C135 PCS 7 (PCS7)
6C
6 Cielo Ciencia y Tecnología
·Publicada en C135 PCS 7 (PCS7)

Monitoring and Displaying Currently Simulated Process Devices on WinCC HMI in PCS 7

Monitoring and Displaying Currently Simulated Process Devices on WinCC HMI in PCS 7

To display a real-time list of all process devices currently operating in simulation mode on a WinCC HMI in SIMATIC PCS 7, the method depends on your software release. In PCS 7 V8.2 and later, use the native PCS 7 Tag Browser (@pcs7tagbrowser.pdl): open the tag browser in runtime, click the yellow hand icon, and select the target plant area to display a live list of simulated blocks. In PCS 7 V8.1 and earlier where this filter is absent, implement one of two engineering solutions: (1) In WinCC AlarmControl, configure a dedicated alarm view filtered to the 'Simulation' message class (which displays currently active, unacknowledged simulation states rather than historical logs); or (2) In CFC, interconnect the SimAct outputs of all channel drivers into an OR collector or SCL summary block bound to an HMI diagnostic table.

Table of Contents

Executive Summary

During plant commissioning, maintenance overrides, or instrument calibration in SIMATIC PCS 7, operators and instrument technicians frequently place analog transmitters (Pcs7AnIn) and digital sensors (Pcs7DiIn) into 'Simulation Mode' via WinCC faceplates or CFC test parameters. Leaving field instruments in simulation mode during normal production poses severe operational risks, as the control system ceases responding to physical process limits. While the WinCC Alarm Logging operation list records the historical event when simulation was toggled, operators need an instantaneous, live dashboard displaying only devices currently in simulation. Because the integrated 'yellow hand' filter in @pcs7tagbrowser.pdl was only introduced in PCS 7 V8.2, facilities running PCS 7 V8.1 require alternative alarm-filtering or logic-based monitoring strategies.

Architecture and Fundamental Mechanics

The simulation state architecture in the PCS 7 Advanced Process Library operates across both AS and OS domains:

  1. APL Simulation Signals in the Controller: Every APL block with simulation capability (Pcs7AnIn, Pcs7DiIn, MonAnL, MotL, VlvL) maintains dedicated internal state parameters:
    - SimOn: Command input to activate simulation mode.
    - SimAct: Output status indicating whether simulation is actively driving the block output (SimAct.Value = 1).
    - Status1: Status word containing a dedicated simulation flag (typically Bit 1). When active, the block propagates quality code 16#60 (Simulated value) and renders a yellow hand icon on its WinCC block icon and faceplate.

  2. The PCS 7 Tag Browser Evolution (V8.1 vs. V8.2+):
    - In PCS 7 V8.2 and V9.0, Siemens enhanced the standard Tag Browser (@pcs7tagbrowser.pdl, accessible via button 12 on the standard button bar). The browser incorporates an automated SQL filter represented by a yellow hand icon. Clicking this button executes a real-time query across all active block tags, filtering for SimAct == 1 and presenting a live equipment table.
    - In PCS 7 V8.1, the Tag Browser lacks this integrated simulation filter icon, restricting operators to manual tag searching.

  3. Alarm-Based Real-Time Simulation Tracking: When an operator activates simulation on an APL block, the block triggers a system alarm assigned to the predefined message class Simulation (or 'Process Control Message - Simulation'). The message remains in the active message list until simulation is turned off. Unlike the historical 'Operation List', the Active Alarm List reflects only currently persisting simulation states.

Step-by-Step Implementation Procedure

Implement real-time simulation monitoring according to your installed PCS 7 version:

Method 1: Native Tag Browser Filtering (PCS 7 V8.2 and V9.x)

  1. In WinCC OS Runtime, click the Tag Browser button on the bottom navigation bar (@button12.pdl).
  2. In the @pcs7tagbrowser.pdl window, locate the toolbar icons.
  3. Click the Yellow Hand button (Filter for Simulated Tags).
  4. Select the target Plant Hierarchy folder (or select root to view the entire plant).
  5. The browser displays a live grid of all tags currently in simulation mode, allowing direct faceplate navigation.

Method 2: WinCC Active AlarmControl Filtering (PCS 7 V8.1 Workaround)

  1. In Graphics Designer, open a maintenance overview screen or save a copy of @alarm.pdl as Simulated_Devices.pdl.
  2. Double-click the WinCC AlarmControl object to open its Properties.
  3. Select the Message Blocks tab -> ensure Process Value, Tag Name, and Message Text are enabled.
  4. Select the Message Lists tab -> configure the view to display Active Alarms (incoming alarms that have not gone out).
  5. Select the Fixed Selection or Filter tab:
    - Set criterion: Message Class == 'Simulation' (or Message Type corresponding to APL simulation events).
  6. Save the PDL and configure a navigation button on the operator console.
  7. In runtime, this screen acts as a live, dynamic dashboard: devices enter the list when simulation starts and automatically disappear the moment simulation is disabled.

Method 3: Central SCL Summary Collector in CFC

  1. In SCL, create a lightweight function block that reads the .SimAct.Value bits of all critical plant instruments.
  2. If any bit is TRUE, assert a global binary tag Plant_Simulation_Active to illuminate a flashing warning beacon on the WinCC header.

Verification

Verify real-time simulation tracking and clearing:

  1. Simulation Initiation: Open the faceplate of a flow transmitter (Pcs7AnIn). Navigate to the Simulation view. Activate simulation and enter a test value (e.g., 50.0 m³/h).

  2. HMI List Verification: Open the simulation monitoring display (or Tag Browser in V8.2+). Confirm that the flow transmitter instantly appears in the list with a yellow hand icon.

  3. Simulation Deactivation Check: Return to the faceplate and turn simulation off. Confirm that the device immediately disappears from the active list in real time without requiring manual screen refreshes.

Limitations and Operational Precautions

Do not rely solely on the Alarm Logging historical operation list to track simulation overrides; the operation list is a static chronological audit trail and does not indicate whether a device is currently simulated. Furthermore, ensure that the 'Simulation' message class in WinCC Alarm Logging is set to 'Without acknowledgment' so that clearing simulation mode removes the entry from active alarm lists immediately.

Engineer FAQ

Why is the yellow hand simulation filter missing in my Tag Browser?

The yellow hand simulation filter was introduced in PCS 7 V8.2. In PCS 7 V8.1 and earlier, the @pcs7tagbrowser.pdl file does not include this automated filter.

Can I copy the @pcs7tagbrowser.pdl from PCS 7 V8.2 into a V8.1 project?

This is not officially supported and can cause script errors due to differences in underlying Split Screen Manager C-script libraries.

What quality code is sent when an APL block is simulated?

APL blocks output signal status 16#60, which represents 'Simulation value' in the NAMUR NE107 / IEC 61158 standard.

Does putting a channel driver into simulation mode stop physical I/O reading?

Yes. When SimOn = 1, the block decouples its output from the peripheral input address (PIW) and substitutes the manual simulation setpoint.

Can operators be prevented from putting devices into simulation mode?

Yes. In WinCC User Administrator, simulation controls require higher authorization (Level 6 'Higher process controlling' or Level 7).

Technical References

Related Articles

Related Tags

  • Simulation Mode
  • Tag Browser
  • WinCC AlarmControl
  • SimAct
  • Pcs7AnIn
  • PCS 7 V8.1
20 respuestas