15 final steps of configuration v1.00_en

PCS 7 System Course
SIMATIC PCS 7 – Final steps of configuration
Training Documentation, V1.00, ST-PCS7SYS 15 - 1
Content 15
15 Final steps of configuration ...................................................................................3
15.1 Learning target....................................................................................................................... 3
15.2 AS-AS Communication.......................................................................................................... 3
15.2.1 Overview................................................................................................................................ 3
15.2.2 Automatically configuration of AS-AS communication .......................................................... 4
15.2.3 Manually configured connection to a specified AS................................................................ 7
15.2.4 Manually configured connection to an unspecified AS.......................................................... 8
15.2.5 Using manually configured AS-AS connections: Communication blocks in CFC charts....... 9
15.2.6 Task and Checkpoint............................................................................................................. 9
15.3 Configuration in Run............................................................................................................ 10
15.3.1 Existing configuration........................................................................................................... 10
15.3.2 Activate CiR capability......................................................................................................... 10
15.3.3 Reservation.......................................................................................................................... 11
15.3.4 Check CiR Compatibility...................................................................................................... 13
15.3.5 Adding modules ................................................................................................................... 13
15.3.6 Download............................................................................................................................. 14
15.3.7 Save and Compile ............................................................................................................... 14
15.3.8 Workflow overview............................................................................................................... 15
15.3.9 Task and Checkpoint........................................................................................................... 15
15.4 Simulation ............................................................................................................................ 16
15.4.1 Block-external simulation..................................................................................................... 16
15.4.2 Block-internal simulation...................................................................................................... 17
15.5 Forcing block I/Os................................................................................................................ 19
15.5.1 Preparation: Support forcing and Add forcing ..................................................................... 20
15.5.2 Forcing active and Force value............................................................................................ 21
15.5.3 Exit forcing ........................................................................................................................... 22
15.5.4 Task and Checkpoint........................................................................................................... 22
1.
2.
3.

PCS 7 System Course
15 - 2 Training Documentation, V1.00, ST-PCS7SYS

PCS 7 System Course
15 Final steps of configuration
15.1 Learning target
The participant will learn about
• Configuration steps required typically
before commissioning of a plant
• How PCS 7 supports testing and
simulation of blocks and IOs
The participant will be able to
• to configure an AS-AS connection
• to prepare later modifications of the
configuration on Profibus during
operation, without stop of the CPU
• to simulate a process signal via a
faceplate on the OS and via CFC on the ES
15.2 AS-AS Communication
15.2.1 Overview
For communication between AS systems, an AS-AS interconnection is required.
AS99AS01
Connection
AS-AS Communication:
Exchange of information
between blocks
Use cases
• Plant expansion or changed customer requirements may result in an overload of an
AS-CPU. In such cases an additional AS system can be a sufficient solution.
• Already existing automation solutions have to be integrated into a plant. This may
require also an integration of already configured AS systems. Possible plant-wide
automation functions require AS-wide communication.

PCS 7 System Course
PCS 7 offers 2 different configuration procedures for the realization of AS-AS
interconnections:
Automatically configured
AS-AS communication
Manually configured
AS-AS Communication
• Automatical creation of an S7 connection in NetPro for
each AS pair, for which an AS-wide interconnection
has been created
• No need for communication blocks in CFC
• Manual creation of an S7 connection in NetPro
for each AS pair
• Specialized communication blocks have to be
configured in CFC charts
15.2.2 Automatically configuration of AS-AS communication
AS-wide interconnections
Since PCS 7 V7.1, cross-chart interconnections are now also possible if the CFC charts
exist in different AS’s. To accomplish this, simply open the CFC charts and arrange
them in such a way that the source can be connected with the destination. If the source
and destination are located in different AS’s, an AS-AS interconnection is automatically
configured in NetPro.
Prerequisite:
The AS stations have to be part of the same ethernet segment.

PCS 7 System Course
"First" cross-chart interconnection
When establishing the first cross-chart interconnection in which the source and
destination are located in different AS’s, a message is displayed.
Open and compile NetPro
Load connection in ASx and ASy
If the "first" cross-chart interconnection was established between ASx and ASy, then
this interconnection need to be loaded as follows.
1. Open and compile NetPro
2. Load connection in ASx and ASy
To load the interconnection in ASx and ASy, you have several options:
− PLC > Download to Current Project > Selected Stations
− PLC > Download to Current Project > Connections and Gateways
− Download selected connections
Only the function "Download selected connections" should be used to download
the connection, to avoid an AS stop or an initialization of the existing connections and
therefore a disturbance of the plant operation.
Select the corresponding AS (e.g. ASx) in NetPro and then the connection which you
want to load.
Result in NetPro

PCS 7 System Course
Merging Subnets
If the AS-wide interconnection is rejected with the "NETPRO error", the cause of the
error has to be corrected, e.g. by merging the subnets in NetPro:
Edit > Merge/Unmerge Subnets > Ethernet Subnets"
After having merged the subnets, the two CFC charts have to be opened again. In one
of the charts, click the connection to be interconnected and in the other chart on the
interconnection partner. An interconnection line to the side bar should now be
established automatically. In the small field on the side bar, the AS-wide interconnection
is marked by a green triangle.
Connection monitoring with the IK_STATE block
The status of an AS-wide interconnection can be queried in the CFC chart with the help
of the IK_STATE block (FC157). For that, the IK_STATE block is placed on a CFC chart
and the NETPRO_I input of this block is parameterized with the numerical value "local
ID" of the connection.
Local ID of the
connectionLocal ID
of AS08
Local ID
of AS99
 See [302] PCS 7 CFC for SIMATIC S7 - Function Manual - 12_2011, 9.7.2 for more
details

PCS 7 System Course
15.2.3 Manually configured connection to a specified AS
For communication between AS systems, an AS-AS connection is required.
Its manual configuration in the tool NetPro is similar to an OS-AS connection. The
communication partner is located inside of the current multiproject.
Starting
point
Connection
partner, specified
in the multiproject
After clicking the OK button, the properties of the connection are displayed:
A Local ID is assigned
to the connection.
After insertion of a new connection:
• Save and compile NetPro
• Download selected connections
without CPU Stop

PCS 7 System Course
15.2.4 Manually configured connection to an unspecified AS
If a connection is to be made to a station, that is connected to the same network, but not
specified in the project, it can be configured as below.
AS06
08-00-06-9C-EA-F6
In the Partner column of the Address
Details dialog, you fill up the data, that is
set in the Local column on the Engineering
station of your partner that is configuring
the connection in his system.

PCS 7 System Course
15.2.5 Using manually configured AS-AS connections: Communication blocks
in CFC charts
After establishment of the AS-AS connection, special communication blocks have to be
placed in the charts of the involved AS stations.
The communication blocks are located in the PCS 7 Library (Standard library).
Chart in AS08
Chart in AS99
15.2.6 Task and Checkpoint
Task: AS-AS communication
Goal
Exchanging data between two AS stations
Checkpoint
What is your opinion?
• What the advantage/disadvantage of
using AS-AS communication for
duplicating an analog input signal,
compared to using an analog input
channel on both AS systems and routing
the same current signal?

PCS 7 System Course
15.3 Configuration in Run
By default, every change to an AS Station Configuration requires a stop of the CPU.
Settings to the Profibus DP can be changed to allow you to:
• Add slaves to the Profibus
• Add modules to existing modular slaves
Check the requirements for using this CiR functionality.
Example
As an example, here we will add 2 modules to an existing modular slave.
15.3.1 Existing configuration
The current AS configuration consist of:
• a central rack with PS, CPU and CP
• a modular DP slave with 2 I/O modules
See its representation in HW Config in the picture below.
What you see here is not yet using the CiR capability.
15.3.2 Activate CiR capability
The CiR capability is to be activated in HW Config, and after checking some setting it is
to be download to the AS station in STOP mode (for the last time). For activating, point
the mouse pointer to the Profibus DP network and select in the context menu:

PCS 7 System Course
15.3.3 Reservation
After the activation of the CiR capability there will be objects displayed to represent
reservation of address areas supported by the CiR function:
Address size for additional modules
By default, additional I/O modules in modular slaves have 16 bytes for input and output
available:
In this example we will not change this setting.

PCS 7 System Course
Address size for additional DP slaves
By default, additional DP slaves can be added using these settings:
The sum of the address ranges
should not exceed the available
size of the Process Images
These settings are to be downloaded in STOP mode.

PCS 7 System Course
15.3.4 Check CiR Compatibility
From now on, you can make changes to the station configuration, regarding the
decentralized I/O on the Profibus DP network.
Any time after making changes, you should check the compatibility, before you start the
download:
The result must be:
15.3.5 Adding modules
Address
ranges left
Drag them on top
of the CiR module
Check
compatibility

PCS 7 System Course
15.3.6 Download
The download can be
done now during RUN
mode of the CPU.
A general warning will be
prompted that an interrupt
(frozen) of the output signal
may last 1000ms.
A message on the OS will
show you how long it took
actually..
15.3.7 Save and Compile
After a successful download, you can make a Save and Compile.

PCS 7 System Course
15.3.8 Workflow overview
mplete workflow
Close HWConfig
WITHOUT saving ! !
Fault?
Fault?
Yes
Yes
No
No
Save and compile. Download in STOP mode
HW Config change
Check CiR function “CTRL+ALT+F”
Download in RUN mode (CPU online check)
System hardware configuration with CiR objects
 For more details see
[223] Configuration in Run - 03_2006 and
[103] PCS 7 V8.0 Engineering System - 12_2011, 8.9.7
Task: Configuration in Run
Goal
Modification of the configuration on Profibus during operation, without stop of the CPU
Checkpoint
Think about the time schedule
your project…
• What is the best moment during the
commission of an application to
activate the CiR functionality?

PCS 7 System Course
15.4 Simulation
Simulation means the manipulation of a signal regardless of the actual source of the
signal or logic that generates this signal.
Simulation is carried out either at the field device (externally from the control system)
itself or at a block (internally in the control system).
During the simulation, every block is considered in isolation. There are two different
forms of simulation here, namely:
• Block-external simulation and
• Block-internal simulation.
In either case the status of the signal is set to the simulation value (16#60)
 ATTENTION!
The process output is not influenced by the simulation. This means that the motor or
the valve will be operated. The only exception is the block-external simulation of the
output driver.
15.4.1 Block-external simulation
Block-external simulation is characterized by the fact that:
• The simulation function is not executed in the block itself and
• A signal whose status has the simulation state, for example, a simulation of the signal
at another block or directly in the I/O device, is applied at an input parameter.
Simulation is
displayed
Value can‘t be
changed in the OS
In the picture above, the process value has been set to simulation.
The block-external simulation has the following effects on the functionality of the block:
• The technological functions are not influenced
• All the process-relevant output signals do not receive the simulation status. In the
case of technologic blocks, process-related output signals are parameters that
actively affect the process, e.g. "Start" for block MotL.

PCS 7 System Course
• In the case of blocks with operator control or monitoring functions (for example
faceplates), these signals are identified in the faceplate with the status for the
simulation as follows:
• Blocks with one or more input parameters for signals with "Generate status from
individual status" receive a group status in accordance with the priority table. This
group status is displayed in the status bar of the block icon and of the operator block
with the simulation status as follows:
• The interlocking functions of the block are not influenced.
 For the output channel blocks, you need to specify the exact block response with
external simulation using the Feature bit 30 “Outputting a de-energized value for
block-external simulation”.
15.4.2 Block-internal simulation
Block-internal simulation is characterized by the simulation function being run in the
block itself.
With operator control and monitoring blocks, all process values which cannot be
controlled (e.g. PV, AV, In) can be simulated. This is used primarily as an aid for
commissioning and servicing of the system. For example, the control settings of a motor
can be simulated and the feedback values corrected without the monitoring functions
being active.
For blocks that can be operated and monitored, simulation can take place via the
faceplate as well as interconnectable inputs:
• SimLiOp = 0: The simulation is activated/deactivated via faceplate (parameter view)
at the input SimOn.
• SimLiOp = 1: The simulation is activated/deactivated via the input SimOnLi. The
interconnectable simulation values (e.g. SimPVLi, SimAVLi, and SimInLi) will
become effective in the process.
Simulation can also be carried out for blocks (such as channel blocks) that cannot be
controlled and monitored by the operator.
The control is simulated in the CFC by setting parameters directly in the block with the
input parameters SimOn = 1 and Simxxxx is set to the desired simulation value (e.g.
SimPV, SimAV or SimIn).
 With channel blocks, ensure that the Mode parameter is set correctly during
simulation. Otherwise this is displayed on the Bad = 1 output parameter with a higher-
level error.

PCS 7 System Course
Simulation takes place in runtime using operator input in the faceplate's parameter view
by clicking on the "Simulation" button.
Value can be
changed in the OS
Simulation is
displayed
This simulation is characterized by the fact that:
• The simulation can only be enabled / disabled with the operator authorization level for
system authorization.
• The technological functions are not influenced.
• All the process-relevant output signals receive the simulation status, for example,
signals for further processing in other blocks.
• In the case of blocks with operator control or monitoring functions (for example
faceplates), these signals are identified in the faceplate with the status for the
simulation as follows:
• The group status of the block is displayed in the status bar of the block icon and of
the operator block with the simulation status as follows:
• All the process values displayed in the faceplate that cannot be operated-controlled
in normal operation (e.g. PV).
• When the control function of the block can be manipulated, the read-back and
feedback values (for example Rbk, FbkSpd1) are adjusted according to the
manipulation of the control settings
• Associated values (for example UserAna1) cannot be simulated.
• The interlocking functions of the block are disabled and are displayed using the
corresponding icon in the faceplate and in the block icon as follows:

PCS 7 System Course
15.5 Forcing block I/Os
Introduction
During commissioning, you can simulate a variety of values for an interconnection by
permanently overwriting the value of an interconnection with a forced value.
During forcing, the interconnections between the blocks are temporarily removed and
force values are assigned to the corresponding inputs (IN or IN_OUT) of these
interconnections.
For reasons of performance, neither the chart folder nor the block inputs are activated
for the forcing. If a block input on a block is to be forced, first the chart folder and then
the desired block input(s) is/are to be released for the forcing.
You can activate and deactivate forcing at the input of the block instance at any time.
 A maximum of 8192 standard and 8192 F I/Os can be forced.
If you activate forcing at the chart folder, the program will need to be recompiled and
downloaded (compilation of the entire program).
 See [103] PCS 7 V8.0 Engineering System - 12_2011, 8.12.3.15 for more details
General procedure
Forcing is controlled by the following attributes:
Support forcing
Add forcing
Forcing active
Force value
Chart folder in the component view of
the SIMATIC Manager.
Requires complete chart compilation.
Block I/O properties. Requires
compilation and download of changes.
Block I/O properties. Can be done in
Test mode
Block I/O properties. Can be done in
Test mode

PCS 7 System Course
15.5.1 Preparation: Support forcing and Add forcing
1. In the object properties of the chart folder, select the "Advanced" tab and activate
the "Support forcing" check box. This will enable the Force function.
SIMATIC Manager CFC Editor, Block I/O Properties
An activated "Support forcing" requires a complete compilation and a download of
changes to the CPU. Therefore, a CPU stop is not necessary.
 In the case of forcing, a new system chart @FRC_CFC is automatically installed with
a runtime group of the same name in OB1 during compilation. The message block
FRC_CFC is added to this chart, as well as being added to the OB100.
If forcing is disabled, the block, the system chart, and the runtime group are removed
again from the program the next time you compile and download.
2. After having activated "Support forcing", "Add forcing" can be activated in the object
properties dialog box of the interconnected block inputs. Now only compilation and
download of changes are required.
The action in the CFC editor is done offline; therefore always a download of changes is
required, to make the changes active.
After the “Add forcing” action, the input parameter is marked by a green rectangle.

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15.5.2 Forcing active and Force value
Forcing in CFC Editor
When the check box “Forcing active” is activated, the value of the interconnection is
permanently replaced by the force value. The value of interconnection becomes active
again when forcing is disabled. Use the "Force value" textbox to enter a value to be
applied to the block input.
After the “Add forcing" and "Forcing active" action, the input parameter is marked by a
red rectangle.
 A change in CFC Test mode does not require recompiling. The "force values" have a
blue background. The “force value” is valid just after activating the checkbox “Forcing
active”.
Forcing in the Process Object view

PCS 7 System Course
In the process object view, the block inputs which have been added for forcing are
displayed when the corresponding attribute (S7_edit) is set. In the process object view,
the user has the option to select block inputs via a filter. There are three filter settings
available for forcing:
• Add forcing
• Forcing active
• Forcing value
15.5.3 Exit forcing
• If you exit the test mode and further values have been added for forcing in this AS, a
corresponding message is displayed.
The "Forced block I/Os" list in the chart reference data provides an overview of all block
I/Os for which "Forcing active" is still activated.
• If "Support forcing" is deactivated in the chart folder, a message is displayed stating
that a complete compilation has to be performed.
Task: Simulation
Goal
Test the high warnings of LIA134
Checkpoint
There are so many different
simulation features…
• When shall I use what type of
simulation?

15 final steps of configuration v1.00_en

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