More flexibility in process automation

In process plants, the process control system is the starting point for optimal value added: All procedures and processes can be operated, monitored and influenced with the process control system.

The higher the performance of the process control system, the more effectively this potential can be used. For this reason, performance is in the foreground with SIMATIC PCS 7, alongside scalability, flexibility and integration. Starting with planning and engineering, SIMATIC PCS 7 offers powerful tools, functions and features for cost-effective and efficient plant operation through all phases of the plant life cycle.

Flexibility through integration

Integration is one of the special strengths of SIMATIC PCS 7. It has numerous aspects:

• Horizontal integration into TIA
• Vertical integration into hierarchical communication
• System-integrated tools for engineering tasks
• Integration of the field level, including drives, switchgear, etc.
• Integrated functions, e.g. for batch process automation, route control, process safety, energy management, telecontrol tasks, etc.

Horizontal integration

A system for integrated automation of the entire process chain, from incoming raw materials to outgoing goods – this is one of the decisive advantages resulting from the seamless integration of SIMATIC PCS 7 into Totally Integrated Automation.

The process control system is mainly responsible for automating the primary processes here, but it can do very much more: All ancillary facilities such as the electrical infrastructure in the form of low-voltage or medium-voltage switchgear or the building management system, can also be integrated into the system.

Integration of selected SIMATIC standard components – automation systems, industrial PCs, network components, or distributed process I/O – into the process control system ensures optimum interaction, and secures economic benefits such as ease of selection, reduced stock keeping, and global support.

Vertical integration

The hierarchal communication of a company encompasses the field level, the control level and the process level, up to management and enterprise resource planning (ERP). Thanks to standardized interfaces – based on international industry standards as well as internal interfaces – SIMATIC PCS 7 is able to provide process data for analysis, planning, coordination, and optimization of plant sequences or production and business processes – in real time, and at any location in the company.

Central engineering

Impressive features of SIMATIC PCS 7 include graded functional diversity, consistent operator control philosophy and uniformly structured engineering and management tools. A central engineering system with a coordinated range of tools for integrated system engineering and configuring of batch automation, safety functions, material transport or telecontrol systems creates value added over the entire life cycle. Reductions in configuring and training costs minimize the total cost of ownership (TCO) over the entire plant life cycle.

Functional diversity

Depending on the typical process automation or customized requirements, the SIMATIC PCS 7 functions can be expanded by the following, for example:

• Batch process automation (SIMATIC BATCH)
• Functional safety and protection functions (Safety Integrated for Process Automation)
• Route control for material transport (SIMATIC Route Control)
• Telecontrol of remote units (SIMATIC PCS 7 TeleControl)
• Automation of electrical switchgear (SIMATIC PCS 7 PowerControl)

Further additional functions that are also integrated or can be integrated, seamlessly into the control system make optimization of processes and reductions in operating costs possible. SIMATIC PCS 7 features, for example, tools for energy and asset management and it offers higher quality closed-loop control functions, as well as industry-specific automation solutions and libraries.

Comparison of distributed I/O systems for SIMATIC PCS 7

I/O system	SIMATIC CFU	ET 200SP HA	ET 200iSP	ET 200M	ET 200SP	ET 200pro
Design
Degree of protection	IP20	IP20	IP30	IP20	IP20	IP65/IP66/IP67
Design	Compact	Modular	Modular	Modular	Discretely scalable	Modular
Assembly	Mounting rail	Mounting rail	Mounting rail	Mounting rail	Standard mounting rail	Mounting rail
Connection system for sensors/actuators	Multi-wire connection Screw-type connection	Multi-wire connection Push-in terminals	Multi-wire connection Spring-loaded/screw-type connections	Single-wire connection Spring-loaded/screw-type connections, FastConnect, TopConnect	Single/multi-conductor connection Push‑in terminals	M8, M12, M23
Special applications
Safety engineering	–	–	●	●	–	●
For use in hazardous areas	Zones 2, 22	Zone 2	Zones 1, 21	Zone 2	Zone 2	–
Increased availability	Redundant	Switched, redundant	Switched, redundant	Switched, redundant	–	–
Temperature range	-40 … +70 °C (horizontal)	-40 … +70 °C (horizontal)	-20 … +70 °C	0 … +60 °C1)	0 … +60 °C1) (horizontal)	-25 … +55 °C
Vibration resistance (continuous)	1 g	1 g	1 g	1 g	Up to 5 g	5 g (module-dependent)
Communication
PROFIBUS (Cu/FO)	– / –	– / –	● / – (1.5 Mbps)	● / – (12 Mbps)	– / –	● / ● (12 Mbps)
PROFINET (Cu/FO)	● / ●	● / ●	– / –	● / –	● / ●	– / –
System functions
Permanent wiring	●	●	●	● (insertion and removal)	●	–
Hot swapping	–	●	●	● (with active backplane bus)	●	●
Expansion/ configuration during ongoing operation	● / ●	● / ●	● / ●	● / ●	– / –	– / –
Diagnostics (module-dependent)	Channel-discrete	Channel-discrete	Channel-discrete	Channel-discrete	Channel-discrete	Channel-discrete
functions
Digital channels	●	●	●	●	●	●
Analog channels	●	●	●	●	●	●
incl. HART	PROFIBUS PA	●	●	●	●	–
Motor starter	–	Available soon	–	–	–	–
Pneumatic interface	–	Available soon	●	–	–	–
Technological functions	Available soon	Available soon	Counting, frequency measuring	Counting/measuring, controlling, weighing	–	–