Configuring SIMIT V9.1 Couplings with SIMATIC Route Control Servers

When coupling SIMIT V9.1 with SIMATIC Route Control (RC) Server, communication errors in AS coupling occur when SIMIT operates in DEMO mode or when named S7 connections are misrouted. SIMIT DEMO mode explicitly restricts multi-station external communication and blocks the continuous bidirectional S7 connection required by the Route Control Server. Establishing a functional virtual coupling requires a fully licensed SIMIT Engineering installation (6DL8913-0AK00-0AB5). Furthermore, configure named S7 connections in NetPro between the Route Control Application and the virtual controller, compile connection tables using the Route Control Wizard, and ensure SIMATIC NET Softbus interfaces are synchronized.

Architecture of SIMIT Virtual Couplings with SIMATIC Route Control

SIMATIC Route Control (RC) manages complex material transport paths, valve matrices, and transfer lines across tank farms and multi-product processing plants. In an integrated PCS 7 system, Route Control comprises three interdependent layers:

Route Control AS Blocks: Embedded Function Blocks (RC_IF_CFG, RC_ROUTE) running in the S7-400 automation station.
Route Control Server: A central PC Station running the RC Server runtime application, communicating with the AS over named S7 connections to arbitrate element reservations and route permissions.
SIMIT Simulation Platform: Simulates field device states (valves, pumps, feedback switches) and process dynamics.

When simulating routes virtually, SIMIT couples to the virtual controller (S7-PLCSIM or SIMIT Virtual Controller / VC). While WinCC OS connects readily via standard tags, the Route Control Server requires an active, uninterrupted bidirectional S7 communication channel with the AS blocks.

Licensing Constraints: Why SIMIT DEMO Mode Blocks Route Control

A frequent stumbling block occurs when testing configurations in SIMIT DEMO mode:

SIMIT DEMO Mode Restrictions: The unlicensed demo version of SIMIT is designed strictly for offline introductory evaluation. It enforces a 45-minute simulation timeout and explicitly disables external communication interfaces.
S7 Communication Interception: Route Control Server requires continuous high-volume S7 packet arbitration across the Terminal Bus / Softbus. In DEMO mode, SIMIT blocks external communication sockets, causing the RC Server to report 'Connection to AS failed' or 'RC coupling disconnected'.
Mandatory License Requirement: Testing SIMATIC Route Control virtual commissioning requires a valid floating license for SIMIT Engineering / SIMIT Simulation Platform (6DL8913-0AK00-0AB5) installed via Automation License Manager (ALM).

Step-by-Step Configuration Workflow for RC Virtual Simulation

Follow this sequence to establish a functional SIMIT-to-Route Control simulation environment:

Verify Software Licenses: Ensure valid licenses for SIMIT V9.1 (6DL8913-0AK00-0AB5) and SIMATIC Route Control Engineering/Server (6ES7658-0AA58-0YB0) are active in ALM.
Configure Named S7 Connections in NetPro:
- Open NetPro on the Engineering Station.
- Under the Route Control PC Station, select the Route Control Application.
- Insert a new S7 connection pointing to the target AS (CPU 410 or S7-400).
- Verify that the connection is defined as a Named S7 connection.
Execute Route Control Wizard:
- In SIMATIC Manager, select Options -> SIMATIC Route Control -> Wizard....
- Complete the wizard steps to compile the RC configuration and generate connection descriptor blocks in the AS.
Establish SIMIT Virtual Controller Coupling:
- In SIMIT, create a new coupling using Virtual Controller (VC) or S7-PLCSIM.
- Import the hardware configuration and symbol table from the PCS 7 project.
- Start the Virtual Controller and load the compiled AS program.
Start Route Control Server: Launch Route Control Server. The server establishes S7 communication with the virtual controller via SIMATIC NET Softbus, allowing complete route requests and valve path execution.

SIMIT Simulation Coupling Capabilities: Full License vs DEMO Mode

The following table details simulation and coupling capabilities between SIMIT licensing tiers:

Simulation FeatureSIMIT DEMO ModeSIMIT Standard LicenseSIMIT Ultimate (6DL8913-0AK00-0AB5)Execution Runtime Limit45 minutes (Auto-shutdown)UnlimitedUnlimitedWinCC OS Simulation CouplingSupported (Local tags)SupportedSupportedSIMATIC Route Control CouplingBlocked (Communication Error)Supported (Full S7 channel)Supported (Full S7 channel)SIMATIC BATCH CouplingBlocked (Communication Error)SupportedSupportedVirtual Controller (VC) Instances1 instance maximumUp to licensed limitScalable multi-controller supportExternal Shared Memory / OPCDisabledSupportedSupported

[!NOTE]
Commercial Accuracy Notice: SIMATIC Route Control Server requires dedicated server software licenses (6ES7658-0AA58-0YB0) > and route capacity authorizations (e.g. 10, 50, or 100 routes). SIMIT simulation licenses (6DL8913-0AK00-0AB5) are independent > engineering packages. Always verify required license quantities with an authorized Siemens distributor.

Verification

Confirm that SIMATIC Route Control communicates and executes routes in simulation:

Route Control Server Status: In the Route Control Server management console, verify that the AS connection status displays a green indicator (Connected / OK) and that no communication timeout alarms are logged.
Route Request Test: In the Route Control Center (RCC), request a material transport path between Source Tank 1 and Destination Tank 2. Verify that RC searches, finds, and successfully reserves the route.
Dynamic Feedback Validation: In SIMIT, verify that simulated valves open and feedback signals toggle, allowing the route to transition from 'Activating' to 'Active'.

Limitations and Operational Precautions

Observe these guidelines when simulating Route Control systems:

Softbus Network Binding: When running SIMIT, PLCSIM, and RC Server on the same PC, ensure the SIMATIC NET PG/PC interface is configured to PC internal.local or PLCSIM.TCPIP to prevent packet routing conflicts.
RC Wizard Recompilation: Any modification to AS block interfaces or NetPro connections requires re-running the Route Control Wizard before testing in SIMIT.
Memory Sizing: Virtual controllers simulating large Route Control projects require adequate host RAM (minimum 16 GB) to handle concurrent execution of WinCC, RC Server, and SIMIT.

Engineer FAQ

Why does SIMIT in DEMO mode communicate with WinCC but not Route Control Server?

WinCC reads local process tags directly, whereas Route Control Server requires an active bidirectional S7 protocol communication channel with the AS. SIMIT DEMO mode explicitly disables external S7 communication sockets.

What SIMIT license is needed to simulate Route Control?

A full commercial license for SIMIT Simulation Platform (Standard, Professional, or Ultimate 6DL8913-0AK00-0AB5) is required to enable external multi-station S7 couplings.

Do I need physical CP 1623 cards to test Route Control in simulation?

No. When simulating on an Engineering Station, Route Control communicates with S7-PLCSIM or SIMIT Virtual Controller via internal Softbus (PC internal.local) without physical communication hardware.

Can SIMIT simulate material tracking and pipe line flushing in Route Control?

Yes. By modeling pipe volumes and valve manifolds in SIMIT, you can simulate realistic material transfer dynamics, pump flow rates, and sensor actuation in real time.