Set new productivity standards
for constant competitive advantages
The optimization of processes improves quality, shortens the
time to market and reduces the total cost of ownership.
To survive in increasingly tougher international competition,
today it is more important than ever to consistently tap all
optimization potentials throughout the entire lifecycle of a
plant. At the same time, the perfect balance between quality,
time and costs is the decisive success factor.
Totally Integrated Automation2
With Totally Integrated Automation (TIA) from Siemens, a
seamless offering of perfectly matched products, systems,
and solutions for all hierarchy levels of industrial automation,
you are optimally equipped for this purpose.
Integration of the telecontrol technology in TIA has made it
possible to combine the automation of central plants and the
monitoring of distributed units in a single process control
system.
Homogenous operator control and monitoring using a common control station, uniform configuration with the same
engineering system, and consistent utilization of hardware
components from the TIA product portfolio result in significant savings with regard to investments, operation and
servicing.
Process control system with integral telecontrol center
Automation of widely spread process plants
In a number of industries, especially the oil & gas,
water & wastewater, power and transportation sectors,
plants may sometimes be extremely widely spread. Individual
distributed units may even be more than a thousand kilometers away from a central unit with a significantly higher degree
of automation.
With a gas pipeline, for example, several slide valve and measuring stations are distributed between one of the compressor
stations at the beginning of the pipeline and the relief station
at the end.
A further example is the canal system of a widely branched
wastewater network connected to a central sewage treatment
plant via pumping stations and stormwater overflow tanks.
In both cases it is necessary to monitor regional units such
as stormwater overflow tanks, pumping stations, slide valve
stations or measuring stations from a far off control center, or
to control them in the context of the complete plant.
Telecontrol systems with which automation functions can be
executed from a remote control center over a telecommunication network (wide area network/WAN) are the ideal solution
for such tasks.
The automation of a process plant, as described above, is distributed in conventional implementation concepts between
heterogeneous system levels. Process control systems (PCS)
are normally used for units with a higher degree of automation, e.g. the central sewage treatment plant. On the other
hand, the local automation of small units with a low degree of
automation (pumping stations, stormwater overflow tanks) is
carried out using simple remote terminal units (RTUs) which
communicate with their control center by means of a telecontrol link. To enable global monitoring, all systems of the automation project (PCS and RTU) are integrated in a host network
control system.
However, it is far more effective if the telecontrol center for
the RTUs is directly integrated into the process control system
using SIMATIC PCS 7 TeleControl. In this case, the network
control system as a superimposed integration level can be
omitted. Uniform process control and totally integrated engineering for central and widely distributed units, together with
simple and convenient data management, result in high efficiency with regard to operation and engineering. Low training
and servicing costs are further positive aspects.
The telecontrol center for the outstations (RTU) is integrated
into the process control of the SIMATIC PCS 7 process control
system in the form of an operator station in single station or
server design (also redundant as option). No additional automation system for conditioning telecontrol-specific data need
be planned in the SIMATIC PCS 7 system. With large quantity
frameworks, a PCS 7 TeleControl operator station (single station/server) is preferably responsible only for the telecontrol
mode (dedicated). With small quantity frameworks, a server
or a single station can also control SIMATIC PCS 7 automation
systems (AS) in central plant areas in addition to the telecontrol systems (dual-channel mode).
The OS clients of the client/server multi-user system are able
to display data from RTUs and SIMATIC PCS 7 AS - which they
receive from a server with dual-channel functionality or from
two separate servers - together in one process image. Display
is primarily on faceplates for process objects such as motors,
valves etc., but also by means of trend curves and messages.
Engineering
To enable engineering of the PCS 7 TeleControl operator station (single station/server), the functions of the engineering
station of the SIMATIC PCS 7 process control system are
expanded by DBA technology (Data Base Automation) and
the SIMATIC PCS 7 TeleControl block library.
Communication with the outstations
(remote terminal units)
For communication with the outstations, SIMATIC PCS 7
TeleControl uses the SINAUT ST7, DNP3 and Modbus protocols
(both via serial and TCP/IP communication connections) as
well as IEC 870-5-101 (serial) and IEC 870-5-104 (Ethernet
TCP/IP).
The serial RTU link is possible at low cost via the following
components which can be connected directly to the PCS 7
TeleControl OS (single station or server):
• SINAUT TIM communication modules
(SINAUT ST7 telecontrol protocol)
• TCP/IP converters – serial
(DNP3, Modbus, IEC 870-5-101 telecontrol protocols)
Devices from MOXA or Lantronix can be used as serial
TCP/IP converters.
By means of Ethernet TCP/IP, the RTUs can be connected directly or via TCP/IP WAN routers to the SIMATIC PCS 7 system
bus (SINAUT ST7, DNP3, Modbus, IEC 870-5-104 telecontrol
protocols). When using the SINAUT ST7 telecontrol protocol,
the SINAUT TIM communication module can be used in addition to the TCP/IP WAN router or as an alternative.
Telecontrol communication over the wide area network is
largely determined by the communication infrastructure
which already exists. Various transmission media such as
dedicated line, analog or digital telephone networks, wireless
networks (GSM or private), DSL or GPRS can also be combined
with each other.
Outstations (remote terminal units)
Since the requirements of the widely distributed units with regard to scope and performance of the automation functions
are usually in the low to mid range, controllers with minimum
dimensioning are normally used as RTUs.
SIMATIC PCS 7 TeleControl particularly supports the following
types of RTU for distributed automation on site:
(IEC 870-5-101/104 and DNP3 telecontrol protocols)
In addition to these, appropriate third-party RTUs can also be
connected to the telecontrol center in SIMATIC PCS 7 by
means of the DNP3, Modbus, IEC 870-5-101/104 telecontrol
protocols.
SIMATIC PCS 7 TeleControl cannot only integrate newly configured RTUs into SIMATIC PCS 7, it can also migrate units which
already exist outdoors by means of DNP3, IEC 870-5-101/104,
Modbus or EDC drivers. The Data Base Automation (DBA) software substantially facilitates project-specific adaptation of the
system and importing of existing configurations during migration. Extensions can be added during plant operation if necessary.
Differently structured telecontrol networks can be implemented in the wide area network (WAN) based on the following
four basic topologies.
Media versions
Depending on the support provided by the selected telecontrol protocol, various transmission media are available for
these basic topologies, e.g. dedicated line, private wireless
networks, mobile radio networks, dial-up networks (wireless/landline), DSL over Internet.
Some of these media versions are shown in the example of the
star topology.
Point-to-
point
Star via
dedicated line
Multi-pointStarRing
Star via
wireless
Dial-up
network via
wireless
Star via
Internet
Combinations of basic topologies and media versions
Through a combination of several basic topologies of the
same or different media versions, it is additionally possible to
design more complex network topologies, even with redundant communication paths.
This allows adaptation to the respective local conditions and
to the existing infrastructure.
Depending on the magnitude of the automation project and
the required number of operator stations, the SIMATIC PCS 7
TeleControl Operator System can be configured either as a single-user system (PCS 7 TeleControl OS single station) or as a
multi-user system with client/server architecture:
• Single-user system
- Up to 5 000 process objects
- Up to approx. 3 000 measuring points
- Low number of operator stations
• Multi-user system (client/server)
- Up to 8 500 process objects per OS server
- Up to approx. 5 000 measuring points per OS server
- Up to 32 operator stations (OS clients)
In a single-user system architecture, all operation and monitoring functions for a complete project (plant/unit) are concentrated in one station.
A multi-user system has up to 32 operator stations (OS clients)
which are supplied with data from one or more servers
(OS server or PCS 7 TeleControl OS server) via the terminal
bus.
The multi-client architecture of the multi-user system allows
an OS client to call data from various servers, e.g. from two
separate servers for local units and for units connected by
means of PCS 7 TeleControl.
The PCS 7 TeleControl OS server of the multi-user system can
also have a redundant design. All internally generated information (e.g. alarm states or results of calculations) is matched
in the redundant pair of PCS 7 TeleControl OS servers.
The graduated scalability of the process objects of PCS 7
TeleControl OS single station and PCS 7 TeleControl OS server
permits fine and flexible matching of the SIMATIC PCS 7
TeleControl Operator System to the size of the respective
automation project.
Uniform process control for central and remote units
Dual-channel operation
OS clients
OS single station
SIMATIC PCS 7
+ TeleControl
(dual ch ann el)
PCS 7
automation system
Dual-channel operation with single-user and multi-user systems
· · ·
OS server
(single or
redundant)
Tel eC on trol
RTUs
PCS 7 TeleControl OS single station and PCS 7 TeleControl OS
server are preferably used just for telecontrol functions (dedicated), but can also access central SIMATIC PCS 7 plant areas
via an additional second channel in the case of small quantity
frameworks (double-channel operation). In this way, data
from the RTUs of the telecontrol system can be displayed in
one process image together with data from SIMATIC PCS 7 AS.
PCS 7 TeleControl blocks for system-conformant operator
control and monitoring
The RTUs are integrated into the PCS 7 TeleControl Operator
System by means of the PCS 7 TeleControl blocks such that
there is no difference for the operator with regard to operating philosophy and alarm behavior for the central or remote
automation functions.
The blocks required for data conditioning and display are
saved in a library. These blocks support SIMATIC PCS 7 compliant operator control by means of symbols and faceplates, as
well as the hierarchy of SIMATIC PCS 7 fault messages.
In addition to blocks for processing of process data, the
library also contains blocks for diagnostics and for control
of communication. If necessary, the supplied basic library can
be extended by new script-based block types specific to the
project by using the DBA Type Editor.
Long-term archiving and
logging
The PCS 7 TeleControl Operator System includes a high-performance cyclic archive based on Microsoft SQL Server for timelimited saving of process values and messages/events. Data
from this cyclic archive can be exported time-controlled or
event-controlled to a long-term archive (StoragePlus/central
archive server).
The logging system of the PCS 7 TeleControl Operator System
supports the display and evaluation of data recorded during
operation by means of various predefined types of protocol
which can also be matched individually:
• Message sequence report
• Message and archive log
• Measured value log
• Operator input log
• System message log
•User log
The logs saved in EMF format can be previewed on the screen,
and can be printed manually or time- or event-controlled.
In order to comply with statutory directives and standards it
may be necessary to provide special proof, e.g. proof of conformity with the ATV M260 standard for sewage treatment
plants. The SIMATIC PCS 7 add-on product ACRON equipped
with additional functionalities for long-term archiving and
logging provides excellent support for this purpose.
Engineering station of the SIMATIC PCS 7 process control system
To enable engineering of the PCS 7 TeleControl operator station (single station/server), the functions of the engineering
station of the SIMATIC PCS 7 process control system are expanded by DBA technology (Data Base Automation) and the
SIMATIC PCS 7 TeleControl block library.
Data Base Automation (DBA)
Engineering can be automated efficiently and in conformance
with SIMATIC PCS 7 using the DBA technology. DBA supports
plant expansion during ongoing operation, and facilitates
project-specific adaptation of the system as well as importing
of existing configurations in the course of migration.
The DBA executed in the engineering station automatically
generates the OS runtime database with the display hierarchy,
required variables, alarms, alarm messages and alarm priorities, as well as the specific faceplates and block symbols.
The display hierarchy is the basis for navigation between the
process displays, for alarm management, and for implementation of safety measures. DBA positions the type-specific block
symbols, e.g. measured value, counter value, motor or gate
valve, in the process images. These symbols are linked to the
corresponding function blocks and faceplates through the database. Manual configuration is mainly limited to the design
and positioning of the static graphic elements, e.g. pipes or
tanks.
SIMATIC PCS 7 TeleControl block library
In addition to the SIMATIC PCS 7 TeleControl basic library,
new user blocks can also be defined using the DBA type editor.
During database generation, the user blocks are treated like
the blocks from the basic library.
Using the DBA type editor it is possible to assign the frequently
unstructured variables of an RTU once to a block type and to
display the variable structured on the operator station via the
block's faceplate.
SIMATIC PCS 7 TeleControl blocks
The PCS 7 TeleControl OS symbols, faceplates and diagnostics
displays created in conformance with SIMATIC PCS 7 take into
account the specific features of telecontrol applications. This
is demonstrated, for example, by the example of the counter
block which offers versatile conditioning options for information on transported or processed quantities. At least one
OS faceplate and one OS symbol are available for each type
of block.
In addition to arrangement of information in a variable structure, the user blocks generated with the DBA type editor can
also calculate derived values using Visual Basic scripts in the
server. This results in numerous possibilities for extending the
functionality and for adapting the system to individual customer requirements.
Type-specific OS faceplates and OS symbols for the user blocks
can be created using the standard tools for SIMATIC PCS 7
OS engineering (Graphics Designer and Faceplate Designer).
RTU Small: controller integrated in SIMATIC ET 200S
RTU with up to approx. 30 I/Os
For small, cost-sensitive applications
RTU Medium: SIMATIC S7-300/S7-300F controller
RTU with up to approx. 100 I/Os
For medium-sized applications;
extremely flexible configuration
S7-300F for safety-related applications
RTU Large: SIMATIC S7-400/S7-400F controller
Possible telecontrol protocols
• ModbusNo buffering
• IEC 870-5-101
• IEC 870-5-104
•SINAUT ST7
•DNP3
• ModbusNo buffering
• IEC 870-5-101
• IEC 870-5-104
Information points/
buffer size
Up to approx. 200 information
points
Buffer size:
800 information points
TIM buffering
(up to 16 000 frames or up to
32 000 frames with TIM 3V-IE
Advanced)
Up to approx. 2 000 information points
Buffer size: 800 to 3 200 information points
RTU with up to approx. 500 I/Os
For larger applications requiring
increased performance
S7-400F for safety-related applications
RTU Large: SIMATIC S7-400H/S7-400FH controller
Like S7-400/S7-400F•DNP3TIM buffering
The remote control units supported by SIMATIC PCS 7
TeleControl have a performance classified as Small, Medium
or Large.
Controllers of SIPLUS extreme design are also available in all
performance classes, and can be operated under extreme conditions, e.g. ambient temperatures from -25 °C to +70 °C, condensation or exposure to media.
•SINAUT ST7
•DNP3
• ModbusNo buffering
• IEC 870-5-101
• IEC 870-5-104
• IEC 870-5-101
• IEC 870-5-104
In addition, the SIMATIC S7-300F and S7-400F controllers can
be used to implement safety-related applications on site and
automatically set the plant to a safe status in the event of a
dangerous fault.
Telecontrol systems use special protocols to implement data
transmission between the control center and the outstations
(RTUs) at the process level for the automation functions on
site. These telecontrol protocols manage the secure and errorfree data transmission over the WAN even with a low bandwidth and poor transmission quality.
In addition to short transmission times for the information,
this task requires effective protection of the frames against:
• Undetected bit errors
• Undetected frame errors resulting from synchronization
errors
• Undetected loss of information
• Frame falsification
• Segregation or fault in related information
This particularly applies to event-controlled frames over transmission channels with a limited bandwidth and uncertain
noise response.
Since irregular bit sequences are compiled for data transmission, no limitation in codes must exist.
Time tagging
When linking RTUs by means of SINAUT ST7, DNP3,
IEC 870-5-101 or IEC 870-5-104 telecontrol protocol, the raw
data in the outstations is provided with a time tag and transmitted to the PCS 7 TeleControl OS (server/single station)
acting as control center. Adaptation, further processing, and
archiving are carried out here. This procedure is appropriate
for the event-based principle of operation of the telecontrol
protocol as well as the subsequent chronological processing
of data previously buffered in the outstation.
Clock synchronization
The PCS 7 TeleControl OS is the clock master for the RTUs
connected by means of SINAUT ST7, DNP3, IEC 870-5-101 or
IEC 870-5-104, and regularly synchronizes their date and time
via the telecontrol connection. Switching over between summertime and wintertime is also considered during the synchronization.
Data buffering
The SINAUT ST7, DNP3, IEC 870-5-101 and IEC 870-5-104
telecontrol protocols support reliable on-site intermediate
buffering of the data including time tag, e.g. if a communication path is faulty or a station has failed. In addition, intermediate buffering of data can also be an effective means
for reducing connection costs in the dial-up network.
A data update for all participating communication partners
is performed automatically following debugging or restarting
of the failed station. Important events are not lost, and the
integrity of the control center archive is assured.
Overview of SIMATIC PCS 7 TeleControl with SINAUT ST 7 telecontrol
protocol
S7-400
and
TIM 4R-IE
Classic
WAN
The telecontrol system based on the SINAUT ST7 telecontrol
protocol is used for fully-automatic monitoring and control of
widely distributed outstations (RTUs) which exchange data
with each other and with one or more control centers over a
wide variety of WAN (Wide Area Network) media.
SIMATIC S7-300/S7-300F and SIMATIC S7-400/S7-400F controllers are used for the outstations and node stations, and
SIMATIC PCS 7 with SIMATIC PCS 7 TeleControl for the control
center. Further hardware and software components round off
the range of products:
• TIM communication modules
• MD modem modules
•GSM/GPRS components
• TCP/IP routers and switches
• SCALANCE S612 and S613 security modules
• Dedicated-line accessories
•Cables
G_PCS7_XX_00262
• SINAUT ST7 engineering software, comprising:
- SINAUT TD7 library with blocks for the data point objects
of the SIMATIC S7 CPU or the TIM module
- SINAUT ST7 engineering package for configuration of
stations, networks and connections as well as for diagnostics
In order to implement complete hierarchical telecontrol networks, the basic topologies of point-to-point, multi-point, star
and ring can be configured using classic or also TCP/IP-based
media, and combined flexibly independent of the infrastructural conditions. SINAUT ST7 is thus distinguished by a wide
range of possible selections and combinations.
SINAUT ST7 - example of secure TCP/IP-based connection over Internet via DSL (star topology)
DSL router
Firewall
Internet
Firewall
DSL router
SCALANCE
S612/613
Star via
Internet
G_PCS7_XX_00265
SINAUT ST7 - example of redundant telecontrol connections (point-to-point topology)
TCP/IP-based WAN media
• Special radio network optimized for Ethernet, e.g. with
SCALANCE W industrial wireless LAN components
• SCALANCE X switches with optical ports and fiber-optic
cables for distances up to 120 km
• Public network and Internet via DSL or GPRS
• Broadband system such as OTN, PCM30, etc.
To achieve redundant data transmission, it is also possible to
connect an outstation via two transmission paths to the control center in the SIMATIC PCS7 process control system or to a
node station. It is irrelevant whether the two paths are of the
same type or different, e.g. dedicated line with telephone network/ISDN and GPRS.
Special characteristics
of SINAUT ST7 communication
Up to 10 000 stations can be addressed with SINAUT ST7.
Information on the source and target addresses is included
in the message frames. The functionality of SINAUT ST7
communication is particularly characterized by the following features:
Change-driven data transmission
• Change-driven transmission of process data between
RTUs as well as between an RTU and the control center
• Signaling of failures in connections, RTUs or the control
center
• Automatic data updating for all communication partners involved following troubleshooting and following
the startup of an RTU or control center
Chronological processing of process data
• Time tagging of all data frames at the place of origin allows process data to be archived by the process control
system in the correct chronological order
• The time of the SINAUT ST7 stations in the WAN can
be synchronized via SIMATIC PCS 7 (including summertime/wintertime switchover)
Local data storage
• Depending on the version, the TIM communication
module can temporarily store (for several hours or even
days) up to 56 000 message frames should the connection or the communication partner fail
• Intermediate storage of message frames of lower priority in the case of priority-controlled data transmission
(with dial-up networks or quantity-dependent data
transmission costs)
Remote programming and remote diagnostics
• Remote diagnostics and remote programming over the
WAN using the "PG routing" function
• PG routing shares the available bandwidth with the process data transmission, but has a higher priority
• Uploads, downloads, remote diagnostics, firmware upgrades or changes in automation functions on the stations can be carried out online from the control center
in SIMATIC PCS 7
Alarm output per text message
• The RTUs can send text messages depending on events
in order to alarm personnel on call
• Receipt of messages can be acknowledged from a
mobile phone
• Depending on the services offered by the mobile radio
provider, the text message can also be output as an
e-mail, fax or voice mail
SIMATIC water library: block symbol and faceplate for a valve
Technological configuration with the
SIMATIC water library
The SIMATIC water library from Siemens supports effective
configuration of the SIMATIC PCS 7 process control system
with technological function blocks for implementing applications for water supply and disposal.
These technological function blocks can now also be used on
the basis of the SINAUT ST7 telecontrol protocol. The telecontrol functions are integrated using additive blocks in the CFC,
i.e. without modifying the existing technological function
blocks or the associated block symbols and faceplates. The
philosophy of SIMATIC PCS 7 TeleControl with regard to uniform process control of central and remote units using an
operator system is thus extended in the direction of uniform
engineering. Standardization and reuse of the ready-made
functions significantly reduces the requirements for engineering, testing and training, as well as maintenance and
updating.
The communication mode between the control center and
outstation (RTU) depends on the support provided by the telecontrol protocol, the configuration of the telecontrol communication, and the type of WAN.
The SINAUT ST 7 telecontrol protocol supports the following
operating modes:
•Polling
- Control of data exchange by the TIM module of the control center
- The TIM of the control center calls the outstations and
node stations one after the other
- Stations with modified data (since the last transmission)
send this when called
- Stations without modified data only acknowledge the
call
- Transmission of control center data for the stations in
between the calls
- Data exchange using internode communication between
the stations is possible via the polling TIM of the control
center
• Polling with time slot procedure
- Operating mode for a radio network with division of the
radio frequency between several providers
- Typically 6 s/min (time slot) for each provider for data
exchange
- Data exchange during the time slot is carried out as
described under "Polling"
- Following the data exchange, the frequency swaps to the
next provider
- Data exchange using internode communication between
the stations is possible via the polling TIM of the control
center
- Control of the polling TIM by DCF77 or GPS radio-controlled clock for exact observation of the time slot
• Spontaneous mode in dial-up networks
- Data from outstations and node stations can be assigned
priorities for transmission in the dial-up network: normal,
high, alarm
- Immediate establishment of a dial-up connection for
data with alarm priority or high priority; priority transmission of alarm frames
- Intermediate storage of data with normal priority; transmission during the next dial-up connection with the partner in the original chronological order (FIFO principle)
- Transmitted data from the control center always has high
priority
- Data exchange possible between the stations with direct
internode communication
• Spontaneous mode in the TCP/IP-based WAN
- Establishment of a permanent S7 connection between
two TIMs or between TIM and control center
- Exchange of SINAUT ST7-specific data packets via this
S7 connection using S7 communication functions with
application of the TCP/IP transport protocol
- If the data transmission costs are related to the data
quantity, processing is carried out with priority as with
spontaneous mode for dial-up networks: immediate
transmission of data with high priority and alarm priority
(latter with priority); collection of data with normal priority and transmission in larger blocks
- If the data quantity is not cost-relevant, all data is transmitted immediately to the respective partner, i.e. without intermediate storage. Message frames with alarm
priority then have priority.
• Multi-master polling with time slot procedure
- Operating mode for communication between outstations and more than one control center via dedicated line
or radio network
- Each control center is assigned one or more time slots
per minute for polling
- Separate data buffer for each control center in the stations (including node stations)
- Data exchange using internode communication between
the stations is possible via the polling TIM of the active
control center
- Redundant internode communication is possible; upon
failure of the preferred control center, internode communication is carried out via the TIM of the alternative control center
- Each TIM of the control centers involved must be controlled by means of a DCF77 or GPS radio-controlled
clock for exact observation of the time slot
Widely distributed outstations (RTUs) can be controlled and
monitored with the DNP3 telecontrol protocol via serial or
Ethernet TCP/IP communication links by means of the telecontrol center in SIMATIC PCS 7. The control center integrated
with SIMATIC PCS 7 TeleControl into the operator system of
the process control system is the master during telecontrol
communication.
The slaves are represented by the outstations. SIMATIC
S7-300/S7-300F and S7-400/S7-400F/S7-400H/S7-400FH
controllers as well as third-party RTUs can be used as outstations.
Control center
SIMATIC PCS 7 TeleControl
DNP3 master
Ethernet
RS 485
MD2
MD2MD2
· · ·
Further hardware and software components round off the
range of products:
• TIM communication modules
•TCP/IP converters – serial and MD modem modules
•GSM/GPRS components
• TCP/IP routers and switches
• SCALANCE S612 and S613 security modules
• Dedicated-line accessories
•Cables
• Engineering package for configuration of DNP3 data
objects, stations, networks and connections as well as
for diagnostics
In order to implement the telecontrol networks, the basic
topologies of point-to-point, multi-point, star and ring can be
configured using classic or also TCP/IP-based media, and combined flexibly independent of the infrastructural conditions.
Range without repeaters (example)
with conductor cross-section 0.8 mm
- 1 200 bit/s max. 33 km
- 2 400 bit/s max. 27 km
TCP/IP to serial
converter
- 19 200 bit/s max. 11 km
Dedicated network
with star topology
RTU S7-400HRTU S7-400
TIM 4R-IE
DNP3 (slave)
DNP3 - example of classic dedicated network (star + multi-point topologies)
MD2
TIM 4R-IE
DNP3 (slave)
MD2
· · ·
Classic WAN media
• Dedicated line via modem, e.g. SINAUT MD2
• Private wireless networks
• Analog telephone network
• Digital ISDN network
• Mobile radio network GSM
RTU S7-300
TIM 3V-IE
DNP3 (slave)
RTU S7-300
TIM 3V-IE
DNP3 (slave)
MD2
MD2
Star +
multi-point
G_PCS7_XX_00267
DNP3 telecontrol protocol20
MD741-1
G_PCS7_XX_00269
Ethernet
RTU S7-300
TIM 4R-IE DNP3 (Slave) MD2
MD2
MD2
RTU S7-400
Ethernet
MD2
SCALANCE
S612/613
Control center SIMATIC PCS 7
TeleControl DNP3 master
Control center SIMATIC PCS 7
TeleControl DNP3 master
Dedicated
line
Redundant transmission path:
classic WAN + classic WAN
Dedicated
line
Redundant transmission path:
classic WAN + TCP/IP-based WAN
• Change-driven transmission of process data between
RTU and control center
• Signaling of RTU, control center or connection failure
• Automatic data updating for all communication partners involved following troubleshooting and following
the startup of the RTU or control center
Chronological processing of process data
• Time tagging of all data frames at the place of origin allows process data to be archived by the process control
system in the correct chronological order
• The time of the DNP3 stations in the WAN can be synchronized via SIMATIC PCS 7 (including summertime/
wintertime switchover)
Local data storage
• The TIM communication module can temporarily store
(for several hours or even days) message frames should
the connection or the communication partner fail
• Intermediate storage of message frames of lower
priority in the case of priority-controlled data transmission (with dial-up networks or quantity-dependent
data transmission costs)
Operating modes
The DNP3 telecontrol protocol supports the following
operating modes (functional principle similar to that
described in the section for the SINAUT ST7 telecontrol
protocol):
Flexible communication options in the WAN with IEC 870-5-101/IEC 870-5-104 telecommunication protocols
A telecontrol center which is seamlessly integrated into the
SIMATIC PCS 7 process control system by means of SIMATIC
PCS 7 TeleControl can control and monitor geographically dis-
The performance of the telecontrol stations can be scaled
with SIPLUS RIC bundles configured as slaves for the tele-
control link as shown below:
persed outstations via serial (IEC 870-5-101 telecontrol protocol) or Ethernet TCP/IP (IEC 870-5-104 telecontrol protocol)
communication links.
SIMATIC S7 controllers (SIMATIC ET 200S with integral CPU,
SIMATIC S7-300/S7-300F, and SIMATIC S7-400/S7-400F/
S7-400H/S7-400FH) as well as third-party RTUs can be used as
Performance
SIPLUS RIC Bundle
with SIMATIC S7-400
outstations in this context. The control center is the master
during communication with the outstations.
SIPLUS RIC Bundle
with SIMATIC S7-300
The IEC 870-5-101 and IEC 870-5-104 telecontrol protocols
are anchored in the telecommunication product range
SIPLUS RIC. Based on specific libraries for telecontrol protocols, SIPLUS RIC comprises low-cost bundles for outstations
SIPLUS RIC Bundle with
SIMATIC ET 200S
which are based on SIMATIC ET 200S with integral CPU,
SIMATIC S7-300 or SIMATIC S7-400.
SIPLUS RIC products require additional material to establish
telecommunication links, e.g. TCP/IP converters – serial,
dedicated line modems, media converters, TCP/IP routers,
SCALANCE S612 and S613 security modules, switches, cables
etc.
In order to implement telecontrol networks, basic topologies
including point-to-point, multi-point, star and ring can be configured using classic or TCP/IP-based media. These can be
combined flexibly independent from existing infrastructure.
Control center
SIMATIC PCS 7 TeleControl
IEC 870-5-104
RTU S7-400
MD741
Ethernet
Internet
Classic WAN media
(IEC 870-5-101 telecontrol protocol)
• Dedicated line via modem, e.g. SINAUT MD2
• Dedicated line over fiber-optic cables
• Private wireless networks
TCP/IP-based WAN media
(IEC 870-5-104 telecontrol protocol)
• Ethernet networks, e.g. SCALANCE X with fiber-optic
cables
• Industrial Wireless LAN with SCALANCE W
• Public networks and the Internet using DSL and/or GPRS
• Satellite communication, e.g. with Inmarsat
SCALANCE
S613
DSL router
CP 443
Third-Party RTU
IEC 870-5-104 - example of TCP/IP-based WAN with GPRS radio network (star topology)
IEC 870-5-104 - example of complex TCP/IP-based WAN with cable and GPRS networks
It is also possible to connect an outstation via two transmission paths to the control center in the SIMATIC PCS7 process
control system to achieve redundant data transmission.
Redundant transmission paths can be based on the same
or different communication protocols.
IEC 870-5-104
MD741
IEC 870-5-104
RTU ET 200S
with IM 151-8
PN/DP CPU
Complex network structure,
combination of different
topolo gies and m edia
G_PCS7_XX_00271
Control center
SIMATIC PCS 7 client
Terminal bus (Ethernet)
PCS 7 TeleControl
OS server,
redundant
Redundant system bus
TCP/IP to serial
converter
RTU S7-300
with 2 x CP 343
RTU S7-400 with
2 x CP 443
IEC 870-5-104
RTU S7-400 with CP 443
(left) and CP 441
IEC 870-5-101IEC 870-5-104
RTU ET 200S
with IM 151-8 PN/DP CPU
and 1 SI interface module
RTU S7-300
with CP 343 (left)
and CP 341
IEC 870-5-101/104 - example of redundant telecommunication links (IEC 870-5-101 representation without modems)
The Modbus telecommunication protocol is suitable for the
integration of existing units with a Modbus infrastructure into
the SIMATIC PCS 7 process control system.
Telecontrol communication for control and monitoring of
widely distributed outstations (RTUs) from a control center in
SIMATIC PCS 7 is possible with this protocol via both serial and
TCP/IP communication links.
The control center, represented by the SIMATIC PCS 7 Operator
System with SIMATIC PCS 7 TeleControl, is the Modbus master.
SIMATIC S7 controllers (SIMATIC ET 200S with integral CPU,
SIMATIC S7-300/S7-300F, and SIMATIC S7-400/S7-400F) as
well as third-party RTUs with a suitable Modbus interface can
be used as outstations (Modbus slaves).
The SIPLUS RIC range includes low-cost bundles for outstations with Modbus telecontrol protocol (serial or TCP/IP),
based on SIMATIC ET 200S with integral CPU and SIMATIC
S7-300. These usually comprise:
•CPU
• Interface/communication module (if necessary)
•Memory card
• CD with library and registration code.
In addition, further material is required to establish
the telecommunication links, e.g. TCP/IP converters – serial,
dedicated line modems, media converters, TCP/IP routers,
switches, cables etc.
The Modbus telecontrol protocol can be used to implement
telecontrol networks based on point-to-point and multi-point
topologies, both serial and TCP/IP. The following media can be
used for this:
Classic WAN media
• Dedicated line via modem, e.g. SINAUT MD2
• Dedicated line over fiber-optic cables
• Private wireless networks
TCP/IP-based WAN media
• Ethernet networks, e.g. SCALANCE X with fiber-optic
cables
• Industrial Wireless LAN with SCALANCE W
• Public networks and the Internet using DSL and/or GPRS
To permit redundant data transmission, outstations can be
connected to the control center in the SIMATIC PCS 7 process
control system over two paths. Two operating modes are
available:
TCP/IP WAN router
SCALANCE
X101-1LD
Fiber-optic cable
SCALANCE
X101-1LD
SIMATIC S7-400 with
CP 443 and software library
(Modbus slave)
Control center
Modbus master
TCP/IP to serial converter
SINAUT
MD2
SINAUT
MD2
SIPLUS RIC bundle
with SIMATIC ET 200S
(Modbus slave)
• Load sharing: parallel utilization of both paths
• Master/standby: only one path is active, the other is passive
SINAUT
MD2
SIPLUS RIC bundle
with SIMATIC S7-300
(Modbus slave)
Point-to-
point
Multi-point
G_PCS7_XX_00273
Modbus - example of serial and TCP/IP telecontrol connections (multi-point/point-to-point topologies)
For the individual telecontrol protocols, reference was already
made as to how the availability of telecontrol communication
can be increased using redundant transmission paths. However, as a result of seamless integration of the telecontrol
technology into the SIMATIC PCS 7 process control system, the
redundant design of the telecontrol communication is embedded in the redundancy concept of the complete system and
must therefore be considered globally.
SIMATIC PCS 7
OS clients
Terminal bus
Control center
SIMATIC PCS 7
TeleControl OS
with redundant
servers
The example of a SIMATIC PCS 7 process control system
with integral telecontrol linking of RTUs on the basis of
the IEC 870-5-101/IEC 870-5-104 protocols demonstrates the
various possibilities for increasing plant availability:
• Redundant SIMATIC PCS 7 TeleControl OS servers for process control of central and widely distributed units and for
archiving
• Redundant system bus for system communication
• Redundant telecontrol communication between control
center and RTUs over two separate transmission paths
• Redundant RTUs on the basis of S7-400H/ S7-400FH controllers for local automation of remote units
• Redundant PROFIBUS for communication between controller and process I/O (I/O modules, process instruments and
devices in the field)
• Redundant process I/O
It is also possible to implement safety-related functions in
the RTU (up to SIL 3) based on the S7-400FH controller and
F modules in the ET 200M remote I/O station.
Redundant system bus
TCP/IP to serial
converter
IEC 870-5-101
redundant
RTU S7-400H
ET 200M redundant
with 2 x CP 341
Redundant telecontrol configuration based on the
IEC 870-5-101/IEC 870-5-104 protocols
The Modbus is widely used in automation plants due to its
straightforwardness and openness. The Modbus telecontrol
protocol can be used to implement both serial and TCP/IP communication links between a control center in SIMATIC PCS 7
and RTUs with a corresponding Modbus interface.
In this manner, existing units with a Modbus infrastructure
can be integrated at low cost into the SIMATIC PCS 7 process
control system. The RTUs of these units can be SIMATIC S7
controllers (SIMATIC ET 200S with integral CPU, SIMATIC
S7-300/S7-300F and SIMATIC S7-400/S7-400F) as well as
third-party RTUs. Whereas RTUs with Modbus TCP/IP interface
can be integrated directly, serial third-party RTUs require specific interface converters for telecontrol communication.
Engineering data of third-party RTUs can be imported in CSV
format into the PCS 7 TeleControl engineering (DBA). The status of the RTUs and the transmission paths is evaluated by the
"Diagnostics Modbus RTU" block and displayed in the control
center.
SINAUT ST1 stations based on SIMATIC S5
During the migration of existing systems, it is possible to integrate outstations based on SIMATIC S5 into the SIMATIC PCS 7
process control system using SIMATIC PCS 7 TeleControl. In
the process, the ST1 telecontrol protocol is converted into the
ST7 protocol in the central TIM communication module.
Third-party stations
In addition to the Modbus telecontrol protocol, the DNP3
(serial and TCP/IP), IEC 870-5-101 (serial) and IEC 870-5-104
(TCP/IP) telecontrol protocols basically also support the control center linking of third-party RTUs when migrating existing
systems. The implementation depends on whether the thirdparty RTU masters the corresponding protocol and whether
the interface converters are available if necessary.
Integration of SINAUT ST1 stations into telecontrol communication
Integration of existing SINAUT LSX systems per PCS 7 TeleControl S7 EDC driver
Processor
S7-300
S7-400
S5 / ST1
(KOMSYS)
Node
station
TIM
S5-115
S7
(EDC)
S5-135
ST1 RTUsST7 RTUs
Integration of third-party stations with OPC
Along with additive engineering performance on the basis of
DBA technology, SIMATIC PCS 7 TeleControl also allows integration of third-party RTUs for which an OPC server exists into
the process control with the SIMATIC PCS 7 Operator System.
SIMATIC PCS 7 TeleControl then supports data exchange
between the operator system (OPC client) and the RTU
(OPC server) per OPC DA.
DSL router
SCALANCE
S612
Master
TIM (ST7)
Control center
IEC 60870-5-104
SIMATIC
PCS 7
S7-400
S7-300
S7-400
G_PCS7_XX_00275
SINAUT LSX systems
Existing SINAUT LSX systems can also be migrated with
SIMATIC PCS 7 TeleControl. The SIMATIC S7 controllers with
EDC communication protocol (Event Driven Communication)
installed in the SINAUT LSX systems are then integrated into
SIMATIC PCS 7 TeleControl per PCS 7 TeleControl S7 EDC
driver. Because the SINAUT LSX system can coexist at all levels
next to the new system architecture as long as necessary,
modernization is possible step-by-step and without shortlived intermediate solutions.
Linking of SIPROTEC or third-party protection equipment
The protocol expansion IEC 870-5-103 Master for SIPLUS RIC
bundles also allows interfacing of SIPROTEC or third-party protective equipment via SIMATIC PCS 7 TeleControl. The RTU
(ET 200S with CPU, S7-300 or S7-400 controller) then serves
as a converter between the IEC 870-5-103 protection data
protocol and the IEC 870-5-101 or IEC 870-5-104 protocol.
SINAUT
MD741-1
SIPLUS RIC bundle
with SIMATIC S7-300
Example of interfacing of SIPROTEC protective equipment
SIPROTEC
7SJ63
IEC 60870-5-103
Compared to PROFIBUS DP interfacing of the protective equipment, this configuration provides the following advantages:
• Greater distances are possible.
• The highly exact time stamps are transferred from the protective equipment to the control system.
The information provided in this brochure contains descriptions
or characteristics of performance which in case of actual use do
not always apply as described or which may change as a result of
further development of the products. The desired features are
only binding if explicitly agreed in the contract. Availability and
technical specifications are subject to change without notice.
Any product names mentioned may be trademarks or product
designations of Siemens AG or their suppliers, whose use by third
parties for their own purposes may infringe the rights of the
trademark owners.
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