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

Understanding APL Compatibility with TIA Portal and Integrating S7-1500 Package Units into PCS 7

Understanding APL Compatibility with TIA Portal and Integrating S7-1500 Package Units into PCS 7

The SIMATIC PCS 7 Advanced Process Library (APL) is an S7-400 and CPU 410-5H specific block library and is not compatible with TIA Portal or SIMATIC S7-1500 controllers. APL algorithms rely on S7-400 system functions (such as Alarm_8P and cyclic interrupt OBs) that do not exist in the S7-1500 architecture. To integrate S7-1500 package units into a PCS 7 plant with consistent operator visualization, engineers must use SIMATIC PCS 7 Open OS (via Database Automation / DBA) or the SIMATIC PCS 7 Industry Library (IL), which provides dedicated TIA Portal blocks with matching APL-style faceplates and block icons.

Table of Contents

Architectural Incompatibility Between APL and TIA Portal

A frequent architectural inquiry in modern process automation projects involves integrating OEM package units (e.g., packaged compressor skids, chillers, centrifuges, or water treatment skids) controlled by SIMATIC S7-1500 PLCs into an existing SIMATIC PCS 7 distributed control system.

Engineers often ask: 'Can we directly copy the APL standard library (e.g., MotL, VlvL, PIDConL) into TIA Portal to program the S7-1500 and compile faceplates into WinCC?'

Technical Reasons Why Native APL Cannot Run on S7-1500

  1. Target Architecture Separation: The PCS 7 Advanced Process Library (APL) is engineered exclusively for SIMATIC S7-400 and CPU 410-5H controllers programmed via CFC in Step 7 V5.x.
  2. System Function Dependency: APL blocks rely on low-level S7-400 system attributes and system function blocks (such as SFB35 ALARM_8P for event-driven message dispatch, S7_m_c metadata attributes, and specific organization blocks OB30 to OB38). These mechanisms do not exist in S7-1500 firmware or TIA Portal.
  3. OS Compiler Coupling: The PCS 7 OS Compiler is designed to parse S7-400 technological hierarchy databases. It cannot directly compile TIA Portal S7-1500 project files.

Strategies for Integrating S7-1500 Package Units into PCS 7

To bridge the gap between factory automation controllers (S7-1500) and process control systems (PCS 7), Siemens provides two official, supported integration paths:

Method 1: SIMATIC PCS 7 Open OS with DBA

  • Function: Open OS allows non-PCS 7 controllers (including S7-1500, S7-1200, third-party PLCs, or DCS systems) to be visualized on the PCS 7 OS.
  • Engineering Tool (DBA): Database Automation (DBA) parses user-defined data types (UDTs) or DB structures exported from TIA Portal and automatically generates WinCC tags, alarm logging messages, and APL-style block icons and faceplates.
  • Communication: WinCC connects to the S7-1500 via Industrial Ethernet using standard S7 communication (SIMATIC S7-1200/1500 Channel) or OPC UA.

Method 2: SIMATIC PCS 7 Industry Library (IL)

  • Function: The Industry Library provides dedicated function blocks specifically designed for TIA Portal (for S7-1500 and S7-300) along with matching WinCC faceplates and Comfort Panel graphics.
  • APL Look-and-Feel: IL blocks in TIA Portal replicate APL operational behavior, status words, and faceplate aesthetics, delivering a unified operator interface across both process areas and package units.

Integration Architecture: Open OS with DBA vs Industry Library

When designing the integration architecture, engineers must evaluate whether logic is processed at the HMI level or controller level:

The Open OS Workflow

  1. In TIA Portal, create technological data blocks using standardized UDTs (e.g., Motor_UDT, Valve_UDT) containing process values, control bits, and fault status words.
  2. Export the tag structure or connect DBA directly to the TIA Portal project.
  3. In DBA, map UDT parameters to Open OS Type Definitions.
  4. DBA compiles the WinCC project: generating structure tags, alarm messages, and placing APL-styled block icons on process screens.

The AS Gateway Alternative (I/O Mapping)

If critical interlocks must exist between the S7-1500 skid and the PCS 7 plant:
* Establish controller-to-controller communication via BSEND/BRCV or Industrial Ethernet PUT/GET.
* Feed the raw signals into standard APL blocks in the PCS 7 S7-400 AS.
* Note: This consumes additional AS RT Process Object (PO) licenses in PCS 7.

Integration Methodology Comparison Matrix

The following table compares the available methodologies for integrating S7-1500 controllers into a PCS 7 supervisory environment:

Technical ParameterPCS 7 Open OS (DBA)PCS 7 Industry Library (IL)Direct APL in S7-1500AS-to-AS GatewayCompatibility with S7-1500100% Supported100% SupportedStrictly Incompatible100% SupportedEngineering SoftwareTIA Portal + Open OS DBATIA Portal + Step 7 V5.xNot applicableTIA Portal + SIMATIC ManagerFaceplate Look-and-FeelAPL-Style FaceplatesAPL-Identical FaceplatesNot applicableNative APL FaceplatesCommunication DriverS7-1500 Channel / OPC UAS7 Protocol Suite / TCPNot applicableS7 Connection (BSEND/BRCV)Additional LicensingOpen OS License per OSIndustry Library LicenseNot applicableAS RT POs on S7-400Operator Station TypePCS 7 WinCC OSPCS 7 WinCC OS / PanelsNot applicablePCS 7 WinCC OS

Selecting Open OS or Industry Library preserves system maintainability without compromising operator consistency.

Verification

To verify successful integration of an S7-1500 package unit:
1. Ensure communication channel status in WinCC Explorer indicates a healthy green link to the S7-1500 IP address.
2. In WinCC Runtime, open the process picture hosting the generated Open OS or Industry Library block icon.
3. Confirm that the block icon displays real-time motor/valve operational states (running, stopped, faulted).
4. Click the block icon: verify that the APL-style faceplate opens, displaying live telemetry.
5. Issue an operator control command (e.g., start motor or change setpoint); confirm that the S7-1500 executes the command in TIA Portal monitor mode.
6. Trigger a fault on the S7-1500; verify that the alarm appears with accurate timestamping in the WinCC AlarmList.

Limitations and Operational Precautions

  • Native PCS 7 time synchronization (e.g., high-resolution 1 ms SOE) cannot be achieved on S7-1500 package units via standard S7 communication; timestamps reflect OS arrival time unless NTP is synchronized.
  • S7-1500 Optimized Block Access must be disabled or configured appropriately to allow external symbolic/absolute address mapping in WinCC channels.
  • Open OS requires dedicated software licensing; verify license requirements in the Siemens catalog and validate final procurement with an authorized distributor.
  • Do not attempt to import S7-400 APL source code into TIA Portal; structural compilation errors will prevent block generation.

Engineer FAQ

Can I use SIMATIC PCS 7 Industry Library for S7-1500?

Yes. The PCS 7 Industry Library contains dedicated function blocks for TIA Portal that interface with WinCC Comfort Panels and PCS 7 Operator Stations with full APL look-and-feel.

What is the role of DBA in PCS 7 Open OS?

DBA (Database Automation) is the engineering compiler for Open OS that automatically translates external controller DBs and UDTs into WinCC tags, alarms, and graphic block icons.

Does connecting an S7-1500 via Open OS consume PCS 7 AS Process Objects?

No. Open OS objects do not run on an S7-400 controller, so they do not consume AS RT POs. However, they consume WinCC OS Runtime POs and require an Open OS engineering license.

Technical References

Related Articles

Related Tags

  • S7_1500
  • Open_OS
  • Industry_Library
  • Package_Units
  • APL_Compatibility
6 respuestas