C135 PCS 7 (PCS7)
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Configuring S7-PLCSIM and WinCC Runtime Simulation for Process Graphics Testing in PCS 7

Configuring S7-PLCSIM and WinCC Runtime Simulation for Process Graphics Testing in PCS 7

In SIMATIC PCS 7, testing Continuous Function Chart (CFC) automation logic and WinCC process graphics without physical controller hardware requires coupling S7-PLCSIM with WinCC Runtime on the Engineering Station. To establish the simulation, open S7-PLCSIM from SIMATIC Manager, set the virtual CPU to RUN-P, and perform an entire program download from the CFC editor. In WinCC Explorer Tag Management, ensure the SIMATIC S7 Protocol Suite is configured for named connections or TCP/IP. Configure Set PG/PC Interface to route S7ONLINE to PLCSIM.TCPIP.1, activate WinCC Runtime, and verify that APL block icons and faceplates reflect live simulation values from the virtual controller.

Table of Contents

Executive Summary

Pre-commissioning validation of DCS logic and human-machine interface (HMI) screens significantly reduces on-site commissioning time and eliminates field wiring hazards. Control engineers frequently require a streamlined method to verify faceplate popups, interlocking status glyphs, and control valve actions without physical automation stations. By combining S7-PLCSIM and local WinCC Runtime on a single Engineering Station, engineers create a fully integrated virtual testbench. Understanding the communication routing parameters between the STEP 7 simulation engine, PG/PC interface access points, and WinCC Tag Management enables reliable software acceptance testing.

Architecture and Fundamental Mechanics

The inter-process communication architecture between S7-PLCSIM and WinCC Runtime operates through specialized virtual network drivers:

  1. The S7-PLCSIM Virtual Backplane:
    * S7-PLCSIM emulates the execution cycle, organization blocks (OB1, OB35, OB100), and memory partitions (DB, M, I, Q) of an S7-400 or CPU 410 controller in host PC memory.
    * It exposes virtual communication ports corresponding to MPI, PROFIBUS, and Industrial Ethernet.
  2. The S7ONLINE Access Point Routing:
    * WinCC and SIMATIC Manager communicate with controllers via the logical access point S7ONLINE.
    * When testing against physical hardware, S7ONLINE binds to a physical network interface card (e.g., CP 1623 or Intel PCIe).
    * When testing in simulation, S7ONLINE must be redirected to PLCSIM.TCPIP.1 (or PLCSIM.ISO.1).
    * This virtual driver redirects all S7 communication packets directly into the PLCSIM shared memory buffer, bypassing the physical network card.
  3. WinCC Named Connections vs. TCP/IP in Simulation:
    * In standard PCS 7 architectures, WinCC communicates via Named Connections configured in NetPro.
    * When S7-PLCSIM is active, the Station Configurator virtual backplane can route named connections directly into S7-PLCSIM, allowing standard APL block icons and faceplates to operate identically to a live plant connection.

Step-by-Step Implementation Procedure

Follow these procedures to configure and run an integrated PCS 7 logic and graphics simulation:

  1. Launch S7-PLCSIM from SIMATIC Manager:
    * Open your PCS 7 Multiproject in SIMATIC Manager.
    * In the top toolbar, click the Simulation On/Off icon (or select Options > Simulate Modules).
    * The S7-PLCSIM interface opens.
    * Set the communication node to TCP/IP (or ISO).
  2. Download Hardware Configuration and S7 Program to PLCSIM:
    * In SIMATIC Manager, open HW Config for the target AS station.
    * Select PLC > Download to download the hardware configuration to PLCSIM.
    * Open CFC editor, select Chart > Compile > Scope: Entire program.
    * Select Target system > Download... > Scope: Entire program and download to PLCSIM.
    * In S7-PLCSIM, switch the CPU mode selector from STOP to RUN-P.
  3. Configure Set PG/PC Interface on the ES:
    * Open Windows Control Panel and launch Set PG/PC Interface.
    * Set the Access Point of the Application (S7ONLINE) to PLCSIM.TCPIP.1 (or PLCSIM.ISO.1).
    * Click OK.
  4. Verify WinCC Tag Management Connection Parameters:
    * In SIMATIC Manager, right-click the OS project and select Compile (AS-OS Compile).
    * Open the OS project in WinCC Explorer.
    * Open Tag Management; locate SIMATIC S7 Protocol Suite > Named Connections (or TCP/IP).
    * Verify that the connection properties point to the simulated controller.
  5. Activate WinCC Runtime and Test Process Graphics:
    * In WinCC Explorer, click the Activate button to start WinCC Runtime.
    * Open the process screens containing your technological block icons (e.g., MotL, VlvL, PidConL).
    * In S7-PLCSIM, insert variable view tables (Insert > Input Variable / Output Variable) or toggle bits directly.
    * Observe that block icons update dynamically, alarms appear in the alarm banner, and clicking icons opens fully functional APL faceplates.

Verification

In WinCC Runtime, click a motor block icon to open its faceplate. Toggle the control mode to 'Manual' and click the 'Start' button. In S7-PLCSIM, open the variable table for the corresponding digital output word; verify that the run command bit asserts immediately. Force a feedback run input bit in S7-PLCSIM; confirm that the motor icon in WinCC turns solid green without generating a transit time fault.

Limitations and Operational Precautions

S7-PLCSIM does not simulate real-time analog process dynamics (e.g., vessel filling or temperature rise) automatically; dynamic loop response requires pairing with Siemens SIMIT or writing basic simulation feedback blocks in CFC. S7-PLCSIM V5.4/V5.5 does not emulate CPU 410-5H Type Change in RUN (TCiR) mechanics.

Engineer FAQ

Why do WinCC block icons show disconnected status in simulation?

This occurs if S7ONLINE in 'Set PG/PC Interface' is still pointed to the physical network card instead of PLCSIM.TCPIP.1, or if the simulated CPU is in STOP mode.

Can I run WinCC Runtime and S7-PLCSIM on the same PC?

Yes. A standard PCS 7 Engineering Station can host both S7-PLCSIM and WinCC Runtime concurrently for testing purposes.

Do I need to compile the OS before running simulation?

Yes. An AS-OS compile must be executed to ensure WinCC Tag Management contains the compiled tag names and DB offsets from the CFC charts.

Can S7-PLCSIM simulate redundant S7-400H controller pairs?

Standard S7-PLCSIM V5.x simulates a single CPU at a time; simulating redundant controller synchronization requires SIMIT Virtual Controllers.

Technical References

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Related Tags

  • S7-PLCSIM
  • WinCC Simulation
  • Graphics Testing
  • Set PG/PC Interface
  • APL Faceplates
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