Siemens SIMATIC PCS 7 BOX User manual

s
Preface, Contents
What is SIMATIC PCS 7 BOX?
1
Concept and Areas
of Application 2
Structure of
SIMATIC PCS 7 BOX 3
Commissioning
and Configuration 4
Additional Commissioning
and Configuration 5
Index
SIMATIC
Process Control System PCS 7
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 f
or 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.

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

Preface
Process Control System PCS 7 - PCS 7 BOX
iv A5E00272813-01
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:
http://www.siemens.com/automation/partner
You will find a guide to the technical documentation offered for the individual
SIMATIC Products and Systems here at:
http://www.siemens.com/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: [phone].
Internet: http://www.sitrain.com

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: [phone]
Fax: [phone]
mailto:ads[email protected]
GMT: +1:00
Europe / Africa (Nuernberg)
Authorization
Local time: Mon.-Fri. 8:00 to 5:00 PM
Phone: [phone]
Fax: [phone]
mailto:ads[email protected]
GMT: +1:00
United States (Johnson City)
Technical Support and
Authorization
Local time: Mon.-Fri. 8:00 to 5:00 PM
Phone: [phone]
Fax: [phone]
mailto:[e-mail]
GMT: -5:00
Asia / Australia (Beijing)
Technical Support and
Authorization
Local time: Mon.-Fri. 8:00 to 5:00 PM
Phone: [phone]
Fax: [phone]
mailto:adsupport.[email protected]
GMT: +8:00
The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English.

Preface
Process Control System PCS 7 - PCS 7 BOX
vi A5E00272813-01
Service & Support on the Internet
In addition to our documentation, we offer our Know-how online on the internet at:
http://www.siemens.com/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
A5E00272813-01 vii
Contents
1What is SIMATIC PCS 7 BOX?.......................................................................................1-1
2Concept and Areas of Application................................................................................2-1
2.1 SIMATIC PCS 7 BOX Concept.........................................................................2-1
2.2 Areas of Application for SIMATIC PCS 7 BOX.................................................2-1
3Structure of SIMATIC PCS 7 BOX.................................................................................3-1
3.1 Hardware Components of SIMATIC PCS 7 BOX .............................................3-1
3.2 Software Components of SIMATIC PCS 7 BOX...............................................3-3
3.3 Compatibility to SIMATIC PCS 7 ......................................................................3-5
3.4 Configuration Variants for SIMATIC PCS 7 BOX..............................................3-6
3.4.1 Configuration Possibilities.................................................................................3-6
3.4.2 SIMATIC PCS 7 BOX as Single Station System ..............................................3-7
3.4.3 SIMATIC PCS 7 BOX with External Engineering Station...............................3-10
3.4.4 SIMATIC PCS 7 BOX in a PCS 7 network......................................................3-12
3.5 Connection Options for SIMATIC PCS 7 BOX................................................3-15
3.5.1 Connecting to PROFIBUS...............................................................................3-15
3.5.2 Network Connection to Ethernet.....................................................................3-16
3.5.3 PS Extension Board........................................................................................3-16
3.6 The Operator Panel of the CPU 416-2 PCI.....................................................3-17
3.6.1 The Operator Panel of the CPU 416-2 PCI.....................................................3-17
4Commissioning and Configuration...............................................................................4-1
4.1 Overview of Commissioning and Configuration................................................4-1
4.2 Configuring SIMATIC PCS 7 BOX for a Single Station System .......................4-2
4.2.1 Step 1: Configuring the PC Stations Using the Commissioning Wizard...........4-2
4.2.2 Step 2: Configuring the PC Using the Component Configurator ......................4-4
4.2.3 Step 3: Creating a New PCS 7 Project .............................................................4-5
4.2.4 Step 4: Configuring a PCS 7 Project and Renaming the SIMATIC PC Station 4-7
4.2.5 Step 5: Setting the Hardware Configuration of PC Stations .............................4-8
4.2.6 Step 6: Configuring NetPro...............................................................................4-9
4.2.7 Step 7: Setting Time Synchronization.............................................................4-11
4.2.8 Step 8: Checking If the PG/PC Interface Is Set to "PC Internal" ....................4-12
4.2.9 Step 9: Opening the Operator Panel of the CPU 416-2 PCI...........................4-13
4.2.10 Step 10: Compiling and Downloading the AS and OS Data...........................4-14
4.2.11 Step 11: Setting the CPU 416-2 PCI to RUN-P..............................................4-16

Contents
Process Control System PCS 7 - PCS 7 BOX
viii A5E00272813-01
5Additional Commissioning and Configuration............................................................5-1
5.1 Configuring SIMATIC PCS 7 BOX with External Engineering..........................5-1
5.1.1 Overview of Hardware and Software Installation..............................................5-1
5.1.2 Overview of Configuration Steps for Commissioning .......................................5-2
5.1.3 Step 1: Configuring the PC stations using the Commissioning Wizard............5-3
5.1.4 Step 2: Configuring the PC Using the Component Configurator ......................5-5
5.1.5 Step 5: Adding an External ES to Your PCS 7 Project.....................................5-6
5.1.6 Step 6: Setting the Hardware Configuration of PC Stations on the ES ............5-7
5.1.7 Step 7: Configuring NetPro for an External ES.................................................5-9
5.1.8 Step 11: Compiling and Downloading the AS and OS Data
for an External ES...........................................................................................5-11
5.2 Configuring SIMATIC PCS 7 BOX in the PCS 7 Network ..............................5-13
5.2.1 Overview of Commissioning and Configuration..............................................5-13
5.2.2 Step 1: Configuring the PC Stations Using the Commissioning Wizard.........5-14
5.2.3 Step 2: Configuring the PC Using the Component Configurator ....................5-15
5.2.4 Step 3: Adding a SIMATIC PCS 7 BOX Station to Your Project.....................5-16
5.2.5 Step 4: Configuring NetPro.............................................................................5-18
5.2.6 Step 5: Synchronizing the Time on the AS via the Plant Bus.........................5-20
5.2.7 Step 6: Synchronizing the Time on the OS via the Plant Bus.........................5-21
5.2.8 Step 7: Configuring AS-AS Communication ...................................................5-22
5.2.9 Step 10: Compiling and Downloading the AS and OS Data
for a PCS7 network.........................................................................................5-23
Index

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.
123
456
789
0
.
+/-
Clear
Enter
ESC
Info
MEAS
ULTRAMAT6
S
63,29
36,72
oCAL oLIM oAR o CODE
24V DC
DP/PA-Link
PROFIBUS PA
PROFIBUS DPPROFIBUS DP
PDM OS
Simatic Net
CP 5611
on board
CPU 416-2
PCI + PS
PCMCIA
card
Ethernet
on board
ES
PROFIBUS MPI/DPPROFIBUS MPI/DP
SIMATIC PCS 7 BOX
MPI/
DP DP

What is SIMATIC PCS 7 BOX?
Process Control System PCS 7 - PCS 7 BOX
1-2 A5E00272813-01
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
A5E00272813-01 2-1
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

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

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.
123
456
789
0
.
+/-
Clear
Enter
ESC
Info
MEAS
ULTRAMAT6
S
63,29
36,72
oCAL oLIM oAR o CODE
24V DC
DP/PA-Link
PROFIBUS PA
PROFIBUS DPPROFIBUS DP
PDM OS
Simatic Net
CP 5611
on board
CPU 416-2
PCI + PS
PCMCIA
card
Ethernet
on board
ES
PROFIBUS MPI/DPPROFIBUS MPI/DP
SIMATIC PCS 7 BOX
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.