Architecting and Configuring Standalone SIMATIC Route Control Servers in PCS 7

To offload an overloaded OS Server by deploying a dedicated standalone SIMATIC Route Control (RC) Server in PCS 7, configure a dedicated SIMATIC PC Station in SIMATIC Manager containing only the 'Route Control Server' application and a network communication card (IE General or CP 1623). A standalone RC Server does not require WinCC Explorer or a WinCC Server application to function. In the Route Control configuration wizard, assign the standalone PC station as the primary RC Server (and optionally configure a redundant standby RC Server), compile RC engineering data, and route route requests from OS Clients via the Route Control Client application.

Executive Summary

In tank farms, grain handling, brewing, and chemical batch facilities with complex material transport networks, SIMATIC Route Control manages dynamic path finding, pipe segment allocation, and valve positioning. While small systems co-locate the Route Control Server application on an existing WinCC OS Server, growing installations experience high CPU and memory utilization, resulting in sluggish faceplates and route search delays. This guide clarifies the PC Station hardware configuration, software package requirements, licensing boundaries, and commissioning procedures for separating Route Control onto a dedicated standalone server.

Architecture and Fundamental Mechanics

SIMATIC Route Control Standalone Architecture and Mechanics:

Co-Located vs Standalone RC Server Topology:
Co-Located RC Server: Runs inside the WinCC OS Server PC Station (WinCC Appl. + Route Control Server). Shares CPU, RAM, and terminal bus sockets with WinCC Tag Logging and Alarm Logging.
Standalone RC Server: Runs on a dedicated PC Station. Contains only the Route Control Server application (and communication hardware). Requires no WinCC software installation on the server machine.
Communication Interfaces:
Plant Bus Interface: Connects the RC Server to S7-400 / CPU 410 controllers via S7 Named Connections, reading element states (limit switches, pump feedback) and issuing route control words (RC_IF_CFG).
Terminal Bus Interface: Connects the RC Server to RC Clients and WinCC OS Clients for operator route requests, path visualization, and diagnostics.
Client-Side Route Control Visualization:
OS Clients host the Route Control Client software and WinCC ActiveX controls (Route Control Faceplates and Path Viewers).
Operator route commands are sent across the terminal bus to the standalone RC Server, which arbitrates path finding and downloads route parameters directly to the controllers.

Step-by-Step Implementation Procedure

Configuring a Standalone Route Control Server in SIMATIC Manager:

Insert a New PC Station for the RC Server:
- In SIMATIC Manager, right-click the Multiproject -> Insert New Object -> SIMATIC PC Station.
- Name the PC Station identically to the Windows Computer Name of the dedicated RC Server PC.
Hardware Configuration of the RC Server Station:
- Open HW Config for the new PC Station.
- From the Hardware Catalog -> SIMATIC PC Station -> Route Control -> select Route Control Server and place it in Slot 1.
- In Slot 2, insert IE General (or CP 1623) and assign the Plant Bus IP address.
- In Slot 3, insert a second IE General adapter for the Terminal Bus.
- Save and Compile HW Config.
Establish S7 Connections in NetPro:
- Open NetPro; select the Route Control Server application.
- Insert an S7 Connection to each S7-400 controller executing Route Control blocks (RC_MASTER, RC_ELEMENT).
- Save and Compile network connections.
Configure Route Control Project:
- Open the Route Control engineering wizard (Route Control Wizard).
- In the Server Configuration dialog, designate the new PC station as the active Route Control Server.
- If redundancy is implemented, add the redundant partner PC station.
- Compile the Route Control project.
Download Configuration to Target RC Server:
- Using Station Configurator on the physical RC Server, verify slot indices match HW Config.
- In SIMATIC Manager, right-click the PC Station -> PLC -> Download to Station.
- Open Route Control Center on the server and activate the project.

Verification

To verify standalone RC Server operation:
1. On the RC Server, open the Route Control Server diagnostic window; verify state reports 'Active / Master' with green communication status to all AS controllers.
2. On an OS Client, launch the Route Control Client application; verify successful connection to the standalone RC Server.
3. Request a material transfer route between Source Tank 1 and Destination Tank 2; verify the standalone RC Server performs path finding and allocates intermediate valves in <2 seconds.

Limitations and Operational Precautions

Operational precautions:
- Do not install WinCC Explorer on a standalone Route Control Server unless explicitly required for local diagnostic displays; keeping it lean prevents database contention.
- A dedicated Route Control Server requires appropriate licensing: 'SIMATIC Route Control Server' license and Route capacity licenses (e.g., 10, 50, 100, or 300 active routes) installed via ALM.
- Ensure low network latency between the RC Server and controllers on the Plant Bus (<10 ms); route allocation can stall if network jitter exceeds timeout limits.

Engineer FAQ

Does a standalone Route Control server require WinCC?

No. A standalone Route Control server requires only the Route Control Server application and SIMATIC NET communication software; WinCC is not required on the server machine.

Can Route Control run on a redundant pair of servers?

Yes. Route Control supports redundant server pairs running in active/standby hot standby mode with automatic switchover.

How do operators interact with Route Control on OS Clients?

Via the Route Control Client application and integrated WinCC Route Control ActiveX faceplates and controls.

What licenses are required for a Route Control Server?

A 'SIMATIC Route Control Server' base license plus Route capacity licenses (e.g., SIMATIC Route Control Routes 50) installed in ALM.

What block coordinates Route Control in the automation controller?

The RC_MASTER block coordinates route allocation and communication with the RC Server.

Technical References

Related Tags

Route Control
RC Server
Standalone Server
Material Transport
PC Station

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Architecting and Configuring Standalone SIMATIC Route Control Servers in PCS 7