C135 PCS 7 (PCS7)
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Bulk Exporting and Importing Signal Scaling Parameters in SIMIT for PCS 7

Bulk Exporting and Importing Signal Scaling Parameters in SIMIT for PCS 7

To bulk modify the scaling parameters (minimum, maximum, and engineering units) for hundreds of analog process signals in SIMIT for virtual commissioning with SIMATIC PCS 7, export the signal coupling table to Microsoft Excel or CSV using the 'Export signals' function in the SIMIT Coupling Editor. In Excel, edit the scaling columns ('Scale.Min', 'Scale.Max', 'Physical.Min', 'Physical.Max') across all 200+ analog channels, save the spreadsheet, and re-import the file into SIMIT using 'Import signals' with update mode enabled, refreshing all coupling points simultaneously.

Table of Contents

Executive Summary

Virtual commissioning using SIMIT Simulation Platform provides comprehensive digital twin testing of PCS 7 automation logic, allowing engineers to validate CFC charts, interlocks, and WinCC faceplates prior to site delivery. A common bottleneck during simulation setup involves scaling hundreds of analog measurements (transmitters 4–20 mA converted to engineering ranges like 0–100 bar or 0–250 °C). Manually editing signal properties point-by-point in the SIMIT GUI is tedious and error-prone. This article details the bulk export, spreadsheet modification, and re-import workflow in SIMIT.

Architecture and Fundamental Mechanics

SIMIT Coupling Architecture and Signal Data Modeling:

  • SIMIT Couplings to PCS 7:
  • SIMIT interfaces with PCS 7 via dedicated couplings: S7-PLCSIM, SIMIT Virtual Controller (VC), or PROFINET / PROFIBUS DP Couplings.
  • Couplings maintain an internal signal dictionary mapping raw controller peripheral addresses (e.g., IW 512) to simulated physical variables.
  • Scaling Architecture in SIMIT:
  • Analog inputs from field transmitters arrive as 16-bit raw integer values ($0\dots 27648$ representing $4\dots 20\text{ mA}$ according to S7 standard format).
  • SIMIT handles scaling between the simulated physical process model (floating-point physical value, e.g., $0\dots 150\text{ m}^3/\text{h}$) and the raw peripheral integer written to the PLC.
  • Bulk Data Interchange:
  • SIMIT supports bidirectional export/import in .xlsx and .csv formats, preserving unique signal GUIDs while allowing bulk spreadsheet editing of ranges, units, and default values.

Step-by-Step Implementation Procedure

Step-by-Step Procedure for Bulk Signal Scaling Modification in SIMIT:

  1. Open SIMIT Project and Access Coupling:
    - Open the SIMIT simulation project.
    - In the Navigation tree, expand Couplings -> double-click the active coupling (e.g., PLCSIM_Coupling or VirtualController).
  2. Export Signals to Spreadsheet:
    - In the Coupling Editor toolbar, click the Export signals button (or right-click signal list -> Export).
    - Select export format: Microsoft Excel Workbook (.xlsx).
    - Save the file as SIMIT_Signals_Raw.xlsx.
  3. Bulk Edit Scaling in Microsoft Excel:
    - Open SIMIT_Signals_Raw.xlsx in Excel.
    - Locate the scaling columns:
    • Simulated Minimum / Simulated Maximum (Physical process limits, e.g., 0.0 to 100.0).
    • Scale Raw Minimum / Scale Raw Maximum (S7 I/O format, typically 0 to 27648).
    • Unit (e.g., bar, degC, kg/h).
    • Apply formulas or paste updated scaling tables from the plant instrument index across all 200+ analog rows.
    • Save and close the Excel file.
  4. Import Updated Signals into SIMIT:
    - Return to the SIMIT Coupling Editor.
    - Click the Import signals button.
    - Browse and select the edited Excel file.
    - In the import dialog, select Update existing signals (matching by signal name/ID).
    - Click OK and verify the import summary reports zero errors.
  5. Compile and Run Simulation:
    - Start the SIMIT simulation; verify that analog outputs drive the PLC with correctly scaled peripheral counts.

Verification

To verify signal scaling in SIMIT and PCS 7:
1. In SIMIT, open a signal component slider for a modified transmitter (e.g., TI_101); set the physical value to $50.0\text{ }^\circ\text{C}$ (50% of span).
2. Check the raw value transmitted in the SIMIT coupling table; verify it reflects decimal 13824 ($50\%$ of 27648).
3. In PCS 7 CFC test mode, inspect Pcs7AnIn.PV_Out for TI_101; verify it reads $50.0\text{ }^\circ\text{C}$ with signal status 16#80 (Good).

Limitations and Operational Precautions

Operational precautions:
- Do not alter the unique Signal ID / Name column during Excel editing; changing names causes SIMIT to create duplicate orphaned signals rather than updating existing points.
- Verify whether the PCS 7 channel block (Pcs7AnIn) has scaling configured internally via Scale.Low / Scale.High; avoid double-scaling where both SIMIT and PCS 7 attempt to apply range transformation.
- Save backup copies of the original SIMIT project prior to executing bulk imports.

Engineer FAQ

What file format is best for bulk signal editing in SIMIT?

Microsoft Excel (.xlsx) or comma-separated values (.csv).

What is the standard S7 raw integer range for 4-20mA signals?

0 to 27648 decimal represents 4 to 20 mA in standard Siemens analog I/O modules.

Why did SIMIT create duplicate signals instead of updating them?

The signal names or identifiers were modified in the spreadsheet, preventing SIMIT from matching them to existing coupling entries.

Can SIMIT import signals directly from the PCS 7 HW Config?

Yes, SIMIT provides an automated import function that reads the STEP 7 HW Config export file (.cfg or .xml).

Does SIMIT require a separate software license?

Yes. SIMIT Simulation Platform requires dedicated engineering and runtime licenses in Automation License Manager.

Technical References

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Related Tags

  • SIMIT
  • Signal Export Import
  • Virtual Commissioning
  • Analog Scaling
  • Digital Twin
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