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How to Integrate S7-1500 Package Units into SIMATIC PCS 7 Using Open OS and DBA

How to Integrate S7-1500 Package Units into SIMATIC PCS 7 Using Open OS and DBA

Integrating SIMATIC S7-1500 package units into a SIMATIC PCS 7 Operator Station is accomplished using SIMATIC PCS 7 Open OS and its engineering utility Database Automation (DBA). In TIA Portal, engineers define standardized technological User-Defined Data Types (UDTs) for motors, valves, and analog transmitters within S7-1500 data blocks. DBA parses these DB structures, maps them to Open OS Type Definitions, and compiles them directly into the WinCC OS project. This automated workflow generates WinCC structure tags, Alarm Logging messages, and certified APL-style block icons and faceplates without manual script programming.

Table of Contents

Role of PCS 7 Open OS and Database Automation (DBA)

Modern industrial manufacturing facilities frequently incorporate specialized mechanical skids—known as Package Units (PUs)—such as packaged refrigeration plants, centrifuges, chemical dosing skids, or air compressors controlled by SIMATIC S7-1500 PLCs programmed in TIA Portal.

Plant operators require a unified, cohesive human-machine interface (HMI). Displaying disparate third-party screens or unmanaged graphics alongside PCS 7 degrades operator situational awareness.

What is SIMATIC PCS 7 Open OS?

SIMATIC PCS 7 Open OS is an add-on engineering package designed to bridge non-PCS 7 controllers into the PCS 7 OS environment:
* Database Automation (DBA): The core software engine of Open OS. DBA acts as an automated OS compiler for external controllers, mirroring the functionality of the standard PCS 7 OS Compiler.
* APL-Styled Visualization: Open OS delivers a pre-engineered library of WinCC block icons and faceplates designed to emulate the look, feel, and navigation hierarchy of the Advanced Process Library (APL).

Configuring S7-1500 UDTs in TIA Portal for DBA Ingestion

To enable DBA to automatically parse and instantiate supervisory objects, data in the S7-1500 controller must be organized into standardized structures:

The User-Defined Data Type (UDT) Strategy

  1. UDT Creation: In TIA Portal, create structured data types corresponding to technological objects:
    * Type_Motor: Contains Commands (Start, Stop), Feedback (Run, Tripped), Interlocks, and OperatingHours.
    * Type_Valve: Contains OpenCmd, CloseCmd, FbkOpen, FbkClose, Fault.
    * Type_Analog: Contains ProcessValue (REAL), HighLimit, LowLimit, AlarmState (BYTE).
  2. Global Data Block Instantiation:
    * Create a global data block (e.g., DB_Motors or DB_Valves).
    * Create instances or arrays of the UDT: Agitator_101 : Type_Motor, Pump_102 : Type_Motor.
  3. Data Block Attributes:
    * Ensure that Optimized Block Access is disabled (or configured for standard accessible addressing) so that absolute offsets and standard communication drivers can read variables via S7 protocol or OPC UA.

Step-by-Step Open OS Engineering Workflow in DBA

Follow this engineering sequence to generate WinCC tags and faceplates automatically via DBA:

Step 1: Export S7-1500 Project Data or Establish Online Link

  1. In TIA Portal, compile the S7-1500 PLC project.
  2. Export the tag and DB definitions, or note the TIA Portal project path for direct DBA parsing.

Step 2: Configure the AS Node in Database Automation (DBA)

  1. On the PCS 7 Engineering Station, launch DBA (Start -> Siemens Automation -> PCS 7 Open OS -> Database Automation).
  2. Open or create the DBA project linked to your PCS 7 multiproject.
  3. Under the AS Objects folder, insert a new AS representing the S7-1500:
    * Select the driver type (e.g., SIMATIC S7-1200/1500 Channel or OPC).
    * Enter the controller IP address and rack/slot (Rack 0, Slot 1).

Step 3: Create Type Definitions and Map UDTs

  1. In DBA, navigate to Type Definitions.
  2. Create technological types (e.g., OpenOS_Motor, OpenOS_Valve).
  3. Map the elements of the S7-1500 Type_Motor UDT to the internal Open OS tag attributes (PV, Status, Command, Alarms).
  4. Assign the default WinCC block icon template (e.g., @OpenOS_Motor_Icon.pdl) and faceplate template.

Step 4: Import Instances and Assign Plant Hierarchy

  1. Right-click the AS node in DBA and select Read AS Objects; select the S7-1500 DBs.
  2. In the DBA Plant View, assign the imported motor and valve instances to the appropriate Plant Hierarchy folders corresponding to the physical plant area.

Step 5: Compile OS from DBA

  1. In DBA, click the blue Compile OS button.
  2. DBA automatically connects to the WinCC OS project:
    * Generates WinCC structure tags and raw tag connections.
    * Configures Alarm Logging messages with proper priorities.
    * Places APL-style block icons on the designated WinCC process pictures (.pdl).

Open OS Type Mapping and Architecture Reference Matrix

The following table summarizes the data mapping relationships between TIA Portal S7-1500 structures and PCS 7 Open OS components:

TIA Portal S7-1500 EntityDBA Engineering LayerGenerated WinCC OS EntityOperational FunctionType_Motor (UDT)Type Definition (OpenOS_Motor)WinCC Structure Tag TypeDefines tag layout in WinCC Tag ManagementAgitator_101 (DB Instance)AS Object InstanceWinCC Tag Structure InstanceLive tag connection communicating via S7 channelFault / Alarm Bits in UDTAlarm Mapping in DBAWinCC Alarm Logging MessageEvent-driven alarm appearing in AlarmControlOpenOS Icon AssignmentSymbol Assignment in DBABlock Icon in .pdlGraphical mimic object with status dynamicsOpenOS Faceplate TemplateFaceplate Link in DBA@PG_OpenOS_Motor.pdlStandard operator control and status dialog

Utilizing DBA ensures that changes in TIA Portal can be re-imported and compiled incrementally.

Verification

To verify that the S7-1500 package unit is functioning seamlessly in PCS 7:
1. In WinCC Explorer, open Tag Management; verify that the S7-1500 connection is active and structure tags are populated.
2. Activate WinCC Runtime.
3. Open the process picture containing the generated Open OS block icons.
4. Verify that the motor/valve icon reflects the actual mechanical state of the S7-1500 skid (green for running, grey for stopped).
5. Click the block icon: confirm that the APL-style faceplate opens smoothly.
6. Issue a manual start/stop command from the faceplate; verify in TIA Portal online monitoring that the S7-1500 receives the command bit.
7. Force a trip condition on the S7-1500; verify that a timestamped alarm appears in the WinCC AlarmList.

Limitations and Operational Precautions

  • Native PCS 7 high-resolution time stamping (1 ms SOE) is not supported through Open OS; alarms reflect arrival time at the OS unless specialized time stamping blocks are engineered.
  • Open OS requires dedicated software runtime and engineering licenses; verify requirements in the Siemens catalog and validate final quotation with an authorized distributor.
  • Do not manually rename tags generated by DBA inside WinCC Tag Management; any subsequent DBA compilation will overwrite manual changes.
  • Ensure S7-1500 communication load limits in TIA Portal CPU properties are configured to prevent high-frequency HMI polling from affecting control logic execution.

Engineer FAQ

Can DBA import S7-1500 data blocks directly without manual mapping?

Yes, if data blocks are constructed using structured UDTs, DBA can parse the data block layout and instantiate hundreds of tags and block icons automatically.

Do I need to program faceplates from scratch when using Open OS?

No. PCS 7 Open OS provides a library of pre-engineered, customizable faceplates and block icons that follow the ergonomic standards of the PCS 7 Advanced Process Library.

How does Open OS communicate with the S7-1500?

Communication is typically established using the native WinCC 'SIMATIC S7-1200, S7-1500 Channel' over Industrial Ethernet TCP/IP, or via an OPC UA Server running on the S7-1500.

Technical References

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Related Tags

  • Open_OS
  • S7_1500
  • DBA_Editor
  • Package_Units
  • TIA_Portal
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