PCS 7 - SIMATIC PCS 7 BOX

s

SIMATIC

PCS 7 BOX Manual

Edition 04/2004

A5E00272813-01

Copyright ? Siemens AG 2004 All rights reserved

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

Siemens AG

Bereich Automation and Drives

Geschaeftsgebiet Industrial Automation Systems Postfach 4848, D- 90327 Nuernberg

Disclaimer of Liability

We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed.

?Siemens AG 2004

Technical data subject to change.

Siemens Aktiengesellschaft A5E00272813-01

Safety Guidelines

This manual contains notices intended to ensure personal safety, as well as to protect the products and connected equipment against damage. These notices are highlighted by the symbols shown below and graded according to severity by the following texts:

Danger

indicates that death, severe personal injury or substantial property damage will result if proper

precautions are not taken.

Warning

indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken.

Caution

indicates that minor personal injury can result if proper precautions are not taken.

Caution

indicates that property damage can result if proper precautions are not taken.

Notice

draws your attention to particularly important information on the product, handling the product, or to a particular part of the documentation.

Qualified Personnel

Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and systems in accordance with established safety practices and standards.

Correct Usage

Note the following:

Warning

This device and its components may only be used for the applications described in the catalog or the

technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens.

This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended.

Trademarks

SIMATIC?, SIMATIC HMI? and SIMATIC NET? are registered trademarks of SIEMENS AG. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners.

Preface

Purpose of the SIMATIC PCS 7 BOX Manual

This manual provides information about the components, areas of application,

design possibilities and commissioning of SIMATIC PCS 7 BOX.

The following basic question are addressed:

? What is SIMATIC PCS 7 BOX?

? What components does SIMATIC PCS 7 BOX contain?

? What software is pre-installed on a SIMATIC PCS 7 BOX station?

? What are the areas of application for SIMATIC PCS 7 BOX?

? How is SIMATIC PCS 7 BOX used?

? What configuration variants can be implemented with SIMATIC PCS 7 BOX?

? How is SIMATIC PCS 7 BOX commissioned and configured?

? How are projects configured with SIMATIC PCS 7 BOX?

The electronic form of the "SIMATIC PCS 7 BOX" manual is located on the CD

"Process Control System PCS 7 - Electronic Manuals". You can read and print it

using the Acrobat Reader.

The "SIMATIC PCS 7 BOX" electronic manual can be called up with the Windows

command Start>SIMATIC>Documentation>English>SIMATIC PCS 7BOX.

The online help can be called up with the Windows command

Start > SIMATIC > Documentation > English > PCS 7 - Basic

Documentation > Configuration -SIMATIC PCS 7 BOX or with the

SIMATIC Manager menu command Help > Help Topics > Configuration -

SIMATIC PCS 7 BOX.

Required Knowledge

This manual is intended for personnel involved in the fields of configuration,

commissioning, and service.

The manual requires the reader to have basic knowledge about the

PC/programming device and Windows 2000. You should also be familiar with the

functions and configurations of SIMATIC S7 (S7-400, STEP 7), SIMATIC NET and

SIMATIC PCS 7.

Scope of Validity

This SIMATIC PCS 7 BOX manual applies to the software package,

SIMATIC PCS 7 V6.0 SP3.

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 iii

Preface

Further Support

If you have any technical questions, please get in touch with your Siemens

representative or agent responsible.

You will find your contact person at:

ab7847da7f1922791688e862/automation/partner

You will find a guide to the technical documentation offered for the inpidual

SIMATIC Products and Systems here at:

ab7847da7f1922791688e862/simatic-tech-doku-portal

Training Centers

Siemens offers a number of training courses to familiarize you with the Process

Control System PCS 7 and SIMATIC S7 automation system. Please contact your

regional training center or our central training center in D 90327 Nuremberg,

Germany for details:

Telephone: +49 (911) 895-3200.

Internet: ab7847da7f1922791688e862

Process Control System PCS 7 - PCS 7 BOX iv A5E00272813-01

Preface

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01

v

A&D Technical Support

Worldwide, available 24 hours a day:

Beijing Peking

Nuremberg

Johnson City

Worldwide (Nuernberg) Technical Support

24 hours a day, 365 days a year Phone: +49 (180) 5050-222 Fax:

+49 (180) 5050-223

mailto:adsupport@ab7847da7f1922791688e862 GMT: +1:00

Europe / Africa (Nuernberg) Authorization

Local time: Mon.-Fri. 8:00 to 5:00 PM Phone: +49 (180) 5050-222 Fax:

+49 (180) 5050-223

mailto:adsupport@ab7847da7f1922791688e862 GMT: +1:00

United States (Johnson City) Technical Support and Authorization

Local time: Mon.-Fri. 8:00 to 5:00 PM

Phone: +1 (423) 262 2522 Fax:

+1 (423) 262 2289

mailto:simatic.hotline@ab7847da7f1922791688e862 GMT: -5:00

Asia / Australia (Beijing) Technical Support and Authorization

Local time: Mon.-Fri. 8:00 to 5:00 PM Phone: +86 10 64 75 75 75 Fax:

+86 10 64 74 74 74

mailto:ab7847da7f1922791688e862@ab7847da7f1922791688e862 GMT: +8:00

The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English.

Preface

Service & Support on the Internet

In addition to our documentation, we offer our Know-how online on the internet at:

ab7847da7f1922791688e862/automation/service&support

where you will find the following:

? The newsletter, which constantly provides you with up-to-date information on your products.

? The right documents via our Search function in Service & Support.

? A forum, where users and experts from all over the world exchange their experiences.

? Your local representative for Automation & Drives.

Information on field service, repairs, spare parts and more under "Services".

Process Control System PCS 7 - PCS 7 BOX vi A5E00272813-01

Contents

1What is SIMATIC PCS 7 BOX?.......................................................................................1-1 2Concept and Areas of Application................................................................................2-1

2.1SIMATIC PCS 7 BOX Concept.........................................................................2-1

2.2Areas of Application for SIMATIC PCS 7 BOX.................................................2-1 3Structure of SIMATIC PCS 7 BOX.................................................................................3-1

3.1Hardware Components of SIMATIC PCS 7 BOX.............................................3-1

3.2Software Components of SIMATIC PCS 7 BOX...............................................3-3

3.3Compatibility to SIMATIC PCS 7......................................................................3-5

3.4Configuration Variants for SIMATIC PCS 7 BOX..............................................3-6

3.4.1Configuration Possibilities.................................................................................3-6

3.4.2SIMATIC PCS 7 BOX as Single Station System..............................................3-7

3.4.3SIMATIC PCS 7 BOX with External Engineering Station...............................3-10

3.4.4SIMATIC PCS 7 BOX in a PCS 7 network......................................................3-12

3.5Connection Options for SIMATIC PCS 7 BOX................................................3-15

3.5.1Connecting to PROFIBUS...............................................................................3-15

3.5.2Network Connection to Ethernet.....................................................................3-16

3.5.3PS Extension Board........................................................................................3-16

3.6The Operator Panel of the CPU 416-2 PCI.....................................................3-17

3.6.1The Operator Panel of the CPU 416-2 PCI.....................................................3-17 4Commissioning and Configuration...............................................................................4-1

4.1Overview of Commissioning and Configuration................................................4-1

4.2Configuring SIMATIC PCS 7 BOX for a Single Station System.......................4-2

4.2.1Step 1: Configuring the PC Stations Using the Commissioning Wizard...........4-2

4.2.2Step 2: Configuring the PC Using the Component Configurator......................4-4

4.2.3Step 3: Creating a New PCS 7 Project.............................................................4-5

4.2.4Step 4: Configuring a PCS 7 Project and Renaming the SIMATIC PC Station4-7

4.2.5Step 5: Setting the Hardware Configuration of PC Stations.............................4-8

4.2.6Step 6: Configuring NetPro...............................................................................4-9

4.2.7Step 7: Setting Time Synchronization.............................................................4-11

4.2.8Step 8: Checking If the PG/PC Interface Is Set to "PC Internal"....................4-12

4.2.9Step 9: Opening the Operator Panel of the CPU 416-2 PCI...........................4-13

4.2.10Step 10: Compiling and Downloading the AS and OS Data...........................4-14

4.2.11Step 11: Setting the CPU 416-2 PCI to RUN-P..............................................4-16

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 vii

Contents

5Additional Commissioning and Configuration............................................................5-1

5.1Configuring SIMATIC PCS 7 BOX with External Engineering..........................5-1

5.1.1Overview of Hardware and Software Installation..............................................5-1

5.1.2Overview of Configuration Steps for Commissioning.......................................5-2

5.1.3Step 1: Configuring the PC stations using the Commissioning Wizard............5-3

5.1.4Step 2: Configuring the PC Using the Component Configurator......................5-5

5.1.5Step 5: Adding an External ES to Your PCS 7 Project.....................................5-6

5.1.6Step 6: Setting the Hardware Configuration of PC Stations on the ES............5-7

5.1.7Step 7: Configuring NetPro for an External ES.................................................5-9

5.1.8Step 11: Compiling and Downloading the AS and OS Data

for an External ES...........................................................................................5-11

5.2Configuring SIMATIC PCS 7 BOX in the PCS 7 Network..............................5-13

5.2.1Overview of Commissioning and Configuration..............................................5-13

5.2.2Step 1: Configuring the PC Stations Using the Commissioning Wizard.........5-14

5.2.3Step 2: Configuring the PC Using the Component Configurator....................5-15

5.2.4Step 3: Adding a SIMATIC PCS 7 BOX Station to Your Project.....................5-16

5.2.5Step 4: Configuring NetPro.............................................................................5-18

5.2.6Step 5: Synchronizing the Time on the AS via the Plant Bus.........................5-20

5.2.7Step 6: Synchronizing the Time on the OS via the Plant Bus.........................5-21

5.2.8Step 7: Configuring AS-AS Communication...................................................5-22

5.2.9Step 10: Compiling and Downloading the AS and OS Data

for a PCS7 network.........................................................................................5-23 Index

Process Control System PCS 7 - PCS 7 BOX viii A5E00272813-01

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 1-1 1 What is SIMATIC PCS 7 BOX?

SIMATIC PCS 7 BOX is a complete process control system consisting of an engineering station (ES), operator station (OS) and automation system (AS).

SIMATIC PCS 7 BOX enables connection to distributed I/O via the integrated AS in the form of a "CPU 416-2 PCI" PC card. SIMATIC PCS 7 BOX enables you to economically construct an autonomous process control system with all of the necessary components and standard software SIMATIC PCS 7 V6.0 SP3.

SIMATIC PCS 7 BOX was especially designed for small-scale plants and stand-alone stations (package units) that can be used for agitators, mixers or water treatment stations. SIMATIC PCS 7 BOX is also very attractive as a beginning system for first-time users of SIMATIC PCS 7. You can also use SIMATIC PCS 7 BOX with an external engineering station or integrate it into an existing PCS 7

process control system. In the following illustration, SIMATIC PCS 7 BOX is shown as a single station variant. PDM OS Simatic Net

CP 5611on board CPU 416-2PCI + PS PCMCIA MPI/DP DP

What is SIMATIC PCS 7 BOX?

Note

This documentation contains important information about commissioning and

configuration of SIMATIC PCS 7 BOX.

The configuration of the automation and visualization conforms to the standards of

SIMATIC PCS 7. Please use the following manuals for configuration within the

SIMATIC PCS 7 V6.0 SP3 software:

? PCS 7 Configuration Manual; Engineering System

? PCS 7 Configuration Manual; Operator station

Process Control System PCS 7 - PCS 7 BOX 1-2 A5E00272813-01

2 Concept and Areas of Application

2.1 SIMATIC PCS 7 BOX Concept

In regard to price and design, SIMATIC PCS 7 BOX represents a convenient,

complete process control system that can be put into operation quickly and easily.

SIMATIC PCS 7 BOX offers an economic and comprehensive entry-level hardware

solution for process automation, especially for engineering offices configured with

SIMATIC PCS 7. As a package unit, SIMATIC PCS 7 BOX can be installed directly

at the location of the automation process since it has been designed for

environmental operating conditions.

2.2 Areas of Application for SIMATIC PCS 7 BOX

SIMATIC PCS 7 BOX is suitable for the following areas of application:

? Autonomous small plants

? Subprocess units (package units) with integrated HMI units

? Testing, educational and training systems

? Research facilities

You can take advantage of a modern process control system by fully integrating

the software into SIMATIC PCS 7. Above all, this applies to the following:

? External installation of the SIMATIC PCS 7 BOX engineering station

? Establishing AS-AS communication using SIMATIC PCS 7 BOX in a PCS 7 network

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 2-1

Concept and Areas of Application

Process Control System PCS 7 - PCS 7 BOX 2-2 A5E00272813-01

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 3-1 3

Structure of SIMATIC PCS 7 BOX 3.1 Hardware Components of SIMATIC PCS 7 BOX

SIMATIC PCS 7 BOX is supplied with the following standard hardware.

Technical Specifications of the Box PC 620

Device/Component Model

Processor

Intel Pentium III; 1.26 GHz, 133 MHz FSB, 512KB SLC; PROFIBUS/MPI; TTY Main memory

1GB SDRAM-133 (including graphic memory) Hard disk 80 GB HDD EIDE

Partitions:

C:\ 10 GB PCS 7 partition NTFS;

D:\ 70 GB user partition NTFS

DVD-ROM/CD-R/RW

8/8/24 speed combo drive Graphics

8MB AGP; 1280 x 1024 at 85 Hz Ethernet

100 Mbps Fast Ethernet; RJ45 on board PROFIBUS

CP 5611 compatible on board Automation system (AS) and

PS extension board Installed as PCI card, SIMATIC S7 CPU 416-2 PCI with firmware version 3.4

DC 5 V for power supply for CPU 416-2 PCI

DC 12 V for power supply for PC fan

Serial port

RS232; 9-pin; COM2 Standard ports for

Mouse, keyboard and printer Floppy drive

3,5 " 1.44 MB External power supply unit 24 volt DC industrial power supply 85 W

Structure of SIMATIC PCS 7 BOX

Accessories

? PROFIBUS connector to CPU 416-2 for two DP cables

? Power supply cable for PS extension board and internal PC power unit

? Batteries

? MONITOR

? German or international keyboard

? Recovery CD

? Windows 2000 Professional, Service Pack 4 Multi-language (MUI)

Optional Components

? Ethernet interface CP1512 as PCMCIA plug-in card

? DP cable for connecting to distributed I/O

Process Control System PCS 7 - PCS 7 BOX 3-2 A5E00272813-01

Structure of SIMATIC PCS 7 BOX

Process Control System PCS 7 - PCS 7 BOX A5E00272813-01

3-3

3.2 Software Components of SIMATIC PCS 7 BOX

Preinstalled Software Components of SIMATIC PCS 7 BOX

? Windows 2000 Professional with Service Pack 4 Multi-language ?

Software components of SIMATIC PCS 7 - PCS 7 Toolset CD - PCS 7 Single Station consisting of all PCS 7 software components - SIMATIC Process Device Manager (PDM)

?

Software "WinAC 3.4 for SIMATIC S7 CPU 416-2 PCI"

Authorizations Required for SIMATIC PCS 7 BOX

Authorizations are based on the configuration used and number of process objects (PO). You activate the preinstalled SIMATIC PCS 7 V6.0 SP3 software with the corresponding authorization diskette. ? Configuration variants: SIMATIC PCS 7 BOX as AS/ES/OS station, single station system

Software components

Small-scale authorization

Number of PO/Tags Large-scale authorization

Number of PO/Tags ES (Engineering Station) 250 2000 OS (Operator Station, WinCC)

250

2000

? Configuration variants: SIMATIC PCS 7 BOX as AS/OS station with external ES and in a PCS 7 network

Software components

Small-scale authorization

Number of PO/Tags Large-scale authorization

Number of PO/Tags OS (Operator Station, WinCC)

250

2000

?

Process Device Manager

The pre-installed PDM software on the SIMATIC PCS 7 BOX station is activated by an authorization that must be purchased separately.

Structure of SIMATIC PCS 7 BOX

Process Control System PCS 7 - PCS 7 BOX

3-4 A5E00272813-01 Note about Authorizations

An authorization of SIMATIC PCS 7 provides the right to use products. This right takes the form of a:

?

CoL (Certificate of License) – a legal proof of the ownership of a copyrighted SIMATIC PCS 7 software product ? Authorization code (license key) – technical form of the authorization installed

on the PC

Accessories

?

Restore CD Windows 2000 SP4 Multi-language (MUI) ?

Internet Explorer 6.0 + SP1 ?

MS SQL Server 2000 + SP3 ?

SIMATIC PCS 7 product CDs and the corresponding authorization diskette for activating SIMATIC PCS 7 software

Structure of SIMATIC PCS 7 BOX

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 3-5 3.3 Compatibility to SIMATIC PCS 7

Functional Compatibility to SIMATIC PCS 7

? CPU 416-2 PCI can communicate with another AS 41x via communication blocks (interconnected in CFC) and physically via the Industrial Ethernet

interface integrated in Box PC 620.

? CPU 416-2 PCI can communicate with an OS server via the on-board

Industrial Ethernet interface in Box PC 620.

? The "Compile and Download Objects" function in SIMATIC Manager can be used for the configured CPU 416-2 PCI.

?

The time synchronization of the CPU 416-2 PCI can be configured similar to

the S7-41x CPUs in HW Config.

The time synchronization between the OS and CPU within the Box PCs can be

established in the WinAC time synchronization dialog via a central clock (clock

master) on the plant bus (Industrial Ethernet) or via the local PC clock of the

Box PCs. Special Features as Compared to SIMATIC PCS 7

?

CPU 416-2 PCI is listed in the catalog V6.0 SP3 in HW Config under SIMATIC PC Station\CPU 416- 2 PCI. ? Remote Engineering via Industrial Ethernet – The SIMATIC PCS 7 BOX CPU can be loaded and diagnosed from a PCS 7 engineering station connected to

the on-board Ethernet interface in the Box PC.

Restrictions Compared to SIMATIC PCS 7

? The "Download Changes to the OS Online" function cannot be performed with

the "SIMATIC PCS 7 BOX as single station system" configuration variant. The

function can be used with the configuration variants "SIMATIC PCS 7 BOX with

external engineering" and "SIMATIC PCS 7 BOX in PCS 7 network".

? The "Configure in Run" (CiR) feature is not possible.

?

It is not possible to load the PC station in run mode.

Structure of SIMATIC PCS 7 BOX

Process Control System PCS 7 - PCS 7 BOX

3-6 A5E00272813-01 3.4 Configuration Variants for SIMATIC PCS 7 BOX

3.4.1 Configuration Possibilities

The following three configuration variants are recommended for the Box PC 620: ?

SIMATIC PCS 7 BOX as single station system (single station variant) with AS/ES/OS ?

SIMATIC PCS 7 BOX as AS/OS with an external ES ?

SIMATIC PCS 7 BOX as AS/OS in a PCS 7 network

Note

In all three configuration variants, the OS with WinCC should be regarded as a single station OS and not a client/server system.

Additional Information

?

SIMATIC PCS 7 BOX as Single Station System ?

SIMATIC PCS 7 BOX with External Engineering Station ?

SIMATIC PCS 7 BOX in a PCS 7 network

Structure of SIMATIC PCS 7 BOX

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 3-7 3.4.2 SIMATIC PCS 7 BOX as Single Station System

The Box PC 620 serves as a combination PCS 7 engineering station and runtime

operator station. The automation function operates on the CPU 416-2 PCI

integrated in the Box PC 620 as a PCI card. The process I/Os are connected via

the integrated PROFIBUS DP interface of the CPU 416-2 PCI. Intelligent field

devices are configured via the on-board CP 5611 standard interface of the

Box PC 620. PDM OS Simatic Net

CP 5611on board CPU 416-2PCI + PS PCMCIA MPI/DP DP

You can activate the complete preinstalled PCS 7 software (Engineering and

Runtime) and the PDM (Process Device Manager) with the corresponding

authorization for this configuration.

Note

The authorization for the PDM must be ordered separately.

Structure of SIMATIC PCS 7 BOX

Process Control System PCS 7 - PCS 7 BOX

3-8 A5E00272813-01 Mode of Operation

The station (Box PC 620 with integrated AS in the form of a CPU 416-2 PCI) is not networked from the viewpoint of the PCS 7 project. You create and edit your PCS 7 project on this station and download the PCS 7 project from the ES to the OS and CPU 416-2 PCI. The program created with SIMATIC PCS 7 operates in runtime on the OS/WinCC and CPU 416-2 PCI.

You can use the Process Device Manager to access the PROFIBUS line and its stations/devices via the special on-board CP5611 interface. In the SIMATIC

Manager, you can access the integrated CPU 416-2 PCI via the PCI interface just like in standard SIMATIC PCS 7.

Note

For more information, read the note in the Chapter "Special Features about the CPU 416-2 PCI Interfaces".

Changes can be made in runtime as usual with PCS 7.

There are no restrictions for the PCS 7 programs that can be created.

Restrictions

The following functions are not possible with the SIMATIC PCS 7 BOX as a single station system:

? The time synchronization between the OS/WinCC and CPU 416-2 PCI can

only be implemented in this configuration variant using the WinAC time

synchronization from the PC clock since no external clock can be connected. ? The PROFIBUS DP/MPI interface of the CPU 416-2 PCI is fully functional but the capacity of the PROFIBUS DP/MPI interface is limited. It is recommended to only connected I/O stations that do not require PDM operation to this

interface.

? Plant changes during ongoing operation using CiR (Configuration in Run) cannot be performed.

?

Configuration changes to the OS cannot be downloaded online.

Structure of SIMATIC PCS 7 BOX

Special Features of the CPU 416-2 PCI DP Interface

The PROFIBUS DP interface of the CPU 416-2 PCI is fully functional and the

capacity of the PROFIBUS DP interface is unrestricted. It is recommended to

connected devices that can be controlled by the PDM only to this interface. You

can connect all I/O station types certified for use in SIMATIC PCS 7.

To be able to access and configure distributed I/O devices via the PDM, a

communication connection must be established between the on-board CP 5611

interface and the PROFIBUS DP line.

Note

The access points in the "S7ONLINE (STEP 7)" in the "Set PG/PC Interface"

dialog must be set for the ES/STEP 7 or PDM. For ES/Step7, the access point

must be set to "PC-internal (local)" – this addresses the PCI interface of the CPU

416-2 PCI. For PDM, the access point must be set to "CP5611 (MPI)".

If the ES/Step7 tries to access the CPU when the access point is set to CP5611, it

attempts to establish the communication via the DP line – and this is not allowed.

The access points can only be changed when no communication is taking place

over the respective interface.

Additional Information

Connection to PROFIBUS

Process Control System PCS 7 - PCS 7 BOX

A5E00272813-01 3-9

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