invisible feature for 'AutModOP'. This makes the connection visible in the sheet. Exit the Properties with (AutModOP OK)
Note: By clicking on the header of a property, the representation after this column can be sorted alphabetically.
14. We can now close the process tag type. It is saved automatically after each change. (Chart Exit)
15. To use the process tag type 'Motor_Lean', it is dragged to the chart folder 'Reactor R001. (Motor_Lean Reactor R001)
16. Because this chart will be used to activate the pump A1T2S003, it is now renamed A1T2S003 and opened with a double-click. (Reactor R001 A1T2S003
A1T2S003)
17. With a right-click, we open the properties of the 'MotL' block.
(Motor_Lean Object Properties)
18. The name of the block is changed in the general properties.
(Pump_A1T2S003 OK)
19. Now the time for feedback monitoring after the motor block was operated successfully is changed to 10.0 seconds. To do this, we open the Properties dialog for
the input 'MonTiDyn' with a double-click and enter 10.0 as Value. We exit the dialog with 'OK.
(MonTiDyn 10.0 OK)
20. Next, the feedback is connected to the input address. This is done by right-clicking on the input 'PV_In in the 'PCS7Diln' block and then selecting the
interconnection to the address. (PV-In Interconnection to Address)
Note: Like the PCS7DiOu block, the PCS7DiIn block is a driver block for interfacing with the PLC IO. If the value 'PV_In' in one of these blocks is interconnected with an
address that is also configured in the hardware configuration, the input MODE is supplied automatically with data during the compilation that is run later.
For this to happen later during the compilation run, 'Generate module driver' has to be selected.
21. The address that signals whether the pump is running can then be selected conveniently directly from the symbol table. (A1.T2.A1T2S003.S0+.0+)
22. Now the activation of the output address has to be interconnected. This is done by right-clicking the output 'PV_Out in the block 'PCS7DiOu' and then selecting
the interconnection to the address. (PV_Out Interconnection to Address)
23. The address for activating the pump can once again be conveniently selected from the symbol table. (A1.T2.A1T2S003.SV.C)
Note: The placeholder at the output of Pcs7DiOu 'output start' should be deleted; otherwise, there will be a warning during compilation!
24. Before the program for the pump motor can be compiled and loaded, the PLC simulation S7-PLCSIM has to be started from the SIMATIC-Manager. ()
25. The PLC simulation acts like a real SIMATIC S7 CPU. However, the inputs and outputs have to be inserted first before they can be monitored and operated. (
Insert Input Insert Output)
26. Next, the correct byte addresses have to be entered. (IB1 QB3)
27. For loading from the SIMATIC Manager to S7-PLCSIM to take place using the correct interface, the PG/PC interface will be set correctly.
(SIMATIC Manager Options Set PG/PC Interface)
28. PLCSIM(TCP/IP) is set as interface here. (PLCSIM(TCP/IP) OK)
29. Now the project folder can be highlighted and compilation and download of the objects can start.
(Plant View SCE_PCS7_Prj PLC Compile and Download Objects)
30. In the following selection, 'Compile and Download Objects' is selected for the hardware and the charts of the AS1. Then the folder 'Charts' is highlighted and its
setting checked using 'Edit'. (Charts Edit)
31. When compiling the charts, it is important to compile the entire program and to have the module drivers generated.
(Entire program Generate module drivers S7 Download)
32. When downloading the charts, it is also important to download the entire program. (Entire program OK OK)
33. Finally, we can start 'Compile and Download Objects'. The warnings and instructions regarding plant safety should be read carefully. Prior to compile and
download, the CPU has to be switched to STOP. (Start OK Yes)
34. Ultimately, the errors and warnings are displayed in a log. Close the window. ()
35. If you want to view log details, check at Logs and click on Single object. (Single Object Close Close)
Note: Four warnings are indicated here. Delete the empty OB1 and existing textual interconnections. They occur because of the unconnected connections of the
template. These connections are connected in chapter P01-05.
36. To test the program, the CPU in S7-PLCSIM is switched to 'RUN-P'. (S7-PLCSIM RUN-P)
37. Before the individual blocks can be monitored in the CFC, the chart has to be switched to the test mode first. (CFC )
38. The blocks that are to be monitored must now be explicitly activated for monitoring. The same applies subsequently to the individual connections of the block.
(Pump_A1T2S003 Watch On)
39. To continue, we have to make the connections for the automatic control 'StartAut' and 'StopAut' of the 'MotL' block visible. If there should be an error, 'RstOp'
and MonDynErr' should be made visible, too.
6. Now implement the high and low level sensor of product container B001. For this, set up a CFC in the chart folder 'Product_tank B001' and name it A1T3L001. Open
the chart and insert the block 'Pcs7DiIn' twice from the catalog (analogous to exercise 5). Name one block A1T3L001_LSA+ and the other A1T3L001_LSA-.
Interconnect 'PV_In' with the sensor signals.
7. Next, create the CFCs for the main switch, the EMERGENCY OFF switch and the switch for local operation. As in exercise 7, a CFC for A1H001, A1H002 and A1H003
is created in the chart folder 'Multi-purpose plant'; the block 'Pcs7DiIn' is added, named, and interconnected with the respective address to 'PV_In'.
Table 4: Symbols for implementation of the valve control and the fill sensor

(Object Properties)
(RstOp)
(MonDynErr)

40. Next, we switch to Automatic with 'AutModOp' == 1 for the manual/automatic mode.
(AutModOp Properties "1")
Note: During testing, we should not omit setting the feedback I1.3 within 10 seconds after activating the output Q 3.4 in S7-PLCSIM. If this is not done, the block
Pump_A1T2S003 shuts off and reads out an error.
Note: If there is no feedback, the pump block not only switches the actuating signal START to 0, but indicates by setting the output 'ModDynErr' to 1 that the run
signal of the pump had not arrived on time. All connections have to be made visible. To prevent damage through repeated switch-on attempts, the pump block has to
be reset before another attempt is made.
To do this, input 'RstOp' has to be briefly set to 1 and then again to 0!
By double-clicking on this input parameter of pump block Pump_A1T2S003, the dialog window shown above is opened. In the field Value, we first enter a 1; this value
is transmitted to the control system by clicking on the button 'Apply' and the error outputs are set to 0. To return to the normal method of functioning, 'RstOp' must
be reset to the original state by entering 0 and 'Apply' once more.

41. Next, the pump is started with (StartAut == 1 and StopAut == 0) and can be stopped again with (StartAut == 0 and StopAut == 1).
(StartAut Properties Value "1")

42. If the run feedback was not switched on in time in the PLCSIM, an error is displayed in 'MonDynErr'. It can be acknowledged with RstOp' == 1.
TESTING THE AUTOMATION LOGIC WITH THE SIMULATION
Entering process states manually in the simulated control system is still possible with justifiable effort for small functions. For more complicated runs with several
dynamic process variables, the limits of what is doable are quickly reached. Here, using process simulation is recommended.
For this course, the essential relationships of the process that we are automating here were mapped with the simulation software SIMIT. The model maps the
dynamic behavior of the pumps, valves, containers, reactors as well as the local operator panel with main switch, EMERGENCY OFF, switch-over to local operation
and the corresponding operator controls. The dynamic processes have been accelerated in comparison to reality by a factor 5 to 50 to keep waiting times short.
The simulator operator interface is shown in Figure 4. On the left side, it shows the process scheme as well as the signal levels of controlled and measured variables.
On the right side, the ochre-shaded local operator panel is shown on top, below that a series of control elements is provided for the simulation.
Using the simulator is simple; we only have to make sure that the assignment of the inputs and outputs was not changed.
With the simulator, pump activation can now be checked very simply:
1. After S7-PLCSIM the simulation program is started.
2. The simulation starts with the 75% filled educt tanks; all others are drained. This state can be restored in the simulation control any time with the option 'RESET'.
The option 'RESET 50%' fills all tanks as shown in Figure 4 to 50%.
3. For testing, the motor block is activated as described in the previous section under Step 41. In the simulation, the actuating signal of the pump is illuminated green.
4. The simulated motor startup takes about 2 seconds. Then, the motors running indicator flashes green in the simulation, and the signal level for binary input I 1.3 of
the control system is set.
5. To open the supply path, the valve for product tank T3.B001 has to be opened as well. In the exercise below, this valve is activated by a suitable individual drive
function. If the pump is switched on and the valve is open, we can watch in the simulation how the contents of reactor T2.R001 are pumped into product tank
T3.B001.
6. Using the simulation controls, the product tanks can be drained and the educt tanks can be filled. When the tanks are filled using the simulation control, first the
simulation has to be separated from the control system. To this end, the button with the horizontal line () is clicked once. Then, the valve can be opened with the
button to the right of it. The actuating signal flashes green. After approximately one second, the signal of the limit switch for the open position follows. After an
additional 5 to 10 seconds, the first level changes are visible.
7. With 'RESET' and 'RESET 50%', the simulation can be returned to a defined state.
Figure 4: User interface of the process simulation
EXERCISES
In the exercises we apply what we have learned from theory and from the step by step instructions. To this end, we utilize and expand the available multi-project
from the step by step instruction (PCS7_SCE_0104_R1503_en.zip).
The objective of this exercise is to create a CFC that can be used for controlling the valves of the plant. The exercise is based on the knowledge acquired through the
step by step instructions where a similar CFC for controlling the motor was created.
In addition, a CFC is created for scaling the level, which means an analog input value, from the digitalized to the physical value. This task adds to our knowledge
because the CFC is created without a template but still with a block from the library. This CFC is required for the chapter 'Functional Safety'.
TASKS
The following exercises are based on the step by step instructions. The corresponding steps of the instructions can be used for each exercise as an aid.
1. Insert the template 'ValveLean' as template in the process tag types (analogous to 'Motor_Lean' ). This template is used to implement the valves.
2. In the chart folder 'Product container B001' of unit T3_Product_memory, an object instance of the valve template is to be inserted and renamed to A1T3X001.
Open the CFC and also adapt the name of the block 'VlvL'. Now, close the feedback and control signals (see Figure 5 and Table 4).
3. Download and test your implementation with the SIMIT model. The following connections should be visible for this: 'ModLiOp', 'AutModOp', 'ManModOp',
'OpenAut', 'CloseAut' and 'RstOp'.
4. To incorporate the analog level sensor A1T2L001 (see Figure 5), create a new CFC in the chart folder 'Reactor R001'. Name it A1T2L001 and open it. Drag the block
'Pcs7AnIn' (FB1869) from the catalog to the CFC. To do this, select the tab Libraries in the left frame and then use either the search function at the very bottom or
open PCS 7 AP Library V81/Blocks+Templates\Blocks/Channel. As soon as the block has been inserted, rename it Level_A1T2L001.
5. Now assign parameters to the block 'Pcs7AnIn' by setting the input value 'Scale' to High = 0 and Low = 1158.0, and the 'PV_InUni' to 1040 (for the unit ml). Connect
the input 'PV_In' of block 'Pcs7AnIn' with the symbol for the actual level value (see Table 4) of Reactor R001.

PA Module P01-05
SIMATIC PCS 7 Functional Safety
FUNCTIONAL SAFETY
TRAINING OBJECTIVE
After working through this module, the students are familiar with the basic requirements for functional safety. They will learn methods to identify potential danger as
well as to evaluate the risks resulting from it. They will know methods and design concepts to safeguard plants with the means of process control engineering. They
will learn the basic connections for interlocking controls.
THEORY IN BRIEF
In modern production plants, process variables are used to control and safeguard technical processes. Based on the given technical general conditions, permissible
and impermissible ranges are defined for these variables. The state of the entire plant results from the current values of all process values. The objective of functional
safety is to prevent the plant from entering an impermissible state. To this end, different interlocking mechanisms are set up. The objective of interlocks is to prevent
combinations, sequences, and time characteristics of signals that can lead to impermissible fault states.
This can be done, among other things, with the means of process engineering through so-called safety set-ups. They prevent faults from occurring, or they limit the
damage if an impermissible fault state occurred despite all measures taken. In order to design suitable interlock mechanisms, a protective concept has to be
developed for the plant. This task requires exact knowledge of the chemical, process and system boundary conditions. For this reason, the protective concept is
developed by an interdisciplinary team using the HAZOP or PAAG analysis.
The technical implementation of the mechanisms in a process control system should be designed as simple as possible, have a direct effect and be manageable. For
this reason, in practice recurring standard protective circuits are resorted to. They can be arranged in four categories.
Combinatorial circuits are used to generate switching conditions by directly combining the corresponding process signals. To this end, the input signals are connected
through the logic operations AND, OR and NOT. The state of the output signal of such a combinatorial circuit can thus be determined anytime through the states of
the input signals.
Prioritization circuits permit giving certain signals precedence over other signals. This is often necessary in the case of operating mode selection as well as for start
and stop functions. Prioritization circuits are often implemented with combinatorial circuits.
Locking circuits prevent that signals having opposite effects can be set simultaneously. If a certain sequence for several control signals is required beyond this, it is
referred to as a sequence lock. Interlocks are implemented using R-S flip-flops that are connected to each other.
Circuits with timing behavior allow for delayed switch-on/switch-off, the definition of a minimum as well as maximum execution time, and the implementation of
protective functions that require a certain reaction time. To implement such circuits, different pre-assembled time blocks are available.
THEORY
PROCESS VARIABLES
Production plants are used to produce material goods. They control and monitor the flow of material and energy that can be described with physical variables such as
volume, mass, temperature or flow. Based on process and system engineering boundary conditions, those physical variables that are relevant to the technical process
and that can be measured are defined and specified. These variables are called process variables.
Process variables are used to control or safeguard technical processes. For each process variable, ranges are specified based on chemical, process or system
engineering boundary conditions for which this process variable is intended (OK range), as well as ranges outside the OK range where no safety related restrictions
exist for further operation (permissible fault range). If the process variable is outside these ranges, undesirable events that result directly in bodily injury and
environmental damage are to be reckoned with (impermissible fault range).
The values of the process variables are recorded and evaluated with the means of process control engineering. From this data, the current state of the system is
determined. Three basic states are differentiated:
OK state: The values of all process variables are in the respective OK range and no danger is emanating from the system elsewhere.
Permissible fault: The values of one or several process variables are in the respective permissible fault range. Otherwise, no danger is emanating from the system
Impermissible fault state: The values of one or several process variables are in the respective impermissible fault range and danger emanates from the system
elsewhere.
Impermissible fault states always exist when bodily harm can occur or the life of employees is jeopardized, the environment is damaged, technical facilities are
destroyed or the product yield is diminished. It suffices in this case that the probability is sufficiently high for these events to occur [1].
FUNCTIONAL SAFETY
Functional safety refers in general to safeguarding the process engineering system against fault states [1]. For many processes states in process systems, certain
events can occur that cause damage. The combination of the frequency of the occurrence of damage and its extent is called the risk of the corresponding process or
state. It is the objective of functional safety to take protective measures that decrease the existing risks to the extent that the remaining risk is below the acceptable
risk that is to be defined, i.e., justifiable [2].
The locking mechanisms described in the chapter Individual Drive Functions protect the plant or plant units from device-related fault states. These include all those
fault states that are caused by a malfunction of the devices themselves, or by operating the device outside the permissible operating range (for example, overheating
a pump because of an undetected dry run). These fault states are device-specific and can be detected regardless of process and system engineering boundary
conditions.
The locking mechanisms described by their very nature cannot safeguard against process related fault states (for example, dry run of a pump) by themselves because
they depend on process and system engineering events (for example, dropping below a minimum tank level causes the pump to run dry). For this reason, plants have
to be made safe by implementing suitable process-related interlocks. These often utilize and expand the locking mechanisms of the individual drive functions (refer to
the chapter Individual Drive Functions). All types of intended plant operations have to be taken into account.
Intended operation refers to the operation for which the plant is intended and designed according to its technical purpose [2]. This usually includes the following
operating modes
Normal mode
Startup and shutdown operation
Commissioning and decommissioning
Test mode
Inspection, maintenance and repair processes
To this end, an interdisciplinary team first develops a safety concept for the plant. The team systematically identifies danger potential and faults that can lead to
danger. Established methods for danger analysis are used, for example, the PAAG procedure [3].
Next, the risks have to be evaluated that result from the dangers that were recognized. Different methods for graduated evaluation of the risk to be covered are
available, for example, the ALARP method, the LOPA method or the method of the risk graph specified in [2]. If the initial risk of danger is larger than the specified
acceptable risk, protective measures have to be taken that reduce the risk accordingly.
FUNCTIONAL SAFETY BY MEANS OF PROCESS CONTROL ENGINEERING
For functional safety, protective equipment that is not based on the means of process control technology is used. Often, however, this is not possible or sufficient
because either of the size or complexity of the plant, or the corresponding solution cannot be efficiently implemented under economical aspects. In this case,
protective functions are implemented with the means of process control technology. For this reason, we distinguish between two types of process control systems
(PCS) equipment:
PCS operating and monitoring equipment (Basic Process Control System - BPCS) implements the automation functions required for production and is therefore used
for the intended operation of the plant in its OK range [2]. PCS monitoring equipment reacts if one or several process variables leave the OK range. It signals
permissible fault states or automatically takes steps to take the process variables back to the OK range. From the perspective of functional safety, no requirements
are made of PCS operating and monitoring equipment.
PCS safety systems (Safety Instrumented Systems - SIS) are used to reduce the risk of recognized danger potential. They do this by either preventing an event or by
limiting the damage. The objective of event-preventing PCS protective equipment is to prevent the impermissible fault to occur in the plant in the first place. It thus
reduces the frequency of an undesirable state to occur as well as the risk connected with this event. The objective of damage-limiting PCS equipment is to limit the
extent of the resulting damage an undesired event causes, and to decrease the risk associated with it. Such protective equipment is used very rarely.
Figure 1 shows the method of functioning of PCS devices within the scope of functional safety. Curve 1 shows a process variable thatprocess relatedcannot reach
the impermissible fault range. For this reason, a PCS monitoring device is sufficient here. In Curve 2, on the other hand, exceeding the limit to the impermissible fault
range is possible. But because a non-PCS protective device exists, a PCS monitoring device is also sufficient in this case. In Curve 3, there is no such safeguarding of the
plant. Therefore, a (event-preventing) PCS protective device is used to prevent the process variable from reaching the impermissible fault range.
For the process control engineering systems of a plant we have to clearly define whether they implement an operational or a monitoring function, or a protective
function This differentiation facilitates planning, setup and operation, but also subsequent changes to the PCS systems.
Figure 1: Schematic display of mode of action of PCS equipment according to [2]
Because functions of PCS devices are required only very rarely, components of protective equipment are sometimes used also by operational devices for economic
reasons. In this case, signals for activating protecive functions must always take precedence over signals of the operational and monitoring equipment.
To implement the protective functions, manageable and immediately effective steps should be taken. The process variables used can be logged directly with simple
and tried methods. This means that the complexity of the control design itself is relatively low.
STANDARD CIRCUITS FOR FUNCTIONAL SAFETY
The objective of safety systems using the means of process control engineering is usually this: to control certain combinations, sequences, time characteristics or
priorities of signals in a way that impermissible process states are prevented. These functions are implemented with recurring standard circuits. The most important
standard circuits are described below.
Combinatorial Circuits
In many cases, certain control signals are permissible only if the process is in a certain state. This state can be described directly as a combination of the
corresponding process signals. To link individual signals into a switching condition, simple combinatorial circuits can be used. They have the ability to determine the
state of an output signal at any time through the state of a set of input signals. To this end, the input signals are combined with the logical operations AND, OR NOT.
The combinatorial circuits themselves are stateless, which means they have no storage properties. The relationship between input and output signals can be
described completely with a function table. The corresponding logic function can always be represented in (at least) two standardized forms.
Disjunctive normal form (DNF): In this representation, first all combinations of the inputs are determined for which the output signal is to be set (which means all
lines of the function table for which O = 1). These combinations are represented as AND operations of the input signals. The outputs of these AND operations are then
connected to each other by means of an OR operation. This sets the output as soon as one of the located combinations occurs.
Conjunctive normal Form (CNF): In this representation, first all combinations of the inputs are determined for which the output signal is not to be set (which means all
lines of the function table for which O = 0). These combinations are inverted and represented as OR operations of the input signals. The outputs of these OR
operations are then connected to each other by means of an AND operation. Inverting the located combinations has the effect that the output is set only if none of
these combinations occurs.
Figure 2 shows an example of a function table with three input signals and the corresponding combinatorial circuits in the disjunctive and conjunctive normal form.
Prioritizing Circuits
Protective functions always take precedence over operational and monitoring functions, which means several control signals control the behavior of an actuating
signal. For this reason, the control signals have to be prioritized accordingly. In most cases, prioritization is static, and can therefore be implemented using a
combinatorial circuit.
Latching Circuits
It is not always possible to represent the conditions for an output state by the current state of the inputs alone. If output signal O is to be set by the input signal I1, for
example, and deleted by another input signal I2, this can no longer be represented combinatorically. O has to remain set when I1 is deleted. Only when I2 is set, is O
to be deleted. This makes the effect of I2 dependent on whether I1 was previously set, which means before the current Out state of the system. This state has to be
stored in the circuit. Such latching circuits are also called sequential circuits. Storing the Out state can be implemented using a reset-set storage element (R-S flip-
flop).
As shown in Figure 3, such a circuit has two inputs: one input for setting (S) and one input for resetting (R) the output. It is important here to define how the output is
to be switched when both inputs are set. Depending on the implementation of the R-S flip-flop, either setting or resetting is dominant (refer to Figure 3).
Figure 3: Design and function symbols of R-S flip-flops
Interlocking Circuits
Often, specific control signals must not be set simultaneously. For example, an electrical motor must not be switched in two directions of rotation at the same time,
forward movement and reverse movement. The two signals F (forward) and R (reverse) have to lock each other out.
Using two connected R-S flip-flops, a lock can be implemented. Two connections are possible: The lock takes place either by means of set inputs or the reset inputs.
Both are shown in Figure 4. It should be noted that locking by means of the reset input works only if the reset input is dominant.
Figure 4: Mutual interlock of two output signals
In some cases the sequence in which specific control signals can be set must also be specified. A sequential lock has to be implemented for this. This also can be
implemented by sequencing storage elements. We need as many R-S flip-flops as steps that are to be coordinated. Figure 5 shows a sequential lock for two signals.
Figure 5: Sequential lock of two output signals
It has to be noted that only activation sequences are implemented with these circuits but no sequences. Setting O2 does not cause O1 to be reset. When locking by
means of the reset input, O2 is reset automatically when O1 is reset.
Circuits with Timing Behavior
Circuits with timing behavior also take into account the time since the occurrence of one or several events. This principle is explained below using the two hand lock
as an example. It is to prevent that workers get hurt when operating a machine (for example, a press). To prevent that a worker still has one hand in the danger zone
of the machine, it can only be activated by operating two buttons at the same time. This task can also be solved with a combinatorial circuit. To prevent that one
switch is continuously set with adhesive tape, however, it also has to be ensured that both buttons are pressed within a fixed time span. To this end, impulse blocks
are used that set the output signal for a specified time and then reset it automatically, regardless of the time duration of the set input signal. Only a state change of
the input (from reset to set) sets the output signal again. Figure 6 shows the function symbol and the switching performance of an impulse block.
Figure 6: Function symbol and switching performance of an impulse block
The corresponding circuit for two hand locks is shown in Figure 7. If one of the buttons is operated, output OUT of the impulse block is set for the duration T. If the
second button is operated while OUT is set, all conditions for the AND element are met and output O is set. Then, the impulse block is jumpered through the OR
operation with output O.
Figure 7: Two-hand lock when using an impulse block
Timing elements are used for a variety of other protective functions; for example, for protective gate controls where open gates close automatically after a specified
time, or for motor startup controls where, after a futile start attempt, a rest period for drive recovery is forced.
LITERATURE
[1] Strohrmann, G. (1983): Anlagensicherung mit Mitteln der MSR-Technik. Oldenbourg Verlag. (Functional Safety using DSG Technology)
[2] VDI 2180 (Ed. 2007-04): Safeguarding of industrial process plants by means of process control engineering.
[3] BS EN 61511 (Ed. 2003-03): Functional safety. Safety instrumented systems for the process industry sector.
STEP BY STEP INSTRUCTIONS
TASK
According to the requirements in the chapter Process Description, the CFCs from the chapter Individual Drive Functions will be supplemented with the manual
operation of the pump motor =SCE.A1.T2-P001. The following interlocking requirements have to be noted:
The pump motor must only be switched on if the main switch of the system is switched on and the emergency stop switch is unlatched.
The pump must not take in air. The minimum level (here: 50ml) in the reactor =SCE.A1.T2-R002 is known numerically and is evaluated by means of the measured
level.
The pump must not press liquid against a closed valve. This means when the pump is switched on, either valve=SCE.A1.T3-V001, valve=SCE.A1.T2-V007 or valve
=SCE.A1.T4-V003 must be open.
14. Next, open the CFC 'A1T2L001' in the Plant View with a double click. (SIMATIC Manager Plant View A1T2L001)
15. In the open chart 'A1T2L001' at block 'Pcs7AnIn' click on the output 'PV_Out'. The cross-chart connection is set up and displayed for both charts on the margin
bar. For chart 'A1T2L001' the destination of the connection is shown on the right. For chart A1T2H011' the source of the connection is shown on the left. (
A1T2L001 Pcs7AnIn PV_Out)
16. Now, the signals that request the reset have to be connected to block Or08. These signals are shown below and are also listed in Table 1. Please note that some
signals are connected inverted. To do this, right click on the connection to open the shortcut menu and select Invert.
17. To complete the chart, the two signals needed for manually operating A1T2H011 Start and Stop are added. To enter them, insert two driver blocks for one digital
input signal. (Libraries PCS 7 AP Library V8.1 Blocks+Templates\Blocks Channel Pcs7DiIn)
18. Next, to differentiate the blocks, change the name and add a comment. In the result, the blocks can now be easily distinguished. (Pcs7DiIn Object Properties
Name: A1T2H011_HS+ and A1T2H011_HS- Comment: Start draining and stop draining)
19. Then, the two driver blocks are connected to the respective signal. (Pcs7DiIn PV_In Interconnection to Address A1T2H011.HS+.Start and A1T2H011.HS-.Stop)
20. Now, we have to connect the output PV_Out of the block for starting with the input SetLi of the flipflop, and the output PV_Out of the block for stopping with
an input of the block Or08.

Note: For the approach to the solution, please note the details regarding latching circuits in the theoretical part. 21. Next, we enter a text field for the description. The inserted text field can be edited with a double click. (Right click Insert New Text "Manual control for
emptying of R001 reactor to product tank B001")
TRAINING OBJECTIVE
In this chapter, the students will learn the following: 22. Using the tables below, check the interconnections you have just set up for A1T2H011.
Implementing expanded boundary conditions and manual operation Table 1: Input Interconnections in Chart A1T2H011/Sheet1
Setting up connections between CFCs Note: A1T2L001(A,1) / 1 PV_out Process value incl. ST means:
Additional possibilities for programming with CFCs Chart A1T2L001
Utilizing additional sheets in the CFCs Subchart A, Sheet 1
Block 1
These instructions are based on the project PCS7_SCE_0104_Ueb_R1305_en.zip. Connection PV_out Process value incl. ST (STRUCT consisting of value and ST)
PROGRAMMING
1. To program the manual operation for draining Reactor R001, set up a new CFC in the SIMATIC Manager in the Plant View in the folder Reactor R001 of the Table 2: Block Interconnections in Chart A1T2H011/Sheet1
subsystem T2_Reaction. Table 3: Output Interconnections in Chart A1T2H011/Sheet1

(SIMATIC Manager View Plant View Reactor R001 Insert New Object CFC) 23. Next, we establish the interlocking conditions for the pump Drainage Reactor R001. To this end, open CFC A1T2S003 in the Plant View with a double click.
(SIMATIC Manager Plant View A1T2S003)
2. The chart is then renamed 'A1T2H011 and opened with a double click. 24. In addition to the individual drive function for the motor MotL, the template Motor_Lean contains more blocks. Block Intlk02 for locking MotL exists three
(A1T2H011) times. The first block is called Permit and permits starting the motor only when the conditions are met. Here, we connect the signal of the main switch for plant
3. In the CFC Editor, drag the 'FlipFlop' block from the 'LogicDi' folder in the Block catalog to the first sheet of the chart. You now have a storage element. For the A1H001. To this end, we first delete the connection to the placeholder Permit in the left margin. Then we establish a cross-chart connection. The result is shown
reset or switch-off to be dominant, the mode has to be set to 1. below.

(Library PCS 7 AP Library V8.1 Blocks+Templates\Blocks LogicDi FlipFlop Mode '1) 25. Now, we do the same for the block Protect. Protect is used for connecting interlocks that require an acknowledgement for the motor to be enabled again. Here
Note: Additional information about the blocks used is provided in the detailed online help. Highlight the corresponding block and press 'F1' on the keyboard. you connect EMERGENCY STOP.

26. The Interlock block is intended for general interlock conditions. Here, you will implement the conditions from the Task (for example, at least one valve open).
4. Next, from the 'LogicDi' folder, drag the block 'Or08' to the chart. Because more than two conditions exist in this example, they have to be combined prior to being interconnected. To do this, we first have to go to Sheet 2 of the CFC.

5. Now, from the 'LogicAn' folder in the PCS 7 AP Library V81 in the 'Library' tab, drag the block 'CompAn02' into the chart. You will need it to take into account the 27. On the new sheet, we now insert an Or04 block from the library. The feedback signals (FbkOpen) of the valves now have to be connected to this block. Because
level of Reactor R001 present as a numerical value for the interlock. only 1 of the 3 valves has been set up so far, you can set up placeholders for these interconnections by means of textual interconnections. When compiled, they issue
(Libraries PCS 7 AP Library V8.1 Blocks+Templates\Blocks LogicAn CompAn02) warnings but the program works anyhow.

28. Now, the minimum level has to be polled using the block CompAn02, and the connections can be linked with And04. The result looks like this.
6. Next, drag the driver block for a digital output signal 'Pcs7DiOu' into the chart.
(Libraries PCS 7 AP Library V8.1 Blocks+Templates\Blocks Channel Pcs7DiOu) 29. Next, output Out of block And04 has to be connected to input In01 of the Interlock block.
7. Assign names to the blocks as shown.
8. Now, the first interconnection of the blocks among each other is established. To this end, connect output 'Out of the 'FlipFlop' block with input 'PV_In' of the 30. Below, an overview of all new interconnections in chart A1T2S003 is provided once more.
'Pcs7DiOu' block. The alignment that this connection shows is automatic and cannot be changed in the CFC Editor. Table 4: Input Interconnections in Chart A1T2S003/Sheet1
(FlipFlop Out Pcs7DiOu PV_In) Table 5: New Blocks in Chart A1T2S003/Sheet2
9. To display the status of the operator request, we now interconnect output 'PV_Out' of the block 'Pcs7DiOu' with the corresponding address from the symbol table. Table 6: Input Interconnections in Chart A1T2S003/Sheet2
Table 7: Block Interconnections in Chart A1T2S003/Sheet2
(Pcs7DiOu PV_Out Interconnection to Address)
31. In Sheet 1 of chart A1T2S003 we now set up interconnections for manual operation with A1T2H011 (to drain reactor R001). Because other manual operations
10. From the symbol table that is then displayed select output Q 4.2 "A1.T2.A1T2H011.HO+-.O+" for the status display of the operator request. can also access the pump, an Or04 is set up on Sheet3.
(A1.T2.A1T2H011.HO+-.O+) Table 9: New Blocks in Chart A1T2S003/Sheet3
Table 10: Input Interconnections in Chart A1T2S003/Sheet3
11. Now, another interconnection is established among the blocks. Simply click on the output of the 'Or08' block and then on the input 'RstLi' of the 'FlipFlop' block. Table 11: Block Interconnections between Chart A1T2S003/Sheet1 and A1T2S003/Sheet 3
Next, the output 'LT' of block 'CompAn02' is connected to an input of the 'Or08' block.
(Or08.Out FlipFlop.RstLi CompAn02.LT Or08.In8) 32. For the manual local Start and Stop to be effective, we have to switch to local operation.
Note: The output 'LT' of block 'CompAn02' has the state 1 if 'In1' is less than 'In2'. Table 12: Additional Input Interconnections in Chart A1T2S003/Sheet1

12. The comparison value is set at input 'In2' by opening the properties with a double click. Enter 50.0 as the value and accept this change with OK. 33. For the manual operation A1T2H011, valve A1T3X001 is needed in addition to pump A1T2S003; the valve was implemented in the exercise in the previous
(CompAn02 In2 Value 50.0 OK) chapter. Below, the interconnections that were set up in chart A1T3X001 additionally for manual operation.
13. Now we establish a cross-chart connection of input 'In1' to the measured level of reactor =SCE.A1.T2.R001. To do this, highlight 'In1' at block 'CompAn02'. ( Table 13: Input Interconnections in Chart A1T3X001/Sheet1
CompAn02 In1)
34. All blocks used in the charts are integrated in the run sequence of the entire program when inserted. By clicking on the symbol the run sequence can be displayed.
To improve the data flow within the overall program, we recommend you optimize the sequence after the program is generated. This is done in the menu of the CFC
editor under Options -> Optimize Run Sequence (independant from the current view.)
(Extras Optimize Run Sequence OK)
Note: A block should be selected beforehand. Otherwise you will end up in the general overview without any clue as to where the blocks are called.
EXERCISES
In the exercises, we apply what we have learned from theory and from the step by step instructions. The multi-project from the step by step instructions
(PCS7_SCE_0105_R1503_en.zip) is to be used and expanded.
In the following exercises, you can design and implement your own additional interlocks. Keep in mind that for interlocking valves, only the EMERGENCY STOP switch,
and the main switch as well as the level of the respective tank (or levels of the respective tanks) are needed.
TASKS
1. Complete the interlocks for the valve that already exists:
A1T3X001
2. Set up the CFC for the level of educt tank B001:
A1T1L001
3. Set up the CFCs for the following valves, including interlocks:
A1T1X004
A1T2X001
4. Set up the CFC for the following pump including interlocks:
A1T1S001
5. Set up the CFC for the following manual operation:
A1T2H001
6. Test the implementation with the simulation. You should now be able to pump from educt tank B001 to reactor R001, and then to product tank B001 with the
manual controls.

PA Module P01-06
SIMATIC PCS 7 Control Loop and Other Control Functions
CONTROL LOOP AND OTHER CONTROL FUNCTIONS
TRAINING OBJECTIVE
In this chapter, the students will be introduced to the essential components and requirements of a block for the continuous control of process variables. This will
enable them to create and configure a temperature control using the blocks PIDConL and PULSEGEN.
THEORY IN BRIEF
In the process industry, certain process variables will have to be kept at a certain value despite interferences (disturbance characteristics), and process variables have
to be set in a stable mode to specified setpoints (command behavior). To this end, control loops are used as shown in Figure 1.
Figure 1: Control loop
For the plant in this training manual, the reactor temperature has to be set to a certain value for a specification-oriented response control. Disturbance variables are
the ambient temperature and the materials used with different temperatures. For the temperature to be controlled, it first has to be determined through
measurement. This measured value that corresponds to the actual value of the process variable is then compared with the desired value (setpoint). The difference
between actual value and setpoint is called (system) deviation.
If the system deviation is known, counter measures can be derived. In the case of temperature control, the heater is switched on when the measured actual value is
less than the specified setpoint. For the process to react automatically, a closed loop controller is needed. A closed loop controller that calculates the manipulated
variable based on the current deviation is called proportional controller (P-controller for short).
In practice, controllers that can be used for a wide variety of processes using only a few parameters have prevailed. These are referred to as PID controllers.
The PCS 7 Advanced Process Library V81 includes well-tried blocks that implement this functionality. Below, the block PIDConL is used.
THEORY
INTRODUCTION
The above mentioned P-controller represents the simplest controller. It processes according to the principle: the larger the current deviation, the larger the
manipulated variable. This means its behavior is derived directly from the current system deviation which makes it fast and relatively dynamic. However, certain
disturbances are not completely adjusted, which means there is a permanent system deviation.
Not every process tolerates a permanent system deviation and additional steps have to be taken. One possibility consists of connecting an integral component; this
turns the P-controller into a PI controller. The effect of the integral component consists of adding up a continuous system deviation. This means the manipulated
variable increases even though the system deviation does not change.
If abrupt disturbances occur in a system, they can be counteracted quickly with an additionally differentiating component. The D-component calculates the
manipulated variable from the time deviation of the system deviation. However, this behavior causes the stochastic interferences (noise) to be amplified. Here, an
effective middle course has to be found.
A combination of P, I and D- component is called a PID controller. In the process industry, 95% of applications are implemented with these controllers, because the
PID controller is set with only three parameters (gain, integral time and derivative time). These few parameters allow for a good adaptation to a variety of different
dynamic processes.
However, setting the parameters presupposes knowledge of the system that is to be controlled. Knowledge of the system can be gained by experience, determined
experimentally, or calculated by modeling the system. For a large variety of processes that are not dominated by dead time and that react in a similar manner to
positive as well as negative changes of the manipulated variable intervention, different setting rules suitable for application in practice were found. Examples are the
settings according to Chien, Hrones and Reswick [1], the Ziegler and Nichols method [2] as well as the T-Sum Rule [3].
The process control system PCS 7 supports setting the parameters using a PID Tuner.
For the closed loop control block PIDConL the parameter for gain is called GAIN, for the integral component TI (integral time) and for the differential component TD
(derivative time). The time is specified in time units of seconds. The input variables of the controller are the controlled variable PV and the setpoint SP whose result is
the system deviation ER. The manipulated value MV is the output variable for the controlled system; it is calculated according to the following formula:
INDUSTRIAL COMPATIBILITY OF CLOSED LOOP CONTROLLERS
For a closed loop controller to also work in everyday industrial applications, additional functions have to be implemented. These include above all:
Bumpless transfer
Anti-reset windup
Support of different closed loop control structures
Bumpless transfer is to prevent an abrupt change of the manipulated variable when switching between manual and automatic mode, between internal and external
setpoint entry or when parameters are changed. Bumpless transfer between manual and automatic mode is required, for example, when a process in process
technology is running semi-automatically; this means when the startup is manual and normal operation is switched to automatic. In manual mode, the operator
specifies the manipulated variable directly; in automatic mode, the PID algorithm calculates the manipulated variable.
The function Anti-Reset Windup (ARW) prevents that the integral component (reset) of the manipulated variable continues to increase (windup), because the system
deviation cannot be adjusted based on the manipulated variable restriction.
The support of different closed loop control structures allows for optimizing the control without changing the controller. In the section Expanded Closed Loop
Control Structures some of these closed loop control structures are explained in greater detail. With PIDConL from the PCS 7 Advanced Process Library V8.1, the
following closed loop control structures can be implemented:
Fixed setpoint control
Cascade control
Ratio control
Feed forward control
Split range control
Smith predicator control
Override
EXPANDED CLOSED LOOP CONTROL STRUCTURES
In some applications, single control loops are not sufficient so that expanded closed loop control structures have to be used to reach the desired goal.
If the command behavior and the disturbance characteristic cannot be optimized satisfactorily for a process variable at the same time, a feed forward/auxiliary
variable control or a cascade control can be used.
If the disturbance variable and its point of application are known, a compensation of the disturbance variable can be feed-forwarded to the controller input or
controller output. With the feed forward control the disturbance variable can be compensated for completely, so that the closed loop control can be set to the
optimized command behavior.
Figure 2: Feed forward control at the input (1) or the output (2) of the loop controller
If the disturbance variable cannot be measured but in its place another variable in the system, this auxiliary variable is switched with a controller to the controller
input. Auxiliary variable feed forward reduces the influence of the disturbance variable, but does not compensate for it completely.
Figure 3: Compensation by auxiliary variables
If it is injected at the controller input, compensation and controller are not independent of each other. This means if the controller parameters are adjusted, the
compensation has to be adjusted as well.
If the feed forward control and the auxiliary feed forward control are not sufficient, if the point of application of the disturbance variables cannot be determined with
sufficient accuracy, or if the subsystems cannot be modeled sufficiently, a two or multi-loop cascade control is used.
When designing a cascade control, it is assumed that the lower level control loops (Loop controller 2 in Figure 4 a so-called slave controller) react faster than the
higher level control loops (Loop controller 1 in Figure 4 a so-called master controller). The loop controller is thus always optimized from the inside to the outside.
Cascade controls reduce the influence of the disturbance variable and speed up controlling the reference variable. For the cascade control to be used,
correspondingly measurable variables have to exist.
Ratio controls are used if the process variable is determined in dependence on another variable. For example, the ratio control of two liquid flows that are to be
mixed, which means controlling the composition of the mixture, or the ratio control of combustion gas and fresh air at a gas burner for optimum combustion. The
setpoint of the process variable w2 is calculated from the ratio Vw and the process variable x1.
CONNECTION TO PROCESSES
The continuous output signal of the loop controller is not always read out directly to the process. This is not advisable particularly in the case of great forces or large
flows so that a binary connection is implemented. To this end, the analog signal is converted into a binary signal by means of pulse width modulation. In the CFC
Library, the elementary building block PULSEGEN [4] is provided.
By modulating the pulse width, the function PULSEGEN transforms the input variable INV (= LMN manipulated value of the PID controller) into a pulse train with a
constant period. It corresponds to the cycle time that is used for updating the input variable and has to be parameterized in PER_TM.
The duration of a pulse for each period is proportionate to the input variable. However, the cycle parameterized with PER_TM is not identical with the processing
cycle of the function block PULSEGEN. As shown in Figure 6, the cycle PER_TM consists of several processing cycles of the function block PULSEGEN. The number of
PULSEGEN calls for each PER_TM cycle represents a measure for the accuracy of pulse width modulation.
Figure 6: Time curve of input INV to output QPOS_P with PULSEGEN [4]
An input variable of 30% at 10 PULSEGEN calls for each PER_TM means the following:
1 at output QPOS for the first three calls of PULSEGEN (30% of 10 calls)
0 at output QPOS for seven additional calls of PULSEGEN (70% of 10 calls)
The pulse duration is recalculated at the beginning of each period. Through a sampling ratio of 1:10 (CTRL_PID calls to PULSEGEN calls), the manipulated value
accuracy is limited in this example to 10%. Specified input values INV can be mapped only in a grid of 10% to a pulse length at output QPOS. Correspondingly, the
accuracy increases with the number of PULSEGEN calls for each PIDConL call. If PULSEGEN is called 100 times and PIDConL only once, a resolution of 1% of the
manipulated value range is reached.
Note: You have to program the down-scaling of the call frequency yourself.
LITERATURE
[1] Chien, Kun Li; Hrones, J. A.; Reswick, J. B. (1952): On the Automatic Control of Generalized Passive Systems. In: Transactions of the American Society of Mechanical
Engineers, Vol. 74, Cambridge (Mass.), P. 175-185.
[2] Ziegler, J. G. and Nichols, N. B. (1942): Optimum settings for automatic controllers. In: Trans. ASME, 64, S. 759-768.
[3] Kuhn, U.: Eine praxisnahe Einstellregel fr PID-Regler: Die T-Summen-Regel. Automatisierungstechnische Praxis, Nr. 5, 1995, S. 10-16. (Practice-Oriented Setting
Rule for PID Controllers: the T-Sum Rule. Automation Engineering Practice, No. 5, Page 10 to 16)
[4] SIEMENS (2009): Process Control System PCS7: CFC Elementary Blocks. 5E33257529-AA.
STEP BY STEP INSTRUCTIONS
TASK
Corresponding to the requirements in the chapter Process Description, we will be supplementing the CFCs from the chapter Functional Safety with the temperature
control and the associated manual control of Reactor R001. The heater of the reactor is implemented using a PID controller with a series-connected pulse generator.
The following CFCs are created here:
A1T2H008 (manual operation heater Reactor R001)
A1T2T001 (heater Reactor R001)
When implementing the temperature control, the following interlock conditions are to be noted in the CFC.
An actuator must only be operated if the main switch of the plant is switched on and the emergency stop switch is enabled.
The temperatures in the two reactor must not exceed 60C
The heaters of both reactors must only be started up if they are covered with liquid (here: a minimum of 200ml in the reactor).
TRAINING OBJECTIVE
In this chapter, the student acquires:
Knowledge for programming a continuous loop controller with pulse output and interlocks
These instructions are based on the project PCS7_SCE_0105_Ueb_R1503_en.zip.
PROGRAMMING
1. First, insert a new CFC in the folder Reactor R001. In this CFC, we then implement the manual control for the heater.
2. The newly created chart is renamed A1T2H008.
3. The A1T2H008 connections differ from those of A1T2H011 only regarding the input and output signals (Pcs7DiIn and Pcs7DiOu) and in the last two reset conditions
(block Or08). The conditions refer on the one hand to the minimum level of 200.0ml and on the other hand the maximum temperature of 60.0C.
4. Now, a new CFC is set up with the name A1T2T001. In this chart, implement the actual heater control for Reactor R001.
5. First add the following blocks and name them appropriately.
Table 5: New Blocks in Chart A1T2T001

6. Now, implement the basic interconnections as shown in the table below. Compare your result with the display.
Table 6: Input Interconnections in Chart A1T2T001

7. Now, we parameterize the gains and the integral time of the PID controller by setting PIDConL.Gain = 2 and TI = 10.0.

8. Next, change to Sheet 2 and set up the interlocks shown below:

Table 9: New Block in Chart A1T2T001/Sheet2

9. Now, connect output Out of block Or04 to input MV_ForOn of block PIDConL and check that MV_Force = 0.0. This sets up the value MV_Force at output
MV of the PID controller (manipulated value of controller) as soon as the interlocking conditions are met.

10. Next, we parameterize local operation. To this end, we are utilizing the programming mode. The programming mode is enabled by means of the input AdvCoEn
and activated by means of AdvCoMst. Parameter AdvCoMod is set to 0 so that in the local mode, the input AdvCoMV (invisible in the standard) is interpreted as
manipulated value and not as setpoint. Then switch AdvCoMV visible and set it to 100. This starts the heater in the local mode without control. .

11. By parameterizing OS_Perm (bits 0 to 31), operator authorizations can be restricted. Set Bit 4 and Bit 7 to zero, so that the operator cannot switch on the
programming mode and cannot change the manual requirement for the manipulated value (Man).

12. Finally, we interconnect chart A1T2H008 and chart A1T2T001.

Table 13: Block Interconnections between Chart A1T2H008/Sheet1 and A1T2T001/Sheet1
EXERCISES
The exercises implement what we learned from Theory and the Step By Step Instructions. We will be using and expanding the existing multi-project from the step by
step instructions (PCS7_SCE_0106_R1503_en.zip).
To prepare for the next chapter, we are implementing the last missing function of reactor R001 the stirrer and the manual operation of the stirrer. The interlocking
conditions are as follows:
An actuator must be operated only if the main switch of the plant is switched on and the emergency stop switch is enabled.
The stirrers of the two reactors should be started up only when they come into contact with a liquid (here: 300ml minimum in the reactor).

In addition, further information about the PID controller, how it works and what parameters can be set is available. However, it is not necessary for the control
functionality.
TASKS
1. Implement stirrer A1T2S001 in the chart folder Reactor R001. Use the same process tag type for the stirrer as for the pumps. Connect the feedback and actuating
signal. Assign appropriate names to the blocks. Then add the interlocks as explained above.
2. Implement the manual control A1T2H007 for the stirrer you just created. Here, implement the interlocking conditions as reset conditions.
3. Inform yourself about the inputs ModLiOp, AutModLi, ManModLi of the block PIDConL. To this end, with the function key F1 call Help for block PIDConL.
Select PIDConL operating modes and then the manual or automatic mode.
4. If you want to learn more about the inputs SP_LiOp, SP_ExtLi, SP_IntLi, etc., in Help under tab Search enter the word Setpoint Input. Under the suggested title
Setpoint Input Internal/External information is provided.
5. What is the purpose of the parameters MV_HiLim and MV_LoLim? On your own, search Help for information regarding these inputs.
 The following must not be changed for the process tags that were generated:
PA Module P01-07 Specific adaptations to the block interconnections that are parameterized by means of the import file. These adaptations are overwritten at the next import with
the parameters that are specified in the import file.
SIMATIC PCS 7 Importing Plant Design Data Block name changes.

Regarding process tag types, subsequent changes can be made easily by performing them at the process tag type and the import file. Then, the modified data is
transferred to all process tags with another import. The following changes are conceivable:
IMPORTING PLANT DESIGN DATA Supplementing a parameter and assigning this parameter via the import file
TRAINING OBJECTIVE Clearing all generated process tags of a process tag type (without manual deletion in the plant hierarchy)
The students learn to identify recurrent structures and to design templates. They know the difference between a process tag type and a model. They will be able to Supplementing an additional block interconnection and parameterizing it through the import file
create and implement both. This allows the students to implement many similar process tag types or units in PCS 7. They become familiar with the process object
view and are able to use it to represent parameters system-wide, and change them if needed. MODEL
THEORY IN BRIEF The model is used as a generic solution when structures of the same kind occur in the project.
In process engineering plants, objects and structures recur again and again that behave in the same way, that are equally integrated in control engineering, and that As a rule, a plant is structured by breaking it down into smaller functional units whose interfaces, performance and logic can be clearly described; for example, a tank
are to be visualized in the same way. with its instrumentation. Instead of implementing these functional units again each time, an inventory of pre-assembled functional units (models) can be set up.
For a model to be used project wide in only one version, all models should be stored centrally in the master data library and adapted prior to generating replicas.
Figure 1: From process tag types to replicas A model consists of hierarchy folders with the following elements:
Such an object can be stored in the project library as process tag type. A process tag type is a single CFC. As shown in Figure 1, a large number of process tags can be CFCs/SFCs
generated in one operation as a copy of one process tag type, using the import/export wizard. This process is controlled by an import file. Then, the process tags can OS pictures
be manually adapted and connected correspondingly to specific automation tasks. OS reports
Additional documents
With models we define more complex functions than with process tag types (up to complete units). A model consists of hierarchy folders containing CFC/SFCs,
pictures, reports and supplementary documents. The entire structure can be stored in the project library as a re-useable template. Based on an import file, a large After a model was configured and an import file was assigned to it, replicas can be generated by means of an import. The following steps are performed
number of replicas can be generated as copy from a model in one operation using the import/export wizard (refer to automatically:
Figure 2). Then, the replicas are adapted to the specific requirements of the respective automation task. Step 1: The hierarchy path in the Hierarchy column of the first data row in the import file is read. A check determines whether this path already exists. Further action
The PCS 7 libraries contain extensive templates. If a template is to be used multiple times, it is copied from the PCS 7 library to the project library, adapted if needed depends on the check result.
and copied by means of the import/export wizard based on an import file. If the hierarchy folder exists and it is a replica of the model, the parameter settings are used from the import file for the existing replica.
THEORY If the hierarchy folder exists and is suitable as a replica of the model, it is made into a replica of the model with its CFC and parameterized according to the import
When designing an automation system with PCS 7, we can resort to general design principles for complex systems that have proven themselves again and again [1]. file.
The most important principles are: If there is no hierarchy folder, it is set up. A replica of the model is generated and parameterized accordingly.
The principle of hierarchical arrangement
The principle of modularization Step 2: The following elements are inserted in the title block of the charts if the columns exist:
The principle of reuse Function designation
Location designation
The principle of hierarchical arrangement was used previously when we structured the plant in the chapter Plant Hierarchy. Through structuring into subsystems CFC name
that can be processed largely independent of each other, a design problem that initially seemed unmanageable is broken down into sub-tasks that are manageable Chart comment
and can be planned.
The principle of modularization implies that a system to be designed is set up with constituent parts (here: blocks, CFCs, SFCs) that have the following characteristics: Step 3: Texts and values of the parameter descriptions and the interconnection descriptions (signals) are written to the corresponding block or chart connections of
The scope is manageable and can be followed easily the replicas.
Largely autonomous functions that can be checked
As few relationships to other constituent parts as possible Note: An interconnection is deleted when the signal name (symbol or textual interconnection) consists of the code word --- (three dashes).
Defined interfaces to other constituent parts An interconnection remains unchanged when no connection name (symbol or textual interconnection) is specified.
Step 4: The data types of the connections for signals are determined and assigned to the interconnections.
This results in two rivaling complexity aspects when an automation solution is broken down into its parts: Note: The following applies to interconnections with global addresses: When the option Enter signal also in the symbol table is set, the names are searched for in the
Low inner complexity of the parts: The more parts, the smaller and more manageable the individual parts. symbol table of the model resource.
High exterior complexity of the parts: The more parts, the higher the number of connections between the parts. For PCS 7 it is recommended not to use this option because these entries are made in HW Config when the hardware is configured.
Note the following rules:
Hierarchical structuring and modularization depend on each another. While hierarchical structuring is determined more by the process engineering system, The symbol name is present in the symbol table:
modularization is dominated by process control engineering implementation. Based on the countercurrent complexity aspects mentioned above and the high
dependency on actual process engineering and automation engineering tasks to be solved, early coordination of both is of advantage. The data type has to be the same, the symbol name must exist only once. The data type is parameterized according to the block/chart connection. The absolute
Through the plant hierarchy, PCS 7 supports the principle of hierarchical structuring. The principle of modularization and reuse is realized in PCS 7 in importing plant address is overwritten and the symbol comment is entered for the symbol (if provided in the import file). Only what has changed is overwritten; existing attributes
design data. are retained.
In larger projects or in the case of recurring similar projects, often a large number of identical or at least very similar objects and structures can be observed. To save The symbol name does not exist in the symbol table:
time and outlay for the configuration, it is advisable to plan the specific search for suitable, recurring objects and structures in the concept phase and the design
phase of an automation project. After such objects and structures are identified, first generic solutions are implemented and tested that subsequently can be used for The interconnection is set up and the data type parameterized according to the connection. The absolute address and the symbol comment are entered for the
a variety of identical or similar objects and structures. The additional effort that the preparation of the generic solution (here also called types and templates) entails symbol (if it exists in the import file).
should lead to considerable time and cost savings over the overall duration of the project because of the following factors: Step 5: For each message, the message text is imported.
A type can be implemented multiple times, which means it has several replicas. Then, steps 1 to 5 are repeated for each row of the import file.
By using a type in several replicas, several tests are performed at the same time. When a hierarchy folder was highlighted that contains several models, the import files are displayed each with the model in the list. If needed, the list can be edited.
If errors should occur or changes are necessary, the generic solution only has to be adapted and all replicas updated. Then, the import is performed for all models in the list as described above.
PARAMETERS AND SIGNALS
Moreover, objects and structures that are available from earlier projects and libraries can be reused. Their advantage is that they have been tried and are largely free For process tag types and models to be generated successfully, it is important to define all inputs and outputs of the CFC as parameter or as a signal. Only connections
of errors. By using well-tried parts, the reliability of a new automation solution in general rises. that are defined as parameter or as signal can be included in the column of the import file and parameterized.
PROCESS OBJECT VIEW
PROCESS TAG TYPE With the process object view, all data of the basic automation are represented project wide in a control oriented view. Project wide means that the data of all
The process tag type is used as a generic solution when a project contains many process tags of the same kind [2]. included projects is recorded in a multi-project.
First, a CFC is prepared that contains all internal blocks and their interconnections. All input and output parameters are defined uniquely as parameters or signals. The process object view is structured similar to the plant hierarchy:
This CFC with all generally valid parameters is used to generate a process tag. In a so-called import file, the process tag specific parameters are specified in which the In the left half of the window, the plant hierarchy is represented as a tree structure (hierarchy window). There, identical operating options are provided. In addition,
replicas differ. the CFCs, SFCs, pictures, reports and supplementary documents are displayed in the hierarchy window.
During the import, the import/export wizard generates the process tag type replicas in the specified hierarchy folders. If there is no hierarchy, it is set up as well. Each
replica is an instance of the process tag type and has its properties. In the right half, a table of the lower level objects with their attributes is displayed (content window). The content window has the tabs shown in Table 1 and
In PCS 7, the process tags (replicas) generated in this way can be specifically adapted in addition by adding, for example, different interlocking mechanisms. Under provides different views to the project data.
certain preconditions, these are not overwritten even if they are re-imported. Table 1: Tabs of the process object view

Figure 3: Replica A1T2H003 of FILL_REACTOR_H


Tab Usage
General This tab displays all lower-level ES objects (process tags,
CFCs, SFCs, pictures, reports, or additional documents)
and their general information for the plant unit currently
selected in the tree view.
Blocks This tab displays the block properties of the blocks of all
lower-level CFCs for the plant unit currently selected in
the tree view. In this context, SFC instances are also
referred to as blocks.
Parameters This tab displays the I/O points that were explicitly
selected for editing in the process object view (S7_edit =
'para') for all the process tags and CFCs displayed in the
"General" tab.
Signals This tab displays the I/O points that were explicitly
selected for editing in the process object view (S7_edit =
'signal') for all the process tags and CFCs displayed in the
"General" tab.
Messages This tab displays the corresponding messages for all the
process tags, CFCs and SFCs displayed in the "General"
tab.
Picture objects This tab displays any picture interconnections which may
exist in WinCC (if available) for all the process tags and
CFCs displayed in the "General" tab.
Archive tags This tab displays any existing interconnected WinCC
archive tags with their attributes for all the process tags,
CFCs and SFCs displayed in the "General" tab. Only those
attributes that are relevant for PCS 7 (subset of all
attributes defined in Tag Logging).
Hierarchy folder This tab displays the hierarchy folders of the plant unit
selected in the tree view (one line per hierarchy folder).
Equipment properties This tab displays the equipment properties for the project
selected in the tree view. These equipment properties are
instances created by the equipment property types
configured in the shared declarations (one line per
equipment property. In case of a type change, that
attributes are applied at the instance.
Shared Declarations This tab shows the attributes of the enumerations, units
and equipment properties included the multiproject.
LITERATURE
[1] Lauber, R. und Ghner, P. (1999): Prozessautomatisierung 2. Springer Verlag
[2] Online Help for PCS 7. Siemens
STEP BY STEP INSTRUCTIONS
TASK
PCS 7 is a software that provides users with many tools for programming large plants and duplicating program parts.
In this task, charts and hierarchy structures are created as library objects. They can then be used multiple times. The import/export wizard and the process object
view are used to help with the task.
The chart for valve A1T2X001 is used here as process tag template. All additional valve inlets for the reactors are created using this process tag.
For the model, use educt tank B001 and create from it all additional educt tanks.
TRAINING OBJECTIVE
In this chapter, the student learns the following:
Importing plant design data using the import/export wizard
Familiarization with the process object view
Copying charts by generating process tags
Copying folder structures by creating models
These instructions are based on the project PCS7_SCE_0106_Ueb_R1503_en.zip.
PROGRAMMING
1. To duplicate a chart that is already created and tested, a process tag is generated from it. In this example, we are using valve A1T2X001. Because this chart is
already associated with the process tag type Valve_Lean, we first have to cancel the connection in the object properties.
(A1T2X001 Object Properties)
2. In the Process tag type tab, highlight the row with the valve and then click Cancel. The valve is removed from the list.
(Process tag type A1T2X001 CancelOK)
3. Now we can generate a process tag type from A1T2X001 by clicking on Process tags in the shortcut menu and then on Create/change Process Tag Type.
(A1T2X001 Process Tags Create/Change Process Tag Types)
4. The dialog Create/Modify Process Tag Type opens. (Next)
5. First, the name of the process tag type is generalized to ReactorDeliveryValve and the comment to Valve inlet reactor R00x from educt tank B00x.
6. Next, the parameters and signals that have to be changed between the individual replicas of the process tag type have to be selected on the left side of the
window. (FbkClse_A1T2X001 PV_In -->)
Note: With "Open Chart" the associated CFC is displayed to get a better overview. (Open Chart)
7. Now, add all signals and parameters that represent I/O points of the CFC. Signals are input and output signals, and parameters are interconnections between
charts. The signals and parameters shown here have to be added for the valve inlets of the reactors. Then the process tag can be finished. (Finish)
8. After Finish, the process tag type is located in the plant view in the project library under Project Tag Types. We now have to create an import file for the project
tag type we have just created.
(Project Tag Types Project TagsAssign/Create Import File)
9. The first dialog is confirmed with Next. (Next)
10. First you have to open the chart. (Open Chart)
11. Confirm the message that follows. (Yes)
12. You can see that all cross-chart connections are set up as textual interconnections, and all input and output signals with their symbolic names. The chart can now
be closed again. (Close)
Note: The textual interconnection A1H001\A1H001.PV_Out is structured as follows:
A1H001 Name of CFCs
\ Separator
A1H001 Name of block in the CFC
. Separator
PV_Out I/O of the block that is to be connected
13. Next, create a new file template. (Create File Template)
14. To the import file we assign the name ReactorDeliveryValve00.IEA and select a memory location. (OK)
15. Next we select the general columns that are to be displayed in the import file. (General Assigned CPU Chart comment Block name Block comment)
16. Then we select the columns that are to be displayed for the parameters and the signals in the import file. (Parameters I/O commentTextual interconnection
Signals I/O commentSymbol name OK)
17. The import file created in this way is then opened. (Open File)
18. Now, duplicate the first row by selecting, after a right click on the first row, the option Duplicate row. (Duplicate Row)
19. In the window that now opens, enter the number of rows. In this case there are 5, because a total of 6 valve inlets exist for the reactors that are to be
edited/created using this process tag type. (5 OK)
20. In the duplicated rows, we now enter the specific properties for each valve. Start with the hierarchy, the ChName and ChComment.
21. Next, we have to set the correct parameters and signals for each row. This can be speeded up by using the row by row Find/Replace. In row 2, for example, we
can replace A1T2X001 with A1T2X002.
22. Now, edit the rows of the file as shown below. The input signals (SymbolName column) should be placed in quotation marks ; otherwise, they cannot be
located. The output signals (SymbolName column) should be set as absolute address, or the CFCs corrected afterwards.
23. Finally, change the parameter for the manual control as shown here. The character - in front of the textual interconnection means invert.
24. After all changes have been made, save the file. (File Save Close)
25. Creating and assigning the import file is now finished. (Finish)
26. We can now start importing the created process tag type. (ReactorDeliveryValve Process Tags Import)
27. The first step of the dialog is confirmed with Next. (Next)
28. In the next dialog box, we select the option Make Textual Interconnections and then click on Next. (Make Textual Interconnections Next)
29. We can now start the import by selecting Finish. (Finish)
30. After this process is completed, the log is displayed.
(Exit)
31. The newly imported CFCs are now in the hierarchy level Reactor R001. In this manner, a large number of charts can be set up quickly and effectively. The
interesting aspect of this method is that the changes in the charts are not performed individually but by means of the import file in table form. Nevertheless, each
individual chart can be viewed with the CFC editor afterwards.
32. Now open the newly created CFCs and check the input signals, the output signals and the block names. Textual interconnections for CFCs that already exist should In the exercises we apply what we learned in the Theory section and in the Step by Step Instructions. The existing multi-project from the step by step instructions
be closed. (PCS7_SCE_0107_R1505_en.zip) will be utilized and expanded.
The tasks in this exercise supplement the plant with all objects not implemented so far. It is up to you where you want to utilize the tools for importing plant design
33. Another method for making changes in several charts that are already set up without opening them is the process object view. data. Effective utilization of importing plant design data does not only depend on the plant structure, but also on the mapping of this structure in the plant hierarchy.
(ViewProcess Object View) With some practice, you will improve your knowledge regarding meaningful plant designations and the structure of the plant hierarchy.
TASKS
34. By setting a filter for the I/O MonTiDynamic in Parameter tab, the value of a parameter can be changed for several CFCs, for example. Only the elements are 1. Complete the following CFCs in Reactor R001:
always displayed that are located below the hierarchy level selected in the left side of the window and that correspond to the filter criteria. Here, change the value for A1T2H002 and A1T2H003
all displayed I/Os to 10.0. (A1_multi_purpose plant I/O name MonTiDynam Value 10.0) A1T2H013 and A1T2H015
A1T2X007.
35. By utilizing the Parameters or Signals tabs, extensive changes can be made quickly on the CFCs. In this example, however, everything is to remain unchanged, 2. Check open textual interconnections between the manual controls in the reactor and other CFCs in Reactor R001. To this end, you can also utilize the function
and we are returning to the plant view. (View Plant View). Close textual interconnections under Options in the CFC Editor. In the result, the interconnections that could not yet be closed are displayed. With a double click or
by pressing the button Go to, select an interconnection that is still open and correct it manually.
36. Before you create a model for the educt tank, complete the interlocking of the pump A1T1S001 with the valve A1T2X004 created from the process tag type (if not
already done) as shown below. Note: Not all open textual interconnections can be closed here. Most important are the connections within Reactor R001.
3. Now, create a model of Reactor R001. Delete the folder Reactor R002 and import the model. Reactor R001 is omitted automatically because the folder already
37. Educt Tank B001 with all its CFCs is used as model. First, delete figure(4) and then create a model. (Educt tank B001 Models Create/Modify Model) exists. Should you delete it, it will also be generated from the model.
4. Next, create a model of Product Tank B001. Delete at least the folder Product Tank B002 and import the model.
38. Confirm the message that follows with OK. (OK) 5. Now set up the missing CFCs for the rinse tank:
A1T4L001
39. Confirm the introductory screen of the dialog assistant with Next. (Next) A1T4S001
A1T4X001, A1T4X002, A1T4X003 and A1T4X004.
40. In the next step, specify the parameters (blue) and the signals (green) that the import/export assistant displays. Select those shown in the picture below. 6. Interconnect the manual control Rinse in a way that the rinsing water flows from the rinse tank into the reactor and right away back into the rinse tank.
(IEA parameter IEA signal Next) 7. Check whether textual interconnections are still open.
8. Finally, check all CFCs for correct designations and correct connections. For the first task, it is best to utilize the process object view. Always select one CFC in the
41. Next we specify the messages that are displayed in the import/export assistant. left window while checking the name of the blocks in the Blocks tab in the right window. To look for errors, however, you should use the simulation.
(IEA message Next)
42. Now create the file template. (Create File Template)

43. We are naming the file template EductTank00.IEA. (OK)

44. Next we select the columns that are displayed in general and those that are displayed for the parameters in the import file. (General PH comment Assigned
CPU Chart name Chart comment Block name Block comment Parameters IO commentTextual interconnection)

45. Here we select the columns that are displayed for the signals and the messages in the import file. (Signals IO comment Symbol name Messages Event
OK)

46. Now open the created file. (Open file)

Note: As an alternative, the included import file can be utilized. Instead of Open File, select the button Other file and select the file that is included. With that file,
the steps below can be skipped. Next step: 51.
47. The first row is again duplicated as often as models are needed. (Duplicate Row)

48. For Number of duplicated rows we set 2 and confirm with OK. (2 OK)

49. First, change the general information in the columns Hierarchy and PHComment. Then change the ChName and the ChComment of the CFCs. For the signals and
parameters you have to adapt the SymbolName (in inverted commas for input signals and as absolute address for output signals), the BlockName/BlockComment and
TextRef.

50. The messages come at the end; leave them unchanged, however. Save the file and close the editing. (Save )

51. The Assistant is exited with Finish. (Finish)

52. The newly created model is located in the project library in the folder Models. Here, the model that was created is renamed to EductTankB00x.

53. Before starting the import, the hierarchy folders B001 to B003 including the CFCs they contain have to be deleted. (educt_tank B00x Delete)

54. Confirm the warning with Yes. (Yes)

55. After the deletion, the plant hierarchy looks like this.

56. Now we can start importing the model. (EductTankB00x Models Import)

57. Confirm the start screen of the import/export assistant with Next. (Next)

58. Check Make textual interconnections and click on Next. (Make textual interconnections Next)

59. The assistant is now finished and the import is started. (Finish)

60. The import process is logged and the result is displayed.(Exit)

61. The imported models are now present in the plant hierarchy.

62. Check to see if the textual interconnections with the existing CFCs are closed.
EXERCISES
PA Module P01-08
SIMATIC PCS 7 Sequential Control Systems
SEQUENTIAL CONTROL SYSTEMS
TRAINING OBJECTIVE
The students will be able to successfully implement sequential control systems by using sequential function charts. They will understand the structure and the
operating principle of sequential function charts and will be introduced to the corresponding design methods. Their knowledge regarding operating modes and
protective measures will be expanded for sequential control systems. The students understand the interaction between the programs of basic automation and
sequential control systems. They know how to generate sequential control systems in PCS 7.
THEORY IN BRIEF
Sequential control systems allow for time-discrete or event-discrete execution of sequential or parallel processes. They are used to coordinate different continuous
functions as well as to control complex process sequences. Depending on defined states and events, operating and state changes are generated in the existing logic
control systems and thus the desired sequential behavior is realized. They are implemented with one or several sequential function charts.
A sequential function chart is the alternating concatenation of steps that trigger certain actions, and transitions that initiate the change from one step to another as
soon as the corresponding step enabling condition is met. Each sequential function chart has exactly one start step and one end step and in addition to any number of
intermediate steps that are connected through oriented edges and interposed transitions. The diagrams may also generate feedback through loops within the SFC.
Likewise, they can include parallel or alternate branches. However, in this case it has to be ensured during the design that the sequence does not contain unsafe or
inaccessible parts.
For designing a sequential control system, particularly the formal design methods using state diagrams or Petri nets can be applied. State diagrams are easily learned,
allow for automatic error diagnostics and can be implemented without a problem in many existing program languages for sequential control systems. However,
designing parallel structures is not possible because state diagrams only have exactly one active state.
Petri nets are considerably more complicated. However, all structures that are permitted in sequential control systems can be modeled and extensively analyzed.
Thus necessary properties of the control system can be verified formally. Petri nets can also be implemented in sequential control systems without any problem.
Sequential control systems parameterize and activate lower level logic control systems by setting corresponding global control signals. The effect of these control
signals can be of short duration or permanent, direct or delayed. Just like logic control systems, sequential control systems have to support different operating
modes; particularly manual control of transitions and temporary or permanent interruption of the process sequences has to be possible. In addition, process specific
protective functions are implemented with sequential control systems.
In PCS 7, sequential control systems are implements with sequential function charts (SFC). SFCs offer an efficient operating mode management, high controllability
through several switching modes as well as extensive parameter assignment through different sequence options. In PCS 7, SFCs and CFCs interact and are linked by
means of process values and control values. The interaction behavior can also be controlled in detail.
THEORY
CONTINUOUS AND SEQUENTIAL CONTROL SYSTEMS
Within the scope of basic automation, different logic control systems are developed; each implements a limited, clearly defined function. The functions are
continuously processing input signals and generate corresponding output signals. By means of different control signals, the functions can also be activated and
parameterized. To implement complicated process sequences, for example, manufacturing specifications for products (recipes), it is necessary to coordinate the
different functions and to activate them at the right time with the correct parameters. This task can be implemented by using sequential control systems.
Sequential control systems enable step by step, event-discrete processing of sequential and parallel processes using sequential function charts (also called
sequencers). Depending on defined states or events they generate operating and state changes in the existing logic control systems and thus implement the desired
sequential behavior.
STRUCTURE OF SEQUENTIAL FUNCTION CHARTS
A sequential function chart is the alternating sequence of steps and transitions. The individual steps activate certain actions; transitions control the change from one
step to another.
The first step of a sequential function chart is called the start step. It is the unique entry point into the sequence and is always performed for that reason. The last
step of a step sequence is correspondingly called end step. It is the only step in the sequence that does not have a sequential transition. After the end step is
processed, the step sequence is terminated or processing starts anew. The latter case is also referred to as sequence loop.
Steps and transitions are connected to each other through directed graphs. A step can be connected with several sequential transitions; the reverse is also possible. A
transition is enabled when all series-connected steps are active and the step enabling condition is met. In this case, first the immediately preceding steps are
deactivated and then the direct sequential steps are activated.
The simplest form of a sequential function chart is the unbranched sequence. Each step is followed by exactly one transition which in turn is followed by exactly one
step. Thus, a purely sequential process sequence is realized. Figure 1 shows the corresponding graphic basic elements.
Figure 1: Basic elements of a sequential function charts
Loops within the sequential function chart occur when a cyclical execution within the sequence is possible through concatenating several steps. The sequence loop is
a special case of a loop in which all steps are executed cyclically.
Sequential function charts can also be structured using jumps. When a jump label is reached, processing is continued with the step to which the jump label points.
Jumps within the sequential function chart can also cause loops. Because this structuring can only be followed with difficulty, it should be dispensed with if possible.
From the process view it is necessary in many cases to react differently to different events at program execution time. If this is the case, a step has several alternative
follower steps. This structure is called alternative branch. The step is connected with each possible follower step over a separate transition. To ensure that no more
than one of these transitions is enabled at any time (and the branches are truly alternative), the transitions should be mutually locked out or prioritized. Otherwise,
transitions are evaluated from left to right in most control systems, and the first transition whose step enabling condition is met is enabled.
Figure 2 shows the general structure of an alternative branch with two branches. It is represented by bordering horizontal single lines with protruding ends. As you
can see, alternative branches always start and end with transitions.
Figure 2: Alternative and parallel branches in sequential function charts
Another frequent requirement consists of this: After a step, several follower steps are to be processed simultaneously. In this case, the output step has exactly one
transition that activates several follower steps at the same time. This structure is called parallel branch. The follower steps of the individual branches are then
processed independent of one another and then merged again. All branches end in a joint transition. Only after all branches are processed completely and the step
enabling condition of the subsequent transition is met can the joint follower step be activated.
The sequence of a parallel branch with two branches is also shown in Figure 2. The branches are represented by bordering horizontal double lines with protruding
ends. As you can see, parallel branches begin and end with actions.
A special control problem is the possibility of generating faulty step sequences through the unfavorable use of jumps and branches. Three possible cases have to be
distinguished.
Uncertain sequence: A sequential function chart contains a structure whose accessibility is not certain through the defined sequence behavior.
Partial jamming: A sequential function chart contains an inner loop that is not exited. Although the steps within this loop can be executed, the steps outside the
loop cannot. This makes parts of the sequential function chart inaccessible.
Total jamming: A sequential function chart contains a structure for which there is no permissible step enabling condition. In this case the sequential function chart
remains permanently in one state and all other steps remain inaccessible.
Such structures are not permitted in sequential function charts and have to be ruled out with corresponding formal design methods. Figure 3 shows an example of
two sequential function charts with illegal structures.
In the left sequence it cannot be ensured that step S6 is accessible because the alternative branch after step S3if transition t3 is enabledprevents that the parallel
branch in transition t4 is merged again. For this reason, the sequence is uncertain. The right sequence, on the other hand, is executed exactly once and then remains
in step S4. Because step S2 is not active in this state, the parallel branch in transition t3 can no longer be merged. Total jamming is the result; step S5 is not accessible.
Figure 3: Uncertain and illegal structures in sequential function charts
DESIGNING SEQUENTIAL CONTROL SYSTEMS
A variety of formal design methods exists for sequential control systems. In practice, however, particularly the models of the state diagram and the Petri nets have
proven themselves.
A state diagram is a connected, directed graph. States are shown as circles and state transitions as arrows that connect exactly two states with each other. In a state
diagram, exactly one state is always active at a time. The states can be linked to certain actions. To these actions, a certain execution behavior can be assigned. They
can be executed once when entering the state or when exiting the state, or cyclically as long as the state is active. State transitions can be subject to transition
conditions.
State diagrams can be arranged hierarchically and linked to each other. State diagrams are considered easy to learn, and enable automatic error diagnostics, for
example, through pair, time or state monitoring. They can be easily implemented into many existing programming languages for sequential control systems.
Petri nets are particularly suitable for modeling asynchronous processes. A Petri net consists of locations and transitions that are connected to each other through
directed edges. This also results in a directed graph. A location is represented with a circle and a transition with a rectangle (often reduced to a cross bar). Active
locations are indicated with labels; they are represented with a dot within the circle for the corresponding location.
The state in a Petri network differs from that of a function diagram in that the state is determined by the number of active locations in the entire network. The
dynamics of the system is modeled through the motion of the labels within the network. The meaning of the locations and transitions for the modeled process (i.e.,
the semantics of the Petri net) is not defined and has to be specified depending on the application. Petri nets whose semantics were specified are called interpreted
Petri nets (IPN). For the control design, signal interpreted Petri nets (SIPN) are used.
Petri nets can be analyzed extensively. They also permit the implementation into existing programming languages for sequential control systems without any
problem. There are numerous expansions for Petri nets that are optimized for specific applications, or provide for more exact process modeling. For this reason, Petri
nets can get rather complex which makes them more demanding as a design method. Based on their structural similarity to sequential function charts and the
capability of modeling parallel processes, Petri nets do also offer clear advantage.
The design method that is used depends ultimately on the requirements of the design task as well on the preference of the developer. Additional information is
provided in the pertinent technical literature.
INTERACTION OF SEQUENTIAL CONTROL AND LOGIC CONTROL SYSTEMS
As described above, each step in the sequential function chart can be assigned certain actions. In general, these actions consist of parameter assignment and
activating logic control systems. To this end, corresponding control signals are set.
Process and control signals that are used by sequential function charts have to be declared globally to be available to the programs of the sequential control and the
logic control systems. The signals are usually listed in a symbol table,
The control signals have an effect as long as the corresponding step is active. For implementing more complicated function sequences it is possible, however, to vary
the processing of the control signals themselves (latching or non-latching, time delayed or limited).
Usually, process specific functions are implemented with sequential control systems while logic control systems implement all device specific functions.
PROTECTIVE FUNCTIONS AND OPERATING MODES IN SEQUENTIAL CONTROL SYSTEMS
As in the case of single control functions, adequate protective functions and operating modes have to be implemented for sequential control systems. Even if there is
a fault, sequential control systems have to be operable. To this end, corresponding operating modes have to be provided in the control system.
Automatic mode: The action of the sequential function chart is performed when the series-connected transition is enabled.
Manual mode: The operator activates the action of the sequential function chart even if the series-connected transition is not enabled.
Mixed mode: The action of the sequential function chart is carried out when the series-connected transition is enabled or when the operator has triggered it.
Alternatively, activation by the operator as well as the enable of the series-connected transition may be required.
Using the manual mode prevents permanent blocking of the sequential control system when there is a fault. The mixed mode allows for manual interruption of the
process for testing or commissioning purposes. The step enabling conditions of all transitions of the sequential control system have to be expanded accordingly.
Sequential function charts have to be able to react to faults in the controlled devices. This requires continuous fault monitoring. It detects and indicates faults in the
controlled devices. It enables automated safeguarding of the plant by automatically stopping the sequential function chart when there is a fault. In addition, it has to
be possible for the operator to stop and abort a sequential function chart when there is a fault.
In both cases, corresponding protective functions have to be activated to take the plant to a safe state. If the sequence is stopped, it has to be ensured that the
sequence can be continued safely and in a permitted mode even after a prolonged interruption. In the sequential control systems, process specific protective
functions such as sequential interlocking of several devices is realized if there is a fault in the process.
SEQUENTIAL CONTROL SYSTEMS IN PCS 7
Sequential control systems in PCS 7 are implemented with Sequential Function Charts (SFC). They include the sequencers and define their sequence topology, the
conditions for the transitions, and the actions of the steps. The start conditions and the sequence characteristics can be defined and prioritized separately for each
sequencer. In addition, pre-processing and post-processing steps can be defined that are performed once prior to or after the sequential function chart is performed.
Operating Modes and Switching Modes
The performance of a sequential control system in PCS 7 depends on the selected operating mode, the specified switching mode, its current operating state and the
sequence options. For sequential control systems, two different operating modes can be selected.
Auto: The program controls the sequence.
Manual: The operator controls the sequence with commands or by changing the sequence options.
In the manual mode, the commands Start, Stop, Hold, Terminate, Cancel, Continue, Restart, Reset and Fault are available to the operator for operating the sequential Button Selection On
control system manually. The behavior of a sequential function chart when enabling active steps to follower steps can be controlled through different switching Button Insert Step + Transition
modes, depending on the selected operating mode. Button Insert parallel branch
Button Insert alternative branch
Switching mode T: The sequential control system is executed process controlled, which means automatically. When the transition is enabled, the predecessor steps Button Insert loop
are deactivated and follower steps are activated. (T = transactions) Button Insert jump
Switching mode O: The sequential control system is executed operator controlled, which means manually. The transition is enabled with an operator command. Button Insert text field
Each follower transition of an active step sets an operator prompt automatically. (O = operator)
Switching mode T or O: The sequential control system is executed process controlled or operator controlled. The transition can be enabled either through an 8. For this task, you will need additional steps and transitions. To insert both, select the button and check the location where you want to insert them. ()
operator command or through a step enabling condition that was met. Note: Step and transition numbering is of no significance to the sequence in which the sequential function chart is processed.
Switching mode T and O: The sequential control system is executed process controlled and operator controlled. The transition is enabled only through an operator
command and through a step enabling condition that was met. 9. After the steps and transitions were inserted in this way, click on the symbol to add a parallel branch. Again indicate the location where you want to enter it. ()
Switching mode T/T and O: In this switching mode we can specify for each step individually whether the sequential control system is executed process controlled or
operator controlled; in the test mode, hold points can be defined in the sequential control system. (T/T = test transactions)
In Auto mode, only the switching modes T as well as T/T and O can be selected. The operating mode of the sequential control system shows the current state in the 10. We are now entering additional steps and transitions in the parallel branch. Switch again to the symbol and insert the other steps and transitions. ()
sequence and the resulting operational performance. A corresponding operating state logic defines the possible states of the permissible transitions between the
states as well as the transition conditions for a state change. PCS 7 defines its own operating state logic for sequential control systems and for sequential function 11. Click on the symbol to edit normally. ()
charts. It is possible to let sequential function charts run dependent on the state of the sequential control system.
Execution Options 12. The screenshot shows how the properties of a step can be changed, To this end, right-click on the step and then select Object Properties. (6 Object Properties)
By using execution options, the runtime behavior of a sequential control system can be controlled. For example, we can specify whether a sequential control system
is processed once or cyclically, (cyclical mode option) or whether the actions of the active step are actually executed (command output option). In addition, time 13. In the object properties, each step is assigned a name and a comment for better transparency. (EductB003ToR001 Educt tank B003 to Reactor R001 Close)
monitoring can be activated for the individual steps in a sequential function chart that indicates a stepping error if the time is exceeded (time monitoring option).
Interaction Behavior 14. Confirm the question whether the changes should be saved with "Yes.
In PCS 7, CFCs and SFCs interact by means of process values and control values. These values are linked to each other by means of the desired signals either from the (Yes)
global symbol table or by specifying the absolute signal address. Controlling the processing of the control signals is possible by means of the SFC characteristics. In the
SFC Library, PCS 7 provides pre-assembled sequential function charts for different standard scenarios. These templates can be used and adapted to current projects. 15. As for the steps, the properties for the transitions can also be changed. Right-click on the transition and then select Object Properties. (1 Object Properties)
LITERATURE
[1] Seitz, M. (2008): Speicherprogrammierbare Steuerungen. Hanser Fachbuchverlag (Programmable Controllers) 16. Here you also change the name and the comment first. (Init_OK All initial conditions fulfilled Close)
[2] Wellenreuther, G. und Zastrow, D. (2002): Automatisieren mit SPS: Theorie und Praxis. Vieweg+Teubner (Automating with PLC)
[3] Uhlig, R. (2005): SPS - Modellbasierter Steuerungsentwurf fr die Praxis: Modellierungsmethoden aus der Informatik in der Automatisierungstechnik. Oldenbourg 17. This change is saved, too. (Yes)
Industrieverlag (Model based control design in practice: Modeling methods from information technology in automation engineering)
[4] SIEMENS (2014): Process Control System PCS7: SFC for SIMATIC S7 (V8.1). A5E33209638-AA. 18. Repeat the previous steps until the SFC looks like this. It is important to also enter a minimum execution time of 10s at the step Stirring. (T#10s)

STEP BY STEP INSTRUCTIONS 19. Now we have to implement the actual function of the sequential function chart. No instructions are entered in the step START. Therefore, start by double
TASK clicking on the transition Init_OK. (Init_OK)
Corresponding to the recipe in the chapter Process Description, we are setting up and programming an SFC.
1. First, 350ml will be drained from the educt tank =SCE.A1.T1-B003 to the reactor =SCE.A1.T2-R001, and at the same time 200ml from the educt tank =SCE.A1.T1- 20. Select the Condition tab and add the initialization conditions by clicking on Browse.
B002 to the reactor =SCE.A1.T2-R002. (Condition Browse)
2. When reactor =SCE.A1.T2-R001 is filled, the liquid it contains is heated to 25C with the stirrer switched on. 21. A window opens for adding I/Os and symbols.
3. When reactor =SCE.A1.T2-R002 is filled, 150ml of educt A from educt tank =SCE.A1.T1-B001 is dispensed to the reactor =SCE.A1.T2-R002. When this is completed,
the stirrer of reactor =SCE.A1.T2-R002 is switched on for 10s. 22. Now, select the Symbols tab where you select the symbol for the main power switch A1.A1H001.HS+-.START; then click on Apply. The symbol is entered on
4. When the temperature of the liquid in reactor =SCE.A1.T2-R001 has reached 25C, the mixture from reactor =SCE.A1.T2-R002 is pumped to reactor =SCE.A1.T2- the left side of the first condition. (Symbol A1.A1H001.HS+-.START Apply)
R001.
5. The mixture in reactor =SCE.A1.T2-R001 is now heated to 28C and then drained to product tank =SCE.A1.T3-B001. 23. Next, enter 1 or TRUE on the right side of the first condition for the next steps to be processed only when the plant is switched on. Apply this value. (1
Apply)
TRAINING OBJECTIVE
In this chapter, the student learns the following: 24. Now add the conditions that EMERGENCY STOP is enabled and local operation is deactivated. Then close the dialog. (A1.A1H002.HS+-.OFF 1 A1.A1H003.HS+-
Setting up and editing SFCs .LOC 0 Close)
Establishing connections between SFCs and CFCs
Establishing connections between SFCs and the addresses from the symbol table 25. Next, open the step EductB001ToR001.(EductB001ToR001)
Testing SFC programs
26. Select the Initialization tab and click on Browse. (Initialization Browse)
These instructions are based on project PCS7_SCE_0107_Ueb_R1504_en.zip.
27. Next, in the Plant View tab of the selection window in CFC A1T1X006 select the valve block Valve_A1T1X006. (A1_multipurpose_plant T1_educt_tanks
PROGRAMMING educt_tank B003 A1T1X006 Valve_A1T1X006)
1. To start, set up a new SFC in the folder A1_multipurpose_plant in the Plant View.
28. First, we set the ModLiOp I/O to 1 for the valve to be controlled only by means of interconnections or SFC. Because the ModLiOp I/O is of the data type
(A1_Multipurpose_plant Insert New Object SFC) STRUCT, we have to open the shortcut menu with a right click; then click on Open Structure. (ModLiOp Open Structure)
2. Then open the object properties of the SFC.
29. The structure dialog opens; select Value of the data type BOOL. With Apply, the selection is included on the left side of the first instruction. (Value Apply)
(SFC(1) Object Properties)
30. On the right side of the first instruction, enter "1". This sets the ModLiOp I/O to the SFC mode. With Apply,"1" is automatically replaced with "TRUE". (1
Apply)
3. Next, under General, the name is changed to SFC_product01 and a comment as well as the author is entered.
(General SFC_product01) 31. Now add the I/Os AutModLi = 1 and ManModLi = 0 for the valve to be set to automatic mode. (AutModLi 1 ManModLi 0 Apply)
4. The operating parameters are set as follows; they can later be changed in the online mode. (AS Operating Parameters)
32. The same has to be done for the pump A1T1S003 and the valve A1T2X003 because they also participate in filling reactor R001 from educt tank B003. Then,
5. It is important that the checkmark is set in the OS option so that the SFC will be available later for visualization. With the display of the version, accept all change to the Processing tab. (A1T1S003 ModLiOp.Value = 1 AutModLi.Value = 1 ManModLi.Value = 0 Apply A1T2X003 Apply Processing)
parameters with OK.
(OS Transfer chart to OS for visualization Version OK) 33. In Processing, we now enter the instructions for opening the valves and starting the pump. For the valves, the I/Os OpenAut.Value = 1 and CloseAut.Value
Note: In the text field "Create block icon", you can specify which block icon is displayed for the block in WinCC. This means you can select different versions for the are set to = 0. For the pump, use the I/Os StartAut.Value = 1 and StopAut.Value = 0. (A1T1X006 A1T1S003 A1T2X003 Apply Close)
same block type, if available. A blank field results in the standard display.
6. In the SIMATIC Manager we now open the sequential function chart SFC_product01 with a double click. (SFC_product01) 34. Now the instructions that have to be executed when terminating this step are entered in Termination. Here, the valves and the pump have to be closed again.
The valves and the pump can also be reset into the manual mode and the operator mode, but we want to wait until the step END to do this. It is easiest to copy the
7. With the following symbols from the toolbar, the sequential control can now be set up in the SFC Editor.
instruction of Processing to Termination and only invert the values (TRUE -> FALSE and vice versa). To copy and insert, the numbers preceding the instructions 65. With a double click, open the sequential function chart from the plant hierarchy. (SFC_Product01)
have to be checked and the shortcut menu called.
66. To watch the sequence, switch on the test mode.
35. Next, close the properties dialog for step EductB003inR001. The SFC Editor shows the transition Init_OK, the steps EductB003inR001 und Stirring grayed out (Test Mode on/off)
because instructions already exist there. (Close)
67. The simulation has to be reset and the main switch and Emergency STOP activated. Local operation has to be deactivated.
36. Now, open the transition L001 >= 350ml. Enter the condition that the level of reactor R001 is larger or equal to 350ml. (L001 >= 350 ml ConditionBrowse
Reactor R001\\A1T2L001\Stand_A1T2L001.PV_Out Right click Open structure Value >= 350 Apply Close) 68. We can now start the SFC. (Start)

37. In step Heat25CStirring, again add the I/Os ModLiOp, AutModLi and ManModLiin Initialization for Stirrer_A1T2S001 and Control_A1T2T001. For the 69. We can now monitor the execution of the sequential function chart. Active steps and steps that have been processed are indicated.
control, switch the setpoint entry to SFC mode SP_LiOp = 1 and to external setpoint entry SP_ExtLi = 1 and SP_IntLi = 0. (Heat25CStirring Initialization
) 70. By double clicking on or opening individual steps or transitions, current conditions and values can be displayed.

38. Then switch to Processing and add the displayed I/Os and values. This starts the stirrer and the control is assigned the setpoint 25C. 71. In the state R001ToProdB001 the SFC and the simulation look like this.
EXERCISES
39. Under Termination the stirrer is stopped. Set the setpoint to 0C. Then close the dialog. In the exercises we apply what we learned in the Theory section and in the Step by Step Instructions. The existing multi-project from the step by step instructions
(PCS7_SCE_0108_R1505_en.zip) is used for this and expanded.
40. Now we parameterize transition T001 >= 25C. For this, we need the measured temperature. This exercise implements an additional recipe that is designed to clean the reactors. The task below suggests a possible concept.
(T001 >= 25C Condition \T2_Reaction\Reactor R001\\A1T2T001\In_A1T2T001 PV_Out Value Apply >= 25.0 Apply Close) TASKS
41. Initialization, Processing and Termination remain empty In the step Wait. This is indicated by the tabs not being highlighted. 1. Create the SFC SFC_Rinse in the chart folder A1_multipurpose_plant that rinses reactors R001 and R002 with rinse water. Cleaning consists of the following
steps:
42. Now fill in the parallel branch. Start with step EductB002ToR002 and utilize the figures below. (EductB002ToR002)
Filling the reactors (up to 500ml) with rinse water
43. The transition L002 >= 200ml then looks as follows. (L002 >= 200 ml) Stirring the rinse water (for 20 seconds) in the reactors
Draining the rinse water into the product tank.
44. The following interconnections have to be set up in step EductB001ToR002.
Design the rinse process in a way that both reactors are cleaned at the same time.
45. Transition L002 >= 350ml then looks like this. (L002 >= 350ml) Check whether both reactors are empty (< 50ml) before rinsing starts.

46. The step Stirring has a minimum execution time of 10 seconds. We parameterized this at the beginning. Now, Stirrer_A1T2S002 has to be initialized, started and
stopped again.

47. Now, the parallel branch is parameterized. Transition Parallel_OK remains blank. This means that as soon as the steps Wait and Stirring are processed, step
R002ToR001 becomes active.

48. Now, the sequential control system looks like this.

49. Next, step R002toR001 is interconnected.

50. Transition L002 <= 50ml must be interconnected as follows.

51. In step Heating28C, the control is activated again. Because it is already set to SFC mode and automatic mode, only the setpoint has to be specified. At
termination, it has to be reset to 0C.

52. The condition in transition T001 >= 28C now looks like this.

53. The last step R001ToProdB001 of the recipe fills the content of reactor R001 into the connected product tank B001. The interconnections are shown below.

54. The transition L001 <= 50ml is the last transition of the recipe. It can be enabled when reactor R001 is empty (<= 50ml).

55. In the step END, the automatic mode has to be switched on for all utilized valves, pumps, stirrers and control and manual mode must be switched on again. (
step 56) Regarding the control, the internal setpoint must be set again. (Initialization)

56. Then, all utilized pumps, valves, stirrers and controls are reset again to the operator mode. (ModLiOp = 0)
(Termination - 1)
(Termination- 2)

57. After all steps and transitions for the SFC are completed, you can compile and download your project in the known manner. (SCE_PCS7_Prj PLC Compile and
download objects)

58. Prior to compiling and downloading, open the settings for compiling and downloading the charts. (Charts Edit)

59. Here it is important to select the entire program for Compile Charts as Program as well as for S7 Download for Scope or Download mode. (Compile Charts as
Program Entire program S7 Download Entire program OK)

60. The warning is confirmed with OK. (OK)

61. Now we can start compiling and downloading. (Start)

62. All warnings that follow are read carefully and confirmed. (OK Yes)

63. In the log, no errors should be shown, warnings at the most. Details for warning are provided in the log of the individual object. (X)

64. Now, set PLCSIM to the RUN-P mode. (PLCSIM RUN-P)