C135 PCS 7 (PCS7)
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Implementing Multi-Way and Diverter Valves in PCS 7 APL and Industry Library

Implementing Multi-Way and Diverter Valves in PCS 7 APL and Industry Library

To implement multi-way valves—such as 4-way valves or multi-position diverter valves with four or more discrete positions—in SIMATIC PCS 7, the standard Advanced Process Library (APL) block Vlv2WayL is insufficient because it supports only two active positions and a neutral center. Instead, two primary architectures should be utilized: 1) Deploy the SIMATIC PCS 7 Industry Library (IL) blocks VlvDsL (Double Seat / Mix-Proof Valve for 4-way sanitary routing) or VlvDiv (Diverter Valve supporting up to 8 discrete selectable positions); or 2) In pure APL environments without Industry Library, engineer a composite CFC control module utilizing MotSpdCL or VlvAnL with discrete setpoint mapping, or combine two coordinated VlvL blocks with interlocking supervisory logic.

Table of Contents

Executive Summary

In chemical processing, food and beverage, and pharmaceutical manufacturing, fluid distribution manifolds frequently rely on specialized valving arrangements, including 4-way multi-port distribution valves, mix-proof double-seat valves, and multi-position diverter valves. Automating these devices within SIMATIC PCS 7 requires careful block selection. The standard PCS 7 Advanced Process Library (APL) provides VlvL (2-way Open/Close) and Vlv2WayL (two-directional valve with neutral off), neither of which natively models 4 distinct operating positions. This article evaluates the dedicated blocks provided in the SIMATIC PCS 7 Industry Library (VlvDiv and VlvDsL), details alternative modeling strategies within pure APL, and outlines WinCC faceplate integration.

Architecture and Fundamental Mechanics

Valve Modeling Architectures in PCS 7

+-------------------------------------------------------------------------+
|                    VALVE CONTROL REQUIREMENTS IN PCS 7                  |
+-------------------------------------------------------------------------+
                                    |
         +--------------------------+--------------------------+
         |                                                     |
         v                                                     v
+------------------------------------+           +------------------------+
| OPTION A: PCS 7 Industry Library   |           | OPTION B: Pure APL     |
| (Dedicated Multi-Port Blocks)      |           | (Composite Engineering)|
|                                    |           |                        |
| 1. VlvDiv (Diverter Valve):        |           | 1. Cascaded VlvL Pair: |
|    - Up to 8 Discrete Positions    |           |    - Master/Slave      |
|    - Multi-Channel Feedbacks       |           |    - Mutual Interlocks |
|    - Native Multi-Way Faceplate    |           |                        |
|                                    |           | 2. VlvAnL / MotSpdCL:  |
| 2. VlvDsL (Double Seat Valve):     |           |    - Analog Setpoints  |
|    - Mix-proof sanitary routing    |           |    - Pos 1 = 0%        |
|    - Seat lifting (Top/Bottom)     |           |    - Pos 2 = 33%       |
|    - CIP flush cycle support       |           |    - Pos 3 = 66%       |
+------------------------------------+           |    - Pos 4 = 100%      |
                                                 +------------------------+
                                                             |
                                                             v
+-------------------------------------------------------------------------+
|                     SIMATIC WinCC OS Operator Faceplate                 |
|                                                                         |
|   - Discrete Selection Buttons for Positions 1, 2, 3, 4, and Closed     |
|   - Position Transition Feedback Monitoring with Configurable Timers    |
|   - Interlock Integration (Permit, Interlock, Protect)                  |
+-------------------------------------------------------------------------+

Functional Capabilities of Industry Library Blocks

  1. VlvDiv (Diverter Valve):
    - Designed specifically for multi-port distribution valves.
    - Supports up to 8 discrete valve positions (e.g., Port A to B, Port A to C, Port A to D, All Closed).
    - Features dedicated digital outputs for each position actuator and evaluates individual feedback inputs with transit-time monitoring (MonTiDynamic).
    - Provides standard APL-compliant faceplates with multi-position selection buttons and interlock status.
  2. VlvDsL (Double-Seat Mix-Proof Valve):
    - Tailored for 4-way sanitary routing valves where two independent valve plugs seal against a common chamber.
    - Controls main open/close movement while independently commanding upper and lower seat-lifting actuators (SeatTop, SeatBottom) during CIP (Cleaning in Place) routines.
    - Prevents cross-contamination between incompatible product streams.

Step-by-Step Implementation Procedure

Approach A: Deploying Industry Library VlvDiv for Multi-Position Valves

  1. Ensure the SIMATIC PCS 7 Industry Library is installed on the Engineering Station and the library blocks are copied into the Master Data Library.
  2. Open the CFC chart for the valve manifold.
  3. Drag the block VlvDiv (FB1164) from the Industry Library into the chart.
  4. Parameterize the operating positions:
    - Configure input NumPos to the required number of positions (e.g., 4).
    - Interconnect digital output commands (Pos1Out, Pos2Out, Pos3Out, Pos4Out) to output driver blocks (Pcs7DiOu).
    - Interconnect position feedback limit switches (Pos1Fbk, Pos2Fbk, etc.) from input drivers (Pcs7DiIn).
  5. Configure transit monitoring times (MonTiDynamic) to detect stuck valve faults if feedback is not received within the specified window.
  6. Connect safety interlocks to pins Permit, Intlock, and Protect.

Approach B: Engineering a 4-Position Valve in Pure APL using VlvAnL

  1. If the plant does not license the Industry Library, use the APL analog valve block VlvAnL.
  2. In CFC, configure VlvAnL to control a motorized or pneumatic multi-port actuator via an analog positioning signal or segmented discrete decoder.
  3. Map discrete operating positions to percentage setpoints:
    - Closed / Off = 0.0%
    - Position 1 = 25.0%
    - Position 2 = 50.0%
    - Position 3 = 75.0%
    - Position 4 = 100.0%
  4. Use an SCL helper block or standard comparator logic to verify actual analog position feedback (MV) against the commanded target within an acceptable tolerance band (PosTol).

Step C: WinCC OS Compilation and Faceplate Deployment

  1. Perform an AS-OS Compilation from SIMATIC Manager.
  2. If using Industry Library, verify that the OS Project Editor integrates the Industry Library screen templates (@PG_VlvDiv.pdl, @PL_VlvDiv.pdl).
  3. Generate block icons in the plant hierarchy picture via Create/Update Block Icons.
  4. Open WinCC Runtime and verify the faceplate controls.

Verification

  1. Manual Position Command Test: In WinCC Runtime, open the VlvDiv faceplate. Switch the valve to Manual mode and command Position 1, Position 2, Position 3, and Closed sequentially. Confirm that corresponding PLC outputs energize.
  2. Transit Monitoring Alarm Test: Command a position change while forcing the feedback switch to remain open. Verify that after MonTiDynamic expires, the valve generates a 'Feedback Error' alarm and returns to a safe position if configured.
  3. Interlock Trip Verification: Activate an interlock condition (Intlock = 0). Verify that the valve immediately closes all ports and disables manual operator selection.

Limitations and Operational Precautions

  1. Industry Library Licensing: Deploying VlvDiv or VlvDsL requires purchasing the SIMATIC PCS 7 Industry Library engineering and runtime licenses. Always validate package part numbers with an authorized Siemens distributor or the Siemens Industry Mall.
  2. APL Vlv2WayL Constraints: Standard Vlv2WayL cannot be extended beyond 3 states (Pos 1, Neutral, Pos 2). Do not attempt to modify standard APL internal protected code to add extra positions.

Engineer FAQ

Why is Vlv2WayL unsuitable for a 4-way valve?

Vlv2WayL models only two operating states plus neutral center; it lacks logic and faceplate controls for four independent flow paths.

What Industry Library block supports up to 8 positions?

The block VlvDiv (FB1164) supports up to 8 configurable discrete valve positions with independent feedback monitoring.

What is a double-seat mix-proof valve?

A sanitary valve featuring two independent plugs that prevent mixing of incompatible fluids, automated in PCS 7 using the VlvDsL block.

Can I control a 4-way valve using pure APL without Industry Library?

Yes, by using VlvAnL with analog setpoint mapping or by combining two coordinated VlvL blocks with interlocking supervisory logic.

Does VlvDiv provide standard APL look-and-feel?

Yes. Industry Library blocks are developed in full alignment with the APL design style guide, faceplate structure, and alarm paradigms.

How are transit times monitored in VlvDiv?

The parameter MonTiDynamic defines the maximum time allowed for position feedback confirmation before triggering an error alarm.

Can VlvDiv be switched between Automatic and Manual mode?

Yes, it supports standard APL mode switching: Auto, Manual, Out of Service, and Local mode.

What happens if multiple position feedbacks become active simultaneously?

VlvDiv evaluates plausibility logic; if contradictory feedback signals occur, it generates an invalid position fault.

Is the Industry Library compatible with PCS 7 V9.0 and V9.1?

Yes, dedicated Industry Library versions (e.g., IL V9.0 and IL V9.1) are available for each corresponding PCS 7 release.

Can I control seat lifting during cleaning with VlvDsL?

Yes, VlvDsL includes dedicated command inputs and timers for upper and lower seat lift during Clean-in-Place (CIP) sequences.

Technical References

Related Articles

Related Tags

  • Industry Library
  • VlvDiv
  • VlvDsL
  • Vlv2WayL
  • Multi-Way Valve
  • Diverter Valve
  • APL
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