C135 PCS 7 (PCS7)
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Configuring Multiple Concurrent S7-PLCSIM Instances for Multi-AS Simulation in SIMATIC PCS 7

Configuring Multiple Concurrent S7-PLCSIM Instances for Multi-AS Simulation in SIMATIC PCS 7

In SIMATIC PCS 7 (such as V8.1 and V8.2), you can run multiple concurrent instances of S7-PLCSIM (up to 8 instances in PLCSIM V5.4) to simulate multiple automation stations (AS) simultaneously within a multiproject. To prevent download cross-talk where the hardware configuration of AS02 downloads into AS01, open the first PLCSIM instance, download the HW Config and CFCs of AS01 (which assigns AS01's unique IP and MAC addresses), and save the simulation file (e.g., 'AS01.plc'). Then, open a new PLCSIM instance via 'File > New PLC', download AS02's HW Config and CFCs, and save as 'AS02.plc'. Once configured, multiple saved PLC files can be launched concurrently, allowing WinCC OS servers and clients to connect seamlessly to each virtual controller using their distinct IP addresses.

Table of Contents

Executive Summary

Virtual testing and integrated multi-controller simulation are critical prerequisites for validating distributed process control software prior to on-site commissioning. In large-scale SIMATIC PCS 7 facilities, automation architectures typically feature multiple autonomous S7-400 controllers exchanging data across the plant bus and interfacing with central Operator Stations (OS). When performing factory acceptance testing (FAT) or functional verification on an engineering workstation, automation engineers frequently need to simulate multiple controllers concurrently.

While engineers commonly assume that S7-PLCSIM V5.4 supports only a single controller at a time, the software officially supports up to 8 concurrent simulation instances. However, engineers frequently encounter a frustrating configuration hurdle: attempting to download a second controller's hardware configuration causes the data to overwrite the first active PLCSIM instance, resulting in communication collisions. This technical guide outlines the internal instance addressing mechanics of S7-PLCSIM V5.4, provides a reliable step-by-step workflow to configure and save multi-AS simulations, and explains how to connect multiple simulated controllers to WinCC Runtime.

Architecture and Fundamental Mechanics

The multi-instance architecture of S7-PLCSIM V5.4 operates through distinct process and networking mechanisms:
1. Instance Isolation and Addressing:
* Each execution of S7-PLCSIM launches an isolated virtual CPU instance (s7wdx99x.exe / s7wsvapx.exe).
* When an instance first launches, it exists in an unparameterized default state (default MPI address 2, no Ethernet IP assigned).
* If two unconfigured PLCSIM instances are open simultaneously, STEP 7 download wizards cannot distinguish between them and will default to downloading into the first detected instance.
2. Hardware Configuration Binding:
* Downloading the Hardware Configuration (HW Config) to a PLCSIM instance assigns that instance the exact network parameters defined in the project: static IP address, subnet mask, MAC address, and rack/slot topology (e.g., 192.168.1.11 for AS01, 192.168.1.12 for AS02).
* Once an instance has received its hardware configuration, it binds to those specific network endpoints in the local virtual communication buffer.
* Subsequent downloads from SIMATIC Manager or CFC use target IP/MAC routing, directing packets precisely to the matching PLCSIM instance.
3. WinCC Named Connections and S7 Communication:
* WinCC OS projects connect to simulated controllers via the SIMATIC S7 Protocol Suite (Named Connections or Industrial Ethernet).
* When Set PG/PC Interface is set to PC Internal.local.1 or PLCSIM(ISO) / PLCSIM(TCP/IP), WinCC routes cyclic tag polling requests directly to the corresponding PLCSIM instance based on the NetPro connection table.
* This enables complete plant-wide simulation: inter-AS communication (via BSEND/BRCV) and multi-AS operator visualization operate simultaneously in software.

Step-by-Step Implementation Procedure

Step 1: Configure Unique Network Addresses in HW Config and NetPro

  1. In SIMATIC Manager, verify that every AS controller in the multiproject has a unique static IP address assigned to its communication interface (CP 443-1 or onboard PN interface):
    * AS01: e.g., 192.168.1.11
    * AS02: e.g., 192.168.1.12
  2. Open NetPro, execute Save and Compile > Compile and check everything, and verify zero network addressing errors.

Step 2: Configure and Save the First Controller Simulation (AS01)

  1. Open S7-PLCSIM from SIMATIC Manager or the Start menu (PLCSIM 1).
  2. In HW Config for AS01, click Download to Module and select the target CPU.
  3. In SIMATIC Manager, select the Charts folder for AS01 and download the CFC user program to PLCSIM.
  4. In PLCSIM, select File > Save PLC As....
  5. Save the simulation file to a dedicated project directory (e.g., C:\Simulations\AS01.plc).
  6. Close PLCSIM.

Step 3: Configure and Save the Second Controller Simulation (AS02)

  1. Open a fresh, empty instance of S7-PLCSIM.
  2. In HW Config for AS02, click Download to Module.
  3. In SIMATIC Manager, download the CFC user program for AS02 into this new PLCSIM instance.
  4. In PLCSIM, select File > Save PLC As....
  5. Save the simulation file as C:\Simulations\AS02.plc.
  6. Close PLCSIM.
  7. Repeat this process for any additional controllers (up to 8 AS instances).

Step 4: Launch All Saved Simulation Instances Concurrently

  1. Open S7-PLCSIM: select File > Open PLC and load AS01.plc.
  2. In the PLCSIM menu, select File > New PLC to spawn a second instance window.
  3. In the second PLCSIM window, select File > Open PLC and load AS02.plc.
  4. Switch both virtual CPU instances from STOP to RUN or RUN-P.
  5. Verify that both windows remain open side-by-side with their respective CPU names displayed in the title bar.

Step 5: Connect WinCC OS Runtime and Verify Multi-AS Polling

  1. Open Windows Control Panel and open Set PG/PC Interface.
  2. Set the Access Point S7ONLINE (STEP 7) to PC Internal.local.1 (or PLCSIM.TCPIP.1).
  3. In WinCC Explorer, activate WinCC Runtime.
  4. Open Tools > Channel Diagnosis and confirm that S7 named connections to both AS01 and AS02 report status 'Ready' with active data exchange.

Verification

  1. In the first PLCSIM window (AS01), force an analog process input (e.g., IW 512 = 13824 / 50%).
  2. In WinCC Runtime, observe the process picture for Unit 1: verify that the corresponding block icon and faceplate display 50.0%.
  3. In the second PLCSIM window (AS02), force a different input (e.g., IW 512 = 27648 / 100%).
  4. In WinCC Runtime, observe the process picture for Unit 2: verify that Unit 2 displays 100.0% without cross-talk or data corruption between units.
  5. If inter-AS communication is configured via BSEND/BRCV, verify that data transmitted from AS01 is received and processed in AS02 within one communication cycle.

Limitations and Operational Precautions

  1. Standard S7-PLCSIM V5.4 supports a maximum of 8 concurrent simulation instances on a single computer.
  2. Simulating multiple S7-400 CPUs simultaneously consumes significant host CPU resources; an engineering PC with a multi-core processor (minimum 4 to 8 physical cores) is strongly recommended.
  3. Standard S7-PLCSIM does not simulate hardware redundancy failover (S7-400H sync links) or PROFINET system redundancy (S2); use SIMIT with Virtual Controller for high-availability hardware simulation.
  4. Always save each configured instance to a .plc file; launching unconfigured instances causes download destination ambiguity.

Engineer FAQ

How many PLCSIM instances can run simultaneously in PCS 7?

Standard S7-PLCSIM V5.4 supports up to 8 concurrent simulation instances on a single Windows operating system instance.

Why did downloading AS02 overwrite AS01 in PLCSIM?

If PLCSIM instances are unparameterized, STEP 7 cannot distinguish between them. You must download HW Config to AS01 and save it before opening and configuring AS02.

Can WinCC connect to multiple PLCSIM instances at the same time?

Yes. When each PLCSIM instance has its hardware configuration loaded, it responds to its configured IP address, allowing WinCC Channel Diagnosis to connect to all simulated controllers.

Can S7-PLCSIM simulate inter-controller communication between AS01 and AS02?

Yes. Standard S7 communication blocks (such as BSEND/BRCV and USEND/URCV) function between concurrent PLCSIM instances across the virtual plant bus.

What is the advantage of SIMIT Virtual Controller over multiple PLCSIM instances?

SIMIT Virtual Controller provides exact cycle emulation, supports S7-410 controllers, emulates hardware redundancy and failover, and handles hundreds of synchronized virtual controllers across distributed PCs.

Technical References

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Related Tags

  • PLCSIM
  • Multi-AS Simulation
  • S7-400
  • WinCC Simulation
  • Virtual Commissioning
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