Migrating Virtual Commissioning Models and Virtual Controller Workflows to SIMIT V10.2

Upgrading process simulation models from SIMIT V9.x or V10.1 to SIMIT V10.2 requires updating Virtual Controller (VC) instances, synchronizing Component Type Editor (CTE) libraries, and adapting hardware coupling parameters. SIMIT V10.2 introduces native compatibility with PCS 7 V9.0 SP3, STEP 7 V5.6 SP2, and S7-PLCSIM Advanced V3.0. To execute migration, open the legacy project in SIMIT V10.2, approve automated database conversion, update all Virtual Controller instances to runtime version V10.2 via the Coupling Editor, recompile custom CTE components, and re-import PCS 7 hardware configurations. When operating without active Automation License Manager licenses, SIMIT runs in Demo Mode with a 45-minute execution limit and disabled saving. Validate all virtual commissioning licensing tiers with an authorized Siemens distributor or the Siemens Industry Mall.

Executive Summary

As process plants modernize engineering baselines to SIMATIC PCS 7 V9.0 SP3, simulation models used for operator training systems (OTS) and virtual commissioning must be upgraded to SIMIT V10.2. Migrating legacy SIMIT models involves more than simple file conversion: Virtual Controller communication endpoints, component type libraries, and timing synchronization parameters must be updated to align with modern controller firmware. This guide outlines the systematic migration workflow, database adaptation, Virtual Controller reconfiguration, and verification steps necessary to ensure seamless simulation continuity in SIMIT V10.2.

Architecture and Fundamental Mechanics

The migration architecture across SIMIT versions encompasses three distinct simulation layers:
1. Project Database and Model Schematics:
- SIMIT V10.2 updates the underlying XML-based project schema.
- Diagrams created in SIMIT V9.x/V10.1 containing standard library components (flanges, pipes, valves, drives) are automatically mapped to V10.2 component definitions.
- Custom components created via Component Type Editor (CTE) require re-compilation to ensure bytecode compatibility with the V10.2 64-bit simulation kernel.
2. SIMIT Virtual Controller (VC) Architecture:
- SIMIT VC emulates S7-400 and CPU 410-5H processors. SIMIT V10.2 updates the VC core to support CPU 410-5H Firmware V8.2.
- Upgrading a project does not automatically change the VC runtime binary; the coupling must be explicitly re-initialized to link with the V10.2 Virtual Controller services.
3. Co-Simulation Interfaces and Time Synchronization:
- SIMIT V10.2 introduces optimized communication drivers for S7-PLCSIM Advanced V3.0 and enhanced OPC UA binary encoders.
- Timing parameters (Time Slice, Macro Step, and Virtual Time Factor) must be reviewed to prevent buffer overflows or communication drops between the simulation kernel and external clients.

Step-by-Step Implementation Procedure

Create Archive of Legacy SIMIT Project:
a. In legacy SIMIT (V9.x or V10.1), open the simulation project.
b. Select Project -> Retrieve / Archive -> Archive to generate a compressed .simit archive.
c. Store the archive in a safe engineering backup location.
Open and Convert Project in SIMIT V10.2:
a. Launch SIMIT V10.2 on the engineering PC.
b. Select Project -> Open and browse to the legacy project or retrieve the .simit archive.
c. When prompted with 'The project was created with an older version. Do you want to convert it?', click 'Yes'.
d. Allow SIMIT to convert project tables and schematic diagrams.
Update SIMIT Virtual Controller Couplings:
a. In Project Navigation, expand 'Couplings' and double-click the existing Virtual Controller coupling.
b. In the coupling configuration tab, verify that controller types (e.g., AS 410-5H) are mapped to VC V10.2.
c. Re-import the hardware configuration from the migrated PCS 7 V9.0 SP3 project (export station data via SIMATIC Manager Options -> Export CAx Data or direct symbol table import).
d. Confirm that memory addresses and communication interfaces match the new hardware baseline.
Recompile Custom Component Type Editor (CTE) Libraries:
a. If custom user components were developed in CTE, open the CTE workspace.
b. Open each custom component library and select Build -> Recompile All.
c. Export the updated library and replace the old library reference in SIMIT V10.2 Task Cards -> Components -> User Components.
Validate Time Synchronization and Run Simulation:
a. In the SIMIT toolbar, open 'Simulation Settings'.
b. Set the base simulation cycle time (typically 100 ms matching OB32/OB35 execution in the AS).
c. Start the simulation by clicking 'Play'.
d. Monitor the Virtual Controller diagnostic window to ensure all VC instances achieve RUN mode without synchronization faults.

Verification

In SIMIT V10.2, open the Virtual Controller coupling: verify that all configured AS stations report 'Connected' and 'RUN'.
In PCS 7 OS runtime or WinCC simulation: actuate a valve or start a motor, and confirm that SIMIT dynamic feedback (e.g., limit switch closures, speed feedback) reflects accurately on WinCC faceplates.
Verify continuous execution for over 60 minutes in licensed mode without runtime stoppage or communication latency warnings.

Limitations and Operational Precautions

Directly running SIMIT V10.2 without Automation License Manager keys restricts operation to Demo Mode (45-minute runtime limit and disabled project saving). Custom DLL couplings developed for 32-bit SIMIT V8/V9 must be recompiled for 64-bit architecture.

Engineer FAQ

Can SIMIT V10.2 open projects created in SIMIT V9.0 or V10.0?

Yes. SIMIT V10.2 includes an automated project conversion utility that migrates project schemas from V9.x and V10.x.

Do SIMIT Virtual Controller couplings need manual updating after migration?

Yes. The coupling configuration must be opened to update the VC runtime version and re-verify I/O signal mappings.

What happens to custom CTE components during migration?

Custom components created in the Component Type Editor must be recompiled in the V10.2 CTE to ensure compatibility with the updated 64-bit simulation engine.