SYSTEM ARCHITECTURE – FERRO ALLOYS PLANT AUTOMATION

42” LCD 22” LCD 22” LCD 22” LCD 22” LCD 22” LCD 22” LCD 22” LCD

ES/OS
OSC01 OSC02 OSC03 OSC04 OSC05 OSC06 MIS ES/OSS

LEGENDS
TB Switch
PROFIBUS
OPTICAL FIBRE 22” LCD
PROCESS BUS
TERMINAL BUS

OS-Server
(redundant)

AS 41x H PB Switch01 PB Switch02

RIO -CD
RIO - AB

EXT RIO
RIO -E

Redundant PROFIBUS DP CP FOR 3RD

PARTY INTERFACE
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SYSTEM ARCHITECTURE as per the Site Requirement
42” LCD 22” LCD 22” LCD 22” LCD 22” LCD 22” LCD 22” LCD 22” LCD
ES/OS
OSC01 OSC02 OSC03 OSC04 OSC05 OSC06 MIS ES/OSS

LEGENDS TB Switch01 TB Switch02

PROFIBUS
OPTICAL FIBRE 22” LCD
PROCESS BUS
TERMINAL BUS

OS-Server
(redundant)

AS 41x H PB Switch01 PB Switch02

RIO -CD
RIO - AB

EXT RIO
RIO -E

CP FOR 3RD
Redundant PROFIBUS DP PARTY INTERFACE 2
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SYSTEM ARCHITECTURE 02

22” LCD 22” LCD 22” LCD 22” LCD 42” LCD
ES/OS
ES/OSS OSS01 OSS02 OSS03 OSS04

TB Switch

PB Switch01 PB Switch02
LEGENDS
PROFIBUS
AS 41x HF OPTICAL FIBRE
PROCESS BUS
TERMINAL BUS

Redundant PROFIBUS DP
RIO -CD
RIO - AB

RIO -E
CP FOR 3RD
PARTY INTERFACE
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SYSTEM ARCHITECTURE 03

22” LCD 22” LCD 22” LCD 22” LCD 42” LCD

ES/OS
ES/OSS OSS01 OSS02 OSS03 OSS04

TB Switch

PB Switch01 PB Switch02

LEGENDS
PROFIBUS
AS 41x HF OPTICAL FIBRE
PROCESS BUS
TERMINAL BUS

Redundant PROFIBUS DP
RIO -CD
RIO - AB

RIO -E
CP FOR 3RD
PARTY INTERFACE 4
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SYSTEM ARCHITECTURE 04
22” LCD 22” LCD 22” LCD 22” LCD 42” LCD

ES/OS
ES/OSS OSS01 OSS02 OSS03 OSS04

TB Switch

PB Switch01

LEGENDS
PROFIBUS
AS 41x HF OPTICAL FIBRE
PROCESS BUS
TERMINAL BUS

Redundant PROFIBUS DP
RIO -CD
RIO - AB

RIO -E
CP FOR 3RD
PARTY INTERFACE
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SYSTEM ARCHITECTURE 05
22” LCD 22” LCD 22” LCD 22” LCD 42” LCD

ES/OS
ES/OSS OSS01 OSS02 OSS03 OSS04

TB Switch

PB Switch01

LEGENDS
PROFIBUS
AS 41x HF OPTICAL FIBRE
PROCESS BUS
TERMINAL BUS

Redundant PROFIBUS DP
RIO -CD
RIO - AB

RIO -E
OLM 15 km CP FOR 3RD
Fiber optic PARTY INTERFACE
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SIMATIC PCS 7 Automation System
High-available CPUs
– Using high-available CPUs to  Robust components from SIMATIC, the worldwide market leader

avoid high restart costs following a fault
Fanless operation up to 60°C

prevent expensive downtimes
Hot swap modules during runtime operation

facilitate operation without monitoring or  Comprehensive configuration
maintenance personnel
Convenient, graphical high-level languages (CFC, SFC)

Standard programming languages (e.g. SCL, Ladder Logic)
– 4 different CPU types  Scalable performance and function

With 2 integrated PROFIBUS DP-Master interfaces
Standard: AS414, AS416, AS417

With 1 integrated 2-port PROFINET IO interface
Failsafe (F) and fault-tolerant (H): AS412H/F, AS414H/F, AS416H/F,

With 2 slots for Sync-Module 417H/F

Can be used with F-runtime license and F-compatible CPU in  Changes can be made during runtime operation
failsafe
User program
S7-400F/FH systems
I/O configuration
 CPU 412-5H
 CPU 414-5H
 CPU 416-5H
 CPU 417-5H

In single mode the high-

high-available CPUs can be used
instead of the standard CPU. 7
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SIMATIC PCS 7 Automation System
High-available controller

 Entry level with CPU 412H

1 MB RAM
 Mid level with CPU 414H

4 MB RAM
 Mid level with CPU 416H

16 MB RAM
 High-end with CPU 417H

32 MB RAM

 Fiber optic connection for

synchronization
 Expandable

Shared rack

Separated rack for distances
up to 10 km (to maximize availability
and minimize common-cause failure)

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SIMATIC PCS 7 Automation System
High-available controller: central controller configurations

compact with rack UR2-H

(splitted backplane bus)

distributed with
two standard racks

10 km

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SIMATIC PCS 7 Automation System
Configuration changes during runtime operation

 Configuration changes during runtime operation (CiR)

For all standard automation systems S7-400 AS 41x
AS 414-3, 416-2, 416-3, 417-4
AS 414-3IE, AS416-3IE
ET200M HF

For failsafe systems and high availability S7-400H/F
AS 412H/F, 414H/F, 416H/F, 417H/F

PROFIBUS DP
ET200S
 Online changes for distributed process I/O

ET 200M and ET200iSP
• Adding new stations (Racks or I/O) SIMOCODE ET200iSP
• Adding new I/O modules to a rack
• Configuring I/O channel parameters
PROFIBUS PA

PROFIBUS DP/PA
• Adding new field devices
• Configuration of intelligent PA devices

ET 200S
• Adding new stations
No CiR for PROFINET IO at time.

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SIMATIC PCS 7 Automation System
High-available controllers: connecting switched periphery

AS 41x HF redundant IM 153-

153-2

ET200M(Standard Modules)
Redundant PROFIBUS DP

L+ ET 200M
ET200iSP L+ with active backplane bus

special bus module (BM)

Y-Link
SIMOCODE IM
active
backplane bus
IM
PROFIBUS PA

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SIMATIC PCS 7 Automation System
High-available controller: automatic event synchronization

Possible synchronization procedures:

Cycle Time Event Command
synchronization synchronization synchronization synchronization

CPU B
CPU A
CPU A

CPU A
CPU B

CPU B
CPU A

CPU B

• Guarantees bumpless switchover SIMATIC S7-400H

– Fast switchover time (typically 30ms)
– No loss of information
– No loss of alarms
– Resumes processing of program where it left off
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SIMATIC PCS 7 Automation System
High-available controller: automatic event synchronization

(Siemens patent)
 Definition: Event
Synchronization whenever the two redundant CPUs could end up synchronization
with different results during execution of the program.

 Automatic operating system function

CPU A
 Synchronized events:

CPU B

Updating of the process image

Direct access to the I/O

Interrupts, alarms

Updating of the timer

Changes to data through
communication functions
SIMATIC S7-400H

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SIMATIC PCS 7 Engineering System
Component view

hardware configuration of an
AS station with I/O

configuration of a module
without hardware
jumpers

one view of all hardware

components
(AS, OS, ES, etc.)
and applications
(OS, Batch, etc.)

 All components and applications of a plant in a single location

 Hierarchical navigation to configuration of the hardware
 Selection of components from hardware catalog and placement using drag and drop

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SIMATIC PCS 7 Engineering System
Plant view: hierarchical representation of the plant

Plants

Process
area
Piece of
equipment Control device integrated in process object
(process object) view
 Good overview provides easy to understand representation of functional plant architecture in
the engineering system
 Powerful navigation helps to search quickly and “dive in”
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SIMATIC PCS 7 Engineering System
Process object view: user friendly

block parameters can be changed without

opening CFC

project library for storing process tag types and example

solutions
import and export of process tags and variations of the example
solutions

collaboration with MS EXCEL using copy

& paste

 Added Efficiency from ability to leverage project data from

MS EXCEL (taglist, alarmlist etc.)
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SIMATIC PCS 7 Operator System
Overview

User
Management
Alarm System Web Access
Process
Visualization
Excel Programming
Archive System Interfaces

Standard
Report System Interfaces
Data Management

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SIMATIC PCS 7 Operator System
Graphical User Interface (GUI)

Alarm line Overview

section
Navigation
window

Picture
Faceplate area

Button area

 Standard user interface (overview and picture area, buttons, trends, alarms, faceplates)
is provided by the system - no engineering required !
 Multi-window design with fixed areas - prevents overlap of the overview and button areas
 Easy to operate due to hierarchical structure and simple navigation

Well--designed GUI for reliable operation of the process – even in critical situations
Well
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SIMATIC PCS 7 Operator System
GUI: Multi-Screen

• Multi-Screen Technology
 One control device (mouse/keyboard) for multiple
monitors (1...4)
 Provides ease-of-use functions
(e.g. store screen composition/layout)
 No additional configuration required

• Configuration of monitor layout

 Project Editor
 Max. 4 Monitor (each max. 1600 x 1200)

 Comprehensive overview of the process (information at your fingertips)

 Simple operation using multiscreen technology

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SIMATIC PCS 7 Engineering System
All OS functions automatically generated
• Complete plant overview
for the operator
– Overview (n levels),
graphic level, key level
• Display hierarchy
– Hierarchical display organization
• Messaging and archiving system
 Alarm summaries, symbols,
faceplates
 User-friendly operator navigation
 Jump from group display directly to
relevant graphic
 Loop-in alarm (jump from alarm directly to graphic)
 Acknowledgements from alarms directly
in the graphic
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SIMATIC PCS 7 Engineering System
All OS functions automatically generated

Automatic generation of symbols, faceplates, alarm and

process value archives

1 4

2 Anlage 1
3

Teilanlage 2

Technische
Einrichtung 3

Technische
Funktion 4

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SIMATIC PCS 7 Engineering System
Libraries

 Blocks in the PCS 7 library for ES

Basic blocks and AS

Diagnostic / communication blocks

Technological blocks

 Block symbols +
 Faceplates

Pre-engineered templates for process

automation
for OS
 Integrated system response

Diagnostics

Alarms

Faceplates

Online help

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Special functions
Local operation permission for OS clients

OS Client 1 OS Client 2

ES
operation not operation
allowed allowed
set up OS clients
PCS 7 administration in
OS Server multiproject
(redundant)

AS 41x

administration via new

block: OpStations
ET 200M
Motor, Dose,

PROFIBUS

Assign up to 16 operator stations Valve, PID, etc.

Release in OS runtime possible ET 200M

Set for groups of motors/valves

Typical use case: pump or compressor stations

e.g. pipeline, package units

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SIMATIC PCS 7 Automation System
Memory, performance, quantity framework (standard CPUs – 1)

CPU 412-
412-1 CPU 412-
412-2 CPU 414-
414-2 CPU 414
414--3 CPU 414
414--3
PN/DP
Working memory 2x 144 kB 2x 256 kB 2x 512 kB 2x 1,4 MB 2x 2 MB

Based on HW 2x 144 kB 2x 256 kB 2x 512 kB 2x 1,4 MB 2x 2 MB

Load memory 512 kB

CPU/processing times min. 0,075 µs min. 0,045 µs

FB / FC 750/750 1.500/1.500 3.000/3.000

DB 1.500 3.000 6.000

Flags/clock memories 4 kByte 8 kByte

Timers/counters 2.048 2.048

Address areas I/O (Byte) 4 k / 4k 8k/8k

Digital channels I/O 32.768 / 32.768 65.536 / 65.536

Analog channels I/O 2048 / 2048 4.096 / 4.096

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; incl. CP 443-5 Extended and IM 467

Communication interfaces X1: MPI X1: MPI X1: MPI X1: MPI X1: MPI
X2: DP X2: DP X2: DP X3: DP (pluggable)
X3: DP (pluggable) X5: PN (2Ports)

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SIMATIC PCS 7 Automation System
Memory, performance, quantity framework (standard CPUs – 2)

CPU 416-
416-2 CPU 416-
416-3 CPU 416
416--3 CPU 417-
417-4
PN/DP
Working memory 2x 2,8 MB 2x 5,6 MB 2x 8 MB 1x 15 MB

Load memory 1 MB

CPU/processing times 0,03 µs 0,018 µs

FB / FC 5.000/5.000 8.000/8.000

DB 10.000 16.000

Flags/clock memories 16 kByte 16 kByte

Timers/counters 2.048 2.048

Address areas I/O (Byte) 16 k / 16 k 16 k / 16 k

Digital channels I/O 131.072 131.072

Analog channels I/O 8.192 8.192

Number of FMs limited by the number of slots and by the number of connections

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; incl. CP 443-5 Extended and IM 467

Communication interfaces X1: MPI X1: MPI X1: MPI X1: MPI
X2: DP X2: DP X3: DP (pluggable) X5: X2: DP
X3: DP (pluggable) PN (2 Ports) X3: DP (pluggable) X4:
DP (pluggable)

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SIMATIC PCS 7 Automation System
Memory, performance, quantity framework (H CPUs V4.5)

CPU 412-
412-3H CPU 414-
414-4H CPU 417-
417-4H

Working memory 512/256 kB 2x 1,4 MB 2x 15 MB

CPU/processing times min. 0,075 µs min. 0,045 µs 0,018 µs

FB / FC 2048 2048 6144

DB 4095 4095 8191

Flags/clock memories 8 kByte 8 kByte 16 kByte

Timers/counters 2.048 2.048 2.048

Address areas I/O (Byte) 8k/8k 8k/8k 16 k / 16 k

Digital channels I/O 65.536 / 65.536 65.536 / 65.536 131.072 / 131.072

Analog channels I/O 4.096 / 4.096 4.096 / 4.096 8.192 / 8.192

Number of FMs limited by the number of slots and by the number of connections

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; incl. CP 443-5 Extended and IM 467

Communication X1: MPI X1: MPI X1: MPI

interfaces X2: DP X2: DP

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SIMATIC PCS 7 Automation System
Memory, performance, quantity framework (H CPUs V6)

CPU 412-
412-5H CPU 414-
414-5H CPU 416-
416-5H CPU 417-
417-5H

Working memory 2x 512 kB 2x 2 MB 5 MB code / 10MB data 2x 16 MB

Based on HW V6

CPU/processing times min. 0,03125 µs min. 0,01875 µs 0,0125 µs 0,0075 µs

FB / FC 3000 8000

DB 6000 16000

Flags/clock memories 8 kByte 16 kByte

Timers/counters 2.048 2.048

Address areas I/O (Byte) 8k/8k 16 k / 16 k

Digital channels I/O 65.536 / 65.536 131.072 / 131.072

Analog channels I/O 4.096 / 4.096 8.192 / 8.192

Number of CP (PtP) limited by the number of slots and by the number of connections

Number of CP (LAN) 14; incl. CP 443-5 Extended and IM 467

Communication interfaces X1: MPI X1: MPI X1: MPI X1: MPI
X2: DP X2: DP X2: DP X2: DP
X5: PN (2 Ports) X5: PN (2 Ports) X5: PN (2 Ports) X5: PN (2 Ports)

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