Subject: Seeking Assistance with WINCC Communication Issues Dear Team, I am currently facing a challenge with communication in WINCC related to our lab's filling station project for students. We are utilizing a simulation library developed by Johnson Company, which operates through PLCsim, allowing us to effectively simulate our system. Our actual filling station setup consists of an RTX PCS7 box connected to an I/O bus (ET200) via Profibus. So far, we have successfully run the simulation and real systems in separate projects without any issues. However, our goal is to integrate both systems within a single WINCC application. Specifically, we want to send commands through PLCsim while simultaneously operating the real PLC. I am reaching out to inquire whether it is possible to have both systems functioning concurrently. In our attempts, we have observed that WINCC disconnects from PLCsim when the real PLC is active, and vice versa. I would appreciate any insights on the configuration we might be missing. For reference, I have attached two screenshots from WINCC and NetPro. Any assistance you can provide would be greatly appreciated. Thank you!
I have developed a lightweight tool known as Nettoplcsim, designed specifically for this purpose. This program utilizes the standard network interface of the PC where Plcsim or Nettoplcsim is installed, effectively transmitting data to the internal Plcsim interface. However, given your specific setup, it seems a bit complex, and I cannot guarantee a 100% success rate. In my experience with Nettoplcsim, I have primarily dealt with simulated PLCs. If I understand your requirements correctly, you aim to establish a connection between Plcsim and a real PLC. What should be feasible is to upload the program to the actual CPU, initiate Plcsim, and load the simulation program. Subsequently, you can connect WinCC to both the real CPU and Plcsim through Nettoplcsim. Keep in mind that you would only be able to program the Plcsim CPU, as the interface configuration is set to Plcsim. Depending on the specific features of PCS7 that you are utilizing, there may be certain functions that are incompatible with Plcsim or Nettoplcsim. I encourage you to test this solution to see if it meets your needs. Feel free to download the tool from this link: http://nettoplcsim.sourceforge.net/. By the way, is your WinCC operating system running on your Engineering Station (ES)?
Thomas_v2 shared: I’ve developed a tool named Nettoplcsim, designed specifically for this purpose. This software interfaces with the standard network setup of the PC where Plcsim/Nettoplcsim operates, enabling data transmission to the internal Plcsim interface. However, given your specific configuration, the process might be somewhat complex, and I cannot guarantee it will function perfectly every time. In my experience using Nettoplcsim, I’ve solely engaged with simulated PLCs. As I understand it, you intend to connect both to Plcsim and a real PLC. What should be feasible is downloading the program onto the actual CPU, initiating Plcsim, and loading the simulated program. Afterward, you can link WinCC to both the real CPU and Plcsim through Nettoplcsim. However, keep in mind that you will be able to program only the Plcsim CPU since the interface is configured for Plcsim. Depending on your specific utilization of PCS7 features, certain functions might not be compatible with Plcsim/Nettoplcsim. I recommend you give it a try and see if it meets your needs. You can easily download the program here: [Nettoplcsim Download](http://nettoplcsim.sourceforge.net/). Is your WinCC Operating System running on the ES? Thank you for your response! We have one ES/OS computer and an additional OS setup. This application is intended for our laboratory to show students the integration of simulation with real systems. Specifically, we have a process where materials enter a mixer, the students modify them, and then these materials proceed to a filling station governed by the real PLC. This filling station executes specific sequences before the materials go to reserve tanks, which are simulated. We currently have one ES/OS station and one OS at the filling station. I have a question regarding your software; I attempted to use it but am unsure how to commence the procedure. Generally, we download the program to the actual PLC, start Plcsim, and then download the software onto it, followed by launching WINCC. Nevertheless, our systems aren’t operating in unison; they seem to function in separate projects, and the tags from the real PLC are not accessible while the simulation is running, and vice versa.
If you're using both the Operating System (OS) and PLCSIM on the same computer, you might not require my software. Based on your screenshot, it appears that your actual PLC connects to WinCC through an ISO connection (Industrial Ethernet), while your simulated PLC utilizes a TCP/IP connection. To address this, launch your WinCC project and access the “System Parameters” for the TCP/IP channel by right-clicking on it. In the "Unit/Logical Device Name" section, select "PLCSIM (TCP/IP)." Once you start PLCSIM, make sure to choose "PLCSIM (TCP/IP)" from the dropdown list. This should ideally allow WinCC to establish a connection with both PLCSIM and your physical CPU. However, be aware that programming both devices can pose some challenges, as you'll need to adjust the PG/PC interface each time you switch to program a different CPU. By ensuring you have the right setup, you'll enhance compatibility and streamline your programming tasks.
Thomas_v2 shared: It seems that in your situation, where both the operating system and PLCSIM are installed on the same computer, my software may not be necessary. Based on your screenshot, it appears that your actual PLC employs an ISO connection (Industrial Ethernet), while your simulated PLC operates using a TCP/IP connection. To resolve this, navigate to your WinCC project and access the "System Parameters" for the TCP/IP channel by right-clicking on it. From there, select "PLCSIM(TCP/IP)" under the Unit/Logical Device Name section. When launching PLCSIM, ensure you also choose "PLCSIM(TCP/IP)" from the dropdown menu. This should allow WinCC to connect to both the PLCSIM and your physical PLC CPU. However, keep in mind that programming both simultaneously can be challenging, as you will need to switch the PG/PC interface each time you want to program a different CPU. Thank you for your response. I've already tried that. The issue is that both systems work perfectly on their own, but I encounter a problem when running PLCSIM. I am unable to send commands through the actual PLC while PLCSIM is active. Once I close PLCSIM in WinCC, I can send commands freely through the real PLC. Essentially, the main issue is that PLCSIM must be closed in order for me to send commands through the real PLC. Our goal is to have both systems operational simultaneously without needing to close PLCSIM.
It seems that the Simatic Manager automatically disables all other communication channels when it detects an active PLCSIM instance. This precaution appears to prevent users from inadvertently programming a physical PLC while intending to conduct tests solely on PLCSIM. Unfortunately, there doesn’t seem to be a straightforward solution for operating this configuration on a single PC. If you have an additional PC equipped with both Step7 and PLCSIM, you may consider installing NETTOPLCSIM on that machine, allowing you to program PLCSIM over the network. However, keep in mind that PCS7 includes specific features such as licensing that are tied to the PLC. When PLCSIM runs on the same system, Step7 recognizes its presence and subsequently disables the licensing functionality. I recall attempting similar tests several years ago, but they didn't yield successful results.
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Answer: - Ensure unique IP addresses or node identifiers for PLCsim and the real PLC. - Verify the communication settings in WINCC and NetPro to confirm both systems are set up correctly. - Make sure that there are no resource conflicts and that
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