Managing Equipment Module Types (EMT) and Control Module Types (CMT) in SIMATIC PCS 7 - Evolution to Plant Automation Accelerator

Managing Equipment Module Types (EMT) and Control Module Types (CMT) in SIMATIC PCS 7 - Evolution to Plant Automation Accelerator

In SIMATIC PCS 7, managing modular technological templates above the individual Control Module Type (CMT) level can be achieved through Equipment Module Types (EMT) or Models and Replicas. While legacy engineering relied on the Import/Export Assistant (IEA) and Process Tag Types (PTT), Siemens evolved bulk technological engineering through Advanced ES (discontinued after v8.0 SP2) into SIMATIC PCS 7 Plant Automation Accelerator (PAA). In native PCS 7 v8.1 and v8.2, engineers can collect multiple CMTs into hierarchy folders to represent Equipment Modules, or use Models/Replicas for unit-level instantiation. However, centralized bidirectional type-instance synchronization for entire multi-CMT Equipment Modules across plant designs is officially realized through Plant Automation Accelerator (PAA).

Table of Contents

• ISA-88 Technological Hierarchy: CMT vs EMT vs Models
• Evolution of Siemens Bulk Engineering Tools: IEA, Advanced ES, and PAA
• Managing Equipment Modules in Native PCS 7 (Folders vs Models/Replicas)
• Plant Automation Accelerator (PAA) Integration Architecture
• Comparative Matrix: Technological Template Management in PCS 7
• Step-by-Step Procedure: Creating and Updating Models in PCS 7
• Verification
• Limitations and Operational Precautions
• Engineer FAQ
• Technical References
• Related Articles
• Related Tags

ISA-88 Technological Hierarchy: CMT vs EMT vs Models

In modern process automation adhering to ISA-88 standards, physical plant assets and control logic are organized into strict hierarchical levels:
- Control Module (CM): The lowest technological control entity performing a specific actuation or sensing task (e.g., an automated block valve, a single-speed motor, or an analog temperature loop). In PCS 7, this is defined as a Control Module Type (CMT) in the Master Data Library.
- Equipment Module (EM): A functional grouping of several Control Modules coordinated to perform a finite processing action (e.g., a Tank Dosing subsystem consisting of a feed valve, a metering pump, and a flow meter).
- Unit: A complete processing vessel or equipment cluster operating one batch at a time (e.g., a Reactor or Mixing Tank).

While PCS 7 natively provides the CMT concept for single charts, engineers frequently seek a mechanism to bundle multiple CMTs into an Equipment Module Type (EMT) that can be instantiated and synchronized across dozens of identical production skids.

Evolution of Siemens Bulk Engineering Tools: IEA, Advanced ES, and PAA

To understand how Siemens addresses bulk template management, consider the software lifecycle:

1. Import/Export Assistant (IEA) & Process Tag Types (PTT):
   - The classic PCS 7 v6/v7 method. Relied on exporting tag parameters to text/Excel files.
   - Limitation: Clumsy re-import routines; modifying a template required regenerating and re-importing the entire project.
2. Advanced Engineering System (Advanced ES):
   - Introduced in PCS 7 v8.0 to support CMT bulk engineering based on COMOS technology.
   - Status: Discontinued after v8.0 SP2; excluded from newer installation media due to architectural limitations.
3. Automation Base:
   - An interim concept planned around 2015/2016 to bridge Advanced ES.
   - Status: Never officially released as a standalone product.
4. SIMATIC PCS 7 Plant Automation Accelerator (PAA):
   - The current flagship Siemens software for integrated electrical, instrumentation, and control engineering.
   - Built on the COMOS software engine, PAA delivers full bidirectional type-instance synchronization for both CMTs and EMTs, automating hardware configuration and CFC chart generation directly into PCS 7.

Managing Equipment Modules in Native PCS 7 (Folders vs Models/Replicas)

Within native PCS 7 without PAA, two primary workflows exist for managing multi-CMT equipment modules:

Approach A: Technological Hierarchy Folders with CMT Instances

• Create a hierarchy folder in the project (e.g., EM_Supply).
• Instantiate the required CMTs into this folder (e.g., Vlv_Feed, Mot_Pump, FQI_Meter).
• Synchronization: Each individual CMT remains linked to its Master Data Library type. If the motor CMT changes, it synchronizes across all pumps. However, the folder structure and inter-chart wiring between the valve and pump must be managed manually.

Approach B: Models and Replicas

• In SIMATIC Manager, assemble the entire equipment module (charts, pictures, and parameters) inside a hierarchy folder in the library.
• Select menu Options > Models > Create/Modify Model to declare the folder as a Model.
• Instantiate the Model into the plant hierarchy as a Replica.
• Synchronization: Replicas remain connected to the Model, but changes to block names or structural rewiring inside the model cannot be automatically propagated to existing replicas.

Plant Automation Accelerator (PAA) Integration Architecture

For enterprise plants requiring true object-oriented Equipment Module Types:
- PAA serves as the centralized digital twin database.
- Engineers define Equipment Module Types (EMT) in PAA containing multiple CMTs, interlocks, and I/O assignments.
- PAA synchronizes directly with the PCS 7 Master Data Library via CAEx / XML interfaces.
- When an EMT is updated in PAA, a single click synchronizes all instantiated equipment modules, updating hardware addresses, CFC charts, and WinCC picture hierarchies automatically.

Comparative Matrix: Technological Template Management in PCS 7

The table below compares the mechanisms for managing modular technological templates:

Step-by-Step Procedure: Creating and Updating Models in PCS 7

To utilize native Models and Replicas for Equipment Modules in PCS 7:

Step 1: Create the Model in the Master Data Library

1. In the Master Data Library Plant View, create a hierarchy folder named Model_PumpSkid.
2. Insert the required CFC charts (e.g., pump motor, suction valve, discharge pressure transmitter).
3. Connect technological interlocks and signals between the charts.
4. Select the folder Model_PumpSkid, click Options > Models > Create/Modify Model.
5. Assign a model name and click OK.

Step 2: Instantiate Replicas in the Plant

1. In the plant project Plant View, navigate to the target unit folder.
2. Drag and drop the Model_PumpSkid from the library into the target plant folder.
3. In the dialog, select Create Replica.
4. Rename the replica instance (e.g., Skid_Tank101).

Step 3: Propagate Parameter Modifications

1. To modify parameters across all instances, update the Model in the library.
2. In SIMATIC Manager, select Options > Models > Synchronize Replicas....
3. Select the target replicas and execute synchronization to update modified parameters.

Verification

To confirm that technological templates are operating correctly:
1. Type-Instance Synchronization Audit: In SIMATIC Manager, select the CMT catalog and click Plant Types > Synchronize...; verify that all instances report status Synchronized.
2. Model Consistency Check: Run Options > Models > Check Consistency; verify that all replica folders maintain valid links to the library model.
3. CFC Runtime Sequence: Open instantiated replica charts; confirm that block execution sequences in OB35 are organized logically without missing runtime groups.

Limitations and Operational Precautions

Engineering teams must observe the following constraints:
- Native PCS 7 Models cannot synchronize structural block renaming or block deletions into existing replicas; structural alterations require re-instantiating the replica.
- Advanced ES is not supported on PCS 7 v8.2 and newer without specific hotfixes and is commercially obsolete; do not specify Advanced ES for new projects.
- Always validate final license quantities and MLFBs against the applicable Siemens catalog and authorized distributor quotation when ordering Plant Automation Accelerator (PAA) software.

Engineer FAQ

Is Plant Automation Accelerator (PAA) free software?

No. PAA is a licensed commercial engineering software suite built upon the Siemens COMOS platform, requiring dedicated engineering and database licenses.

Can I convert legacy Process Tag Types (PTT) into Control Module Types (CMT)?

Yes. SIMATIC PCS 7 provides a built-in migration utility in the Master Data Library: right-click the PTT chart and select 'Plant Types > Convert Process Tag Type to Control Module Type'.

Can a single CMT contain multiple equipment phases?

No. A CMT represents a single Control Module (e.g., motor or valve). Equipment Phases (EPH) that coordinate multiple control modules are authored using SFC Types.

Technical References

• SIMATIC PCS 7 Plant Automation Accelerator Engineering Manual (A5E38517205)
• SIMATIC PCS 7 Control Module Type (CMT) Engineering Manual (A5E36987332)
• SIMATIC PCS 7 Advanced Engineering System (Advanced ES) User Guide (A5E02779836)

Related Articles

• Documenting Technological I-O Variant Interconnections in SIMATIC PCS 7 Control Module Types
• Configuring SCL Attributes and WinCC Block Icons for Custom Technological Blocks
• Managing Recipe Operation Status Changes and Continuous Phase Transitions During SIMATIC BATCH Upgrades

Related Tags

• Control Module Type
• Equipment Module Type
• Plant Automation Accelerator
• PAA
• Models and Replicas