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Resolving Connection Failures Between SIMATIC Route Control Server and SIMIT Virtual Controller

Resolving Connection Failures Between SIMATIC Route Control Server and SIMIT Virtual Controller

When SIMATIC Route Control (RC) Server V9.0 fails to connect to a SIMIT V10 Virtual Controller (VC), the fault typically originates from communication stack restrictions on single-PC simulation hosts or operating under unlicensed SIMIT Demo mode. SIMIT Demo mode restricts VC communication and signal capacity, preventing the S7 Named Connections required by Route Control. On single-PC testbeds, create a SoftPlc7.ini file in the SIMIT project directory (.../io/VCROOT/VC1/SoftPlc7.ini) containing AllowFullQualifiedConnection.bool.TPKT=false to unblock local TPKT loopback, re-export the NetPro configuration from STEP 7 into SIMIT, and ensure a full SIMIT Virtual Controller license is activated in Automation License Manager. Validate all licenses via an authorized Siemens distributor or the Siemens Industry Mall.

Table of Contents

Executive Summary

Virtual commissioning of material transport systems pairing SIMATIC Route Control (RC) V9.0 with SIMIT V10 enables engineers to validate complex piping routes, valve sequences, pump interlocks, and element state logic without physical automation hardware. However, commissioning engineers frequently encounter an issue where the Route Control Server remains offline with respect to the simulated controller, showing disconnected status in Route Control Center. This disconnect stems from two primary technical causes: the rigid functional constraints of SIMIT Demo mode, which disables unrestricted S7 Named Connections and limits signal counts, and local transport restrictions (TPKT loopback) when both Route Control Server and the SIMIT Virtual Controller run concurrently on the same Windows operating system.

Architecture and Fundamental Mechanics

The architecture connecting SIMATIC Route Control Server to an S7 controller relies on high-integrity S7 communication:

1. Route Control S7 Named Connection Architecture

Unlike simple I/O polling, Route Control utilizes dedicated S7 Named Connections created by the Route Control Wizard in NetPro. The Route Control Server reads routing tables, element states, and commands execution blocks (RC_IF_CFG, RC_ROUTE) in the AS using high-speed S7 protocol blocks. In a physical plant, this communication traverses the Industrial Ethernet plant bus via CP1623 or standard network adapters.

2. SIMIT Virtual Controller Emulation Mechanics

The SIMIT Virtual Controller (VC) emulates an S7-400 or CPU 410-5H within Windows memory. When RC Server and SIMIT VC reside on the same PC:
- The Windows TCP/IP stack enforces RFC 1006 (ISO-on-TCP / TPKT) port 102 exclusivity. The local SIMATIC NET communications manager and the Virtual Controller compete for loopback endpoints.
- By default, the VC rejects fully qualified connection strings over local loopback interfaces. Inserting SoftPlc7.ini with AllowFullQualifiedConnection.bool.TPKT=false forces the Virtual Controller to accept local TPKT connection handshakes.

3. SIMIT Demo Mode Boundary

SIMIT Demo mode imposes a hard cap of 30 signals and strictly disallows full Virtual Controller network coupling. In demo mode, the VC will either drop connection requests after initialization or fail to register the S7 Named Connection endpoints, leaving Route Control Server unable to bind to the simulated AS.

Step-by-Step Implementation Procedure

To successfully connect Route Control Server to a SIMIT Virtual Controller on an engineering testbed:

Step 1: Verify SIMIT Licensing in Automation License Manager

  1. Open Automation License Manager (ALM) on the simulation workstation.
  2. Confirm that a valid runtime license exists for SIMIT Virtual Controller (e.g., SIMIT VC 1 or SIMIT Engineering).
  3. If operating in Demo mode, transfer a full license; Route Control S7 Named Connections cannot operate reliably under Demo mode restrictions.

Step 2: Configure SoftPlc7.ini for Local TPKT Connections

  1. Close SIMIT and terminate all running Virtual Controllers.
  2. Navigate to your SIMIT project directory in Windows Explorer: <Project_Dir>\io\VCROOT\VC1\ (or the corresponding VC number).
  3. Create a new text file named SoftPlc7.ini (ensure no hidden .txt extension).
  4. Add the following configuration line:
    ini AllowFullQualifiedConnection.bool.TPKT=false
  5. Save the file and restart SIMIT.

Step 3: Re-export Hardware and NetPro Configuration from STEP 7

  1. Open SIMATIC Manager on the Engineering Station.
  2. Run the Route Control Wizard (Options -> SIMATIC Route Control -> Wizard) to ensure all S7 connections are generated in NetPro.
  3. In NetPro, execute Save and Compile.
  4. Export the station hardware and connection configuration using the SIMIT VC Export Tool or re-import the .s7p project directly in SIMIT.
  5. In SIMIT, verify that the Virtual Controller station matches the AS name and IP address configured in NetPro.

Step 4: Synchronized Startup Sequence

  1. In SIMIT, start the simulation model (Simulation -> Start). Confirm the Virtual Controller transitions to RUN mode (green LED).
  2. In SIMATIC Manager, perform a full download of the AS program (HW Config, NetPro, and CFC charts) to the Virtual Controller.
  3. Open the Route Control engineering tool, compile Route Control, and activate the RC Server.
  4. Launch Route Control Center (RCC) and verify connection status.

Verification

To verify active Route Control communication:

  1. Route Control Center Inspection:
    - Open Route Control Center on the OS station.
    - In the Server view, confirm that the connection status to the AS reads Connected / Operational (green indicator).

  2. Route Request Test:
    - Request a test route between a source tank and a destination vessel.
    - Verify that Route Control successfully reads element states (valves, pumps) from the Virtual Controller and commands route alignment.

  3. Diagnostic Logging:
    - Inspect C:\Program Files (x86)\Siemens\Route Control\Diagnose\ for connection logs, confirming zero S7 communication timeout errors.

Limitations and Operational Precautions

Operational limitations and precautions:

  1. Single-PC Memory Overhead: Running Route Control Server, WinCC OS Runtime, and SIMIT Virtual Controller concurrently on a single workstation requires substantial RAM (minimum 32 GB) to prevent CPU thread starvation.
  2. Real-Time Timing Discrepancies: The SIMIT Virtual Controller runs on Windows standard kernel time-slicing. Complex routes with dozens of sequential element checks may exhibit slight timing variances compared to physical S7-410 hardware.
  3. Firewall Blocking: Ensure Windows Firewall permits TCP traffic on port 102 for both inbound and outbound loopback traffic.
  4. Commercial Disclaimer: Verify all software licenses, SIMIT VC packages, and Route Control options with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Can Route Control Server connect to SIMIT Virtual Controller in Demo mode?

No. SIMIT Demo mode imposes a 30-signal maximum and restricts advanced network coupling stacks, preventing the establishment of S7 Named Connections required by Route Control.

What is the purpose of the SoftPlc7.ini parameter?

The parameter AllowFullQualifiedConnection.bool.TPKT=false permits local S7 ISO-on-TCP (TPKT) connection binding when Route Control and SIMIT VC run on the same physical PC.

Why must NetPro be compiled before exporting to SIMIT?

Route Control creates dedicated S7 communication connections in NetPro. If NetPro is not compiled, SIMIT will not import the necessary communication endpoints.

Does Route Control support redundant Virtual Controllers in SIMIT?

Yes, SIMIT Virtual Controller supports S7-400H / CPU 410-5H redundancy, but this requires an appropriate multi-controller SIMIT license.

Which port does Route Control use to communicate with the Virtual Controller?

It uses standard Siemens S7 communication over ISO-on-TCP via TCP port 102 (RFC 1006).

Technical References

Related Articles

Related Tags

  • Route Control
  • SIMIT V10
  • Virtual Controller
  • S7 Communication
  • Simulation
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