Serv2 02e Hw Sw-comm

Hardware and Software Commissioning

SIMATIC S7 Siemens AG 2005. All rights reserved.

Date: File:

02.12.2005 SERV2_02E.1

SITRAIN Training for Automation and Drives

Contents Page Objectives .......................................................................................................................................... 2 Commissioning Checklist ............................................................................................................... 3 LEDs on the S7-300™ Power Supply ............................................................................................. 4 LEDs on the S7-300™ CPU ............................................................................................................ 5 LEDs on Digital Modules ................................................................................................................. 6 LEDs on the S7-400™ Power Supply ............................................................................................ 7 LEDs on the S7-400™ CPU ............................................................................................................. 8 Performing a Memory Reset and Warm Restart .............................................................................. 9 Hardware Configuration and Parameter Assignment ....................................................................... 10 Inserting a Station .......................................................................................................................... 11 Starting the HW Config Editor ........................................................................................................... 12 Generating a Hardware Setpoint Configuration ................................................................................. 13 CPU Properties: Cycle/Clock Memory ........................................................................................... 14 Saving the HW Setpoint Configuration and Downloading it in Module ............................................. 15 Uploading the Actual HW Configuration into the PG/PC ................................................................... 16 Module Address Overview ............................................................................................................... 17 HW Config: Edit Symbolic Names, Monitor / Modify Variables ...................................................... 18 Monitoring and Modifying Variables ................................................................................................. 19 Saving the Variable Table ............................................................................................................... 20 Opening a Variable Table and Establishing a Connection to the CPU ............................................. 21 Modifying Outputs in the Stop State ................................................................................................ 22 Exercise 1: Performing a CPU Memory Reset and Warm Restart ...................................................... 23 Exercise 2: Retrieving a Project and Save As .................................................................................... 24 Exercise 3: Adapting the Setpoint Configuration ................................................................................. 25 Exercise Preparation: Attaching the Fault Simulation Connector ..................................................... 26 Exercise 4: Testing the Sensor‘s Wiring on the Conveyor Model ....................................................... 27 Exercise 5: Testing the Actuator‘s Wiring on the Conveyor Model .................................................. 28 Exercise 6: Checking the Interface of the TP170B.............................................................................. 29 Exercise 7: Downloading a ProTool Project ........................................................................................ 30 Exercise 8: Downloading the Program ................................................................................................ 31 Exercise 9: Function Test of the Conveyor Model............................................................................... 32 SITRAIN Training for Automation and Drives

Page 1

ST-SERV2 Hardware and Software Commissioning

Objectives Upon completion of this chapter the participant will ... ...

know the meanings of the LEDs on the S7 modules

...

be able to perform a CPU memory reset

...

with the "Monitor/Modify Variables" tool...



•

...be able to create and save a variable table

•

...be able to check the wiring of the sensors

•

...be able to check the wiring of the actuators

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02.12.2005 SERV2_02E.2

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Commissioning Checklist

• Perform a CPU memory reset. • Carry out a CPU warm restart. • Check the LEDs on the modules. • Start the SIMATIC Manager. • Download the hardware configuration • Check inputs using the Monitor/Modify Variable tool. • Check outputs using the Monitor/Modify Variable tool.


Checklist

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The checklist shows the individual preparatory steps for commissioning the hardware. If you do not want to use the default setting, it may be necessary to assign parameters to the modules before you check the inputs and outputs. The individual steps are described in more detail on the following pages.


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LEDs on the S7-300™ Power Supply LED "DC24V"

State

Reaction of the Power Supply

Continuous On 24 V available

24 V available

Output circuit is overloaded: • Voltage dip, voltage recovery when overload no longer exists

• up to 130% (dynamic)

Flashing

• up to 130% (static) voltage depression, reduces the service life

• up to 130% (static)

Off

Short circuit in output circuit

Voltage interruption, automatic recovery when short circuit eliminated

Off

Overvoltage or undervoltage on the primary side (permissible range: 187V to 264 VAC)

Overvoltage can cause destruction. With undervoltage, automatic interruption.


LED


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The power supply has a diagnostic LED "DC24V" on the front side of the module. Use this LED to determine the state of the power supply.

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LEDs on the S7-300 CPU

SIMATIC S7

Date: File:

Siemens AG 2005. All rights reserved.

Status Displays ( LEDs )

SF BATF DC 5V FRCE RUN STOP

SF DP BUSF (BF)


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= System Fault: group error, programming error or fault from a diagnostics-capable module = Battery fault: battery is empty or is not present = 5V supply voltage present. = Lights up when a forcing is active. = Flashes when the CPU starts up and is steady on in the RUN mode. = Is steady on in the STOP mode, Flashes slowly when a memory reset is requested and flashes quickly when a memory reset is carried out. = System Fault DP: group error in the Distributed Peripherals is steady on when there is a fault in the distributed peripherals = Bus fault, is steady on when there is an interrupted cable, for example. Flashes when there is a station failure, for example

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LEDs on Digital Modules S7-300

Status LEDs for every individual channel

S7-400

Signal state at the terminals • Signal state at the terminals (for digital inputs) • Internal state, before the optocoupler (for digital outputs)


Status LEDs


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There are LEDs for diagnostics purposes for every input and output channel on the module. These LEDs can be helpful in locating program errors. The LEDs indicate: • the process state for digital inputs • the process state for S7-300 digital outputs • the internal state before the optocoupler for S7-400 digital outputs.

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LEDs on the S7-400 Power Supply "INTF" -> internal fault "BAF" -> battery fault "BATT1F"-> Battery 1 empty or missing "BATT2F"-> Battery 2 empty or missing "DC 5V" -> 5 V OK "DC 24V"-> 24 V OK "FMR" Acknowl. switch (Fault Message Reset) On/Off switch (Standby) Battery compartment

Selection switch for battery monitoring "BATT INDIC" "VOLTAGE" selector 3-pin power connection


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Power Supply

The power supply (PS) supplies the internal 5V voltage for the modules. Automatic adjustment is made for line frequencies from 48 to 64 Hz.

LED "INTF"

Lights up in the event of internal faults, such as • Short circuit or overload at 5V/24V • Standby switch on "0" and impermissible external supply • Battery fault

LED "BAF"

Battery fault. Lights up if the battery voltage on the backplane bus is too low. Example: No batteries present or battery failure and there is no external power supply available.

LED "BATT1F/ BATT2F"

Lights up in the case of battery reversal, if no battery is present, or the battery is half discharged. The BATT.INDIC switch for battery monitoring is set to the 1BATT position (for one battery), the 2BATT position (for 2 batteries) or OFF (no battery monitoring).

LED "DC 5V/DC 24V" Is lit when the 5V/24V DC output voltage is within the tolerance limits and flashes to indicate voltage recovery after a short circuit or overload. "FMR" Ackn.Switch

Acknowledgement switch for acknowledging and resetting a fault message when the fault has been eliminated.

ON/OFF Switch (Standby)

Switches the output voltage (5/24 VDC) to 0V and switches off the LEDs by interrupting the control current circuit. (The power supply is then in standby mode because the primary line voltage cannot be switched off.)


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LEDs on the S7-400 CPU

INTF

INTF

EXTF

EXTF

BUS1F

BUS1F

FRCE

BUS2F FRCE

CPU with one interface


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CPU with two interfaces SITRAIN Training for

02.12.2005 SERV2_02E.8

Automation and Drives

Fault LEDs

CPUs have fault LEDs that provide first information about an occurred error or that give the CPU status:

LED "INTF"

Indicates an internal fault (error in the user program ).

LED "EXTF"

Indicates an external fault (fault in an I/O module).

LED “BUS1F"

Indicates a bus fault of the MPI/DP interface.

LED “BUS2F"

Indicates a bus fault of the DP interface.

LED "FRCE"

Indicates that inputs/outputs are forced.


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Performing a Memory Reset and a Warm Restart RUN-P

1. Set the mode selector switch to STOP

RUN STOP MRES

2. Hold the mode selector switch in the MRES position until the STOP LED has flashed twice slowly. Release the mode selector switch so that it returns to the STOP position.

RUN STOP MRES

RUN STOP MRES RUN-P RUN STOP MRES

within 1 sec RUN-P

3. Turn the mode selector switch to the MRES position once more until the STOP LED begins to flash quickly. Release the mode selector switch so that it returns to the STOP position.

RUN STOP

RUN STOP MRES

MRES RUN-P RUN

4. Set the mode selector switch to the RUN-P (RUN) position ! (A warm restart is carried out in the transition from STOP to RUN/RUN-P)

STOP

RUN STOP MRES

MRES


Memory Reset

Warm Restart


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When a memory reset is performed on an S7 CPU, the following happens: • all CPU user data as well as the entire load and work memory are cleared • the CPU interrupts all connections to other communications partners • the CPU parameters and all modules are set to default values • in the case that a memory card is used, the CPU copies the relevant portion of the stored program needed for execution into the internal RAM During a warm restart, the process images and the non-retentive data are deleted. A new cycle begins after the process image input tables (PII) are read in.

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Hardware Configuration and Parameter Assignment Configuration

Parameter assignment

Assignment of racks, blocks and distributed I/O in the Hardware Configuration tool. You can select the components from a hardware catalog.

Parameter assignments such as retentive areas, scan cycle time, and set-up of analog input cards

Setpoint configuration

Planned hardware configuration and parameter assignment.

Actual configuration

Actual configuration and parameter assignment of existing hardware.


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HW Configuration

The modules are supplied from the factory with preset parameters. If these default settings are OK, a hardware configuration is not necessary. A configuration is necessary: • if you want to modify preset parameters or addresses of a module (such as to enable the hardware interrupt of a module) • if you want to configure communication connections • with stations that have distributed peripherals (PROFIBUS-DP) • with S7-400™ stations that have several CPUs (multicomputing) or expansion racks • with fault-tolerant programmable logic controllers (option package).

Setpoint Configuration

When you configure a system, a setpoint configuration is created. It contains a hardware station with the planned modules and the associated parameters. The PLC system is assembled according to the setpoint configuration. During commissioning, the setpoint configuration is downloaded to the CPU.

Actual Configuration In an assembled system, the actual existing configuration and parameter assignment of the modules can be uploaded from the CPU. This creates a new HW station in the project. A configuration upload is necessary, for example, if the project structure does not exist locally at the PG. After the actual configuration is read out, you can set parameters and add part numbers. Notes


With the S7-400™, the CPU can be assigned parameters in such a way, that when there are differences between the setpoint configuration and the actual configuration, the CPU startup is interrupted. To call the HW Config tool, there must be a hardware station in the SIMATIC® Manager.

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Inserting a Station


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Insert Station You insert a new station in the current project by selecting the menu options Insert -> Station -> SIMATIC® 300 Station or SIMATIC® 400 Station. You can then change the name that is automatically given to this station "SIMATIC® 300 (1)" - to one of your choice.


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Starting the HW Configuration Editor


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HW Config

This tool helps you configure, assign parameters to and diagnose the hardware.

Starting HW Config

To start the HW Config tool: • select a hardware station in the SIMATIC® Manager and choose the Edit --> Open Object menu or • double-click the hardware object.

"Hardware Configuration"

This is a window in the "HW Config“ application you use for inserting components from the "Hardware Catalog" window. The title bar of this window contains the name of the project and the station name.

"Hardware Catalog"

To open the catalog: • select the View -> Catalog menu or • click the icon in the toolbar. If “Standard” is selected as the catalog profile, all racks, modules and interface modules are available in the "Hardware Catalog" window. You can create your own catalog profiles containing frequently used elements by selecting the menu options Options -> Edit Catalog Profiles. You can add Profibus Slaves that do not exist in the catalog later on. To add slaves, you use GSE files that are provided by the manufacturer of the slave device. The GSE file contains a description of the device. To include the slave in the hardware catalog, use the Options -> Install New GSE Files menu and then Options -> Update Catalog. You will find the new devices in the catalog under Profibus, additional field devices.


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Generating a Hardware Setpoint Configuration


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Generating a Setpoint Configuration

This means specifying how the modules are to be arranged in the rack. This configuration, specified by you, is referred to as the setpoint configuration.

Rack

For example, you open a SIMATIC® 300 station in the Hardware Catalog. Opening the "RACK-300" folder shows the icon for a DIN rail. You can insert this in the "Hardware Configuration" window by double-clicking on it (or using drag & drop). Two rack component lists then appear in the two-part window: a plain list in the top part and a detailed view with order numbers, MPI addresses and I/O addresses in the bottom part.

Power Supply

If a load current power supply is required double click or use drag & drop to insert the appropriate "PS-300" module from the catalog in slot no.1 in the list.

CPU

You select the CPU from the "CPU-300" folder, for example, and insert it in slot no. 2.

Slot No. 3

Slot no. 3 is reserved as the logical address for an interface module (for multitier configurations). If this position is to be reserved in the actual configuration for the later installation of an IM, you must insert a dummy module DM370 (DUMMY).

"Inserting" Modules

From slot no. 4 onwards, you can insert a choice of up to 8 signal modules (SM), communications processors (CP) or function modules (FM) from the HardwareCatalog using drag & drop or with a double-click. The slots on which the selected module can be inserted are automatically highlighted in green.


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CPU Properties: Cycle / Clock Memory

Double-click

Clock Memory Bit Frequency (Hz) Period (s)

SIMATIC S7

6

2

1.6

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Cycle

7

0.5 0.62

•

•

5

4

3

2

1

0

1

1.25

2

2.5

5

10

1

0.8 0.5 0.4 0.2 0.1

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"Scan cycle monitoring time (ms):" - If this time is exceeded, the CPU goes into the STOP mode. Possible causes why this time is exceeded: communications processes, frequently from interrupt events, errors in the CPU program. - If you have programmed an error OB 80, the scan cycle time is doubled. After that, the CPU also goes into the STOP mode. "Cycle load from communication (%):" - Communication (such as data transmission to another CPU through MPI or test functions the PG/PC triggered) is restricted to the specified percentage of the current scan cycle time. - Restricting the cycle load can slow down communication between the CPU and PG. - Example: Restricting communication to 20% results in a maximum communication load of 20ms for a scan cycle time of 100ms.

Size of the Process Image

With the CPU 318-2 and several S7-400™ CPUs, you can specify the size of the process image (in bytes). The process image area always begins with input and output byte 0.

Clock Memory

Clock memories are bit memories that change their binary value periodically (pulse-to-pause ratio 1:1). Each bit in the clock memory byte is assigned a particular period/frequency. Example of a flashing light with a flashing frequency of 2Hz :


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Saving the HW Setpoint Configuration and Downloading it in Module

Download (only when CPU is in STOP mode)


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SITRAIN Training for

02.12.2005 SERV2_02E.15


Save

You select the Station->Save menu to save the current configuration in the current project (without generating system data blocks).

Save and Compile

When you select the Station->Save and Compile menu or click the icon in the toolbar, the configuration and parameter assignment data are also saved in system data blocks.

Consistency Check

You select the Station -> Consistency Check menu to check whether it is possible to generate configuration data from the entries made.

Download in Module You select the PLC -> Download menu or click the download the selected configuration to the PLC. The PLC must be in "STOP" mode!

icon in the toolbar to

System Data Blocks The system data blocks (SDBs) are generated and modified when you configure the hardware and compile the hardware configuration. SDBs contain configuration data and module parameters. When a system data block is downloaded, it is stored in the CPU‘s work memory. This makes it easier to replace modules, because the parameter assignment data is downloaded to the new module from the system data blocks on startup. In the programming device, the system data blocks are saved under: Project \ Station \ CPU \ S7_program \ Blocks \ System_data. You double-click the System data briefcase icon to see the list of system data blocks. If you use a memory card as Flash EPROM, you should save the SDBs there as well. That way, the configuration is not lost if you operate without battery backup and there is a power failure.


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Uploading the Actual HW Configuration to the PG/PC


Introduction

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A configuration is necessary only in the following cases: • if you want to modify the basic module settings • for stations with distributed I/O • for S7-400™ with several CPUs or with expansion racks You can read out the actual configuration from the CPU and look at the set parameters in an existing system.

Actual Configuration During startup, the CPU generates an actual configuration. That is, the CPU saves the arrangement of the modules and allocates the addresses in accordance with a fixed algorithm. If no parameters have been assigned, the default parameters defined at the factory are used. The system stores this actual configuration in system data blocks. Uploading to PG/PC

There are two ways of uploading the actual configuration to the PG/PC: 1. In the SIMATIC® Manager: select the PLC -> Upload Station menu. 2. In the HW Config tool: select the PLC -> Upload menu or click the icon.

Storage on PG/PC

The actual configuration read from the hardware is inserted as a new station in the selected project on the PG/PC.

Note

When you read out the actual configuration, the order numbers of the modules cannot be completely identified. For this reason, you should check the configuration. If required, insert the exact module type of the existing modules. To do so, choose the module, and then select the Options -> Specify Module menu.


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Module Address Overview

“Address Overview”


Address Overview

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Views the I/O addresses of the station configured. Select: View -> Address Overview … Abbreviations: R Rack number S Slot number of the relevant module DP Relevant only when Distributed Peripherals (I/O) are used IF Interface module ID when programming the M7 system (in C++).


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HW Config: Edit Symbolic Names, Monitor/Modify Variables

Once with right


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Edit Symbolic Names You can directly access the symbol table from the "HW Config" tool. This allows you to assign symbolic names to the inputs and outputs during hardware configuration or at a later date when you can make suppliments or changes. You open the symbol table with a right mouse click on the module. Select Edit Symbolic Names in the follow-up box. A section of the symbol table with the relevant addresses is then opened. Monitor/Modify Variables

You can monitor or modify the addresses of the configured modules directly from the HW Config tool. The signals of the input modules can be "checked" and the signals of the output modules can be "controlled" using the Monitor/Modify (Variables) function.

Product Support Information

Directly from the Internet, you can fetch information on modules or components from the Product Support pages. As well, it is also possible to update HW Config by incorporating individual components such as new CPUs or new DP devices into the current STEP 7 version. Requirements: The PG/PC has an Internet connection, a browser for displaying Internet pages, and the function is enabled in the HW Config Settings along with the specification of the Internet address.

Note

"Symbolic Addressing" and the editing of symbol tables is dealt with in depth in the "Symbols" chapter. The Monitor / Modify Variables function is dealt with in the "Troubleshooting" chapter.


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Monitoring and Modifying Variables

SIMATIC S7

Date: File:


Monitor


You can monitor variables in two ways: • The monitor values can be updated once when you select the Variable -> Update Monitor Values menu option or click the icon. •

Modify

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The monitor values can be updated every cycle when you select the Variable -> Monitor menu option or click the icon.

Procedure for modifying variables: 1. With the left mouse button, click the line in the “Modify Value” column for the variable that you want to modify. 2. Enter the value in the correct form for the data type selected. 3a. To activate the modify values once, select the Variable -> Activate Modify Values menu option or click the icon (or item 3b). 3b. To activate the modify values every cycle, select the Variable -> Modify menu option or click the icon. 4.

Modify Value Valid

Use the "Monitor" function to confirm that the modify value has been entered in the variable you selected.

You can make the "Modify value" entered in a table invalid by selecting that value and clicking on the icon. The now "invalid" value is displayed like a comment. You can make the modify value "valid" again when you click on the icon again. Only valid modify values can be activated.


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Saving the Variable Table


Saving the Variable Table

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You can use Table -> Save or Table -> Save as... to save a variable table. The first time a variable table is saved, the Save As... dialog window opens. The Save as ... window allows the user to select the Blocks folder that the variable table will be stored in. You can give the variable table any name you choose. The name is inserted as the symbolic name in the symbol table. You can reuse saved variable tables for monitoring and modifying, making it unnecessary to re-enter the variables.


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Opening a Variable Table and Establishing a Connection to the CPU

Accessible CPUs Directly connected CPU

Station11 Station

Configured CPU (VAT from HW Station "Station 2")

Station 2

Station 3

PG


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Area of Use

You can double-click to reopen variable tables that are stored in a Blocks folder of an S7 program at a later time for test purposes. However, before you can activate the "Monitor" and "Modify" functions, an online connection to a CPU has to be established. Using the menu commands PLC -> Connect to . . . provides three connection choices: Configured CPU, Direct CPU and Accessible CPU. There are toolbar icons for connecting to the Configured CPU or Direct CPU.

Configured CPU

If the variable table is stored in the Blocks folder of a hardware-dependent S7 program (assigned to a CPU in the project view), a connection to the station with the MPI address is established. This station was also assigned to the higherlevel CPU with the help of the HW Config tool. If the variable table is stored in the Blocks folder of a hardware-independent S7 program folder (assigned directly to the project root in the project view), the MPI address of the hardware-independent S7 program can be established using the Properties dialog of the program folder while in the online view of the SIMATIC® Manager.

Direct CPU

This menu command establishes an online connection between the active variable table and the CPU to which the MPI cable from the PG/PC to the programmable controller is connected. The PG can determine to which PLC it is connected through the MPI cable.

Accessible CPU

This menu command establishes an online connection between the active variable table and a CPU that you select. If the user program is already linked to a CPU, this menu command can be used to change the CPU. Select a CPU to which you want to establish an online connection in the dialog box. You can choose between configured and accessible CPUs.


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Modifying Outputs in the Stop State


Function and Area of Use

What To Do

Note


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The "Enable Peripheral Outputs" function can only be activated when the CPU is in the STOP state. It switches off the output disable of the peripheral outputs (PQ). This enables you to modify the peripheral output when the CPU is in the STOP mode. The "Enable Peripheral Outputs" function is used mainly to check the wiring of the peripheral outputs. It can, however, also be used to continue to control actuators in the process, even though the CPU has gone into the STOP mode because an error has occurred. To enable the peripheral outputs, proceed as follows: 1. Open or edit a variable table (VAT) that contains the peripheral outputs that you want to test or modify (specify the peripheral outputs byte-by-byte, word-by-word or doublewordby- doubleword; you cannot modify individual output bits!) 2. Select the PLC -> Connect to… menu option to establish a connection to the CPU you want 3. Switch the CPU to the STOP state 4. Enter the appropriate values for the peripheral outputs you want to modify in the "Modify Value" column. Examples: PQB 7 Modify Value: 2#01000011 PQW 2 W#16#0027 PQD 4 DW#16#0001 5. Use Variable -> Enable Peripheral Outputs to activate the modifying of the outputs 6. Use Variable -> Activate Modify Values to modify the peripheral outputs. 7. To assign new modify values, enter these and then activate them with Variable -> Activate Modify Values Modifying or "Enable Peripheral Outputs" remains active until you deactivate it using Variable -> Enable Peripheral Outputs or you press the ESC key. When you change the operating mode of the CPU from STOP to RUN or STARTUP, the Enable Peripheral Outputs is deactivated and a message appears.

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Exercise 1: Performing a CPU Memory Reset and Warm Restart Memory Re set Function

Request Memory Reset

Manually - Mode selector in “STOP” position

- Mode selector in “RUN-P” position

- Hold mode selector in “MRES” position until the “STOP” LED flashes twice (slowly)

- Menu options: PLC -> Diagnostic/Setting -> Operating Mode -> Stop

- Release mode selector (returns automatically to the “STOP” position)

Perform Memory Reset

Perform Warm Restart

From the PG

- Switch the mode selector quickly to the "MRES" again and release (fast flashing of "STOP" LED indicates memory reset being performed) - Switch mode selector to "RUN" or "RUN-P" position


- Menu options: PLC -> Diagnostic/Setting -> Clear/Reset

- Confirm memory reset by clicking the “OK” button (fast flashing of "STOP" LED indicates memory reset being performed) - Menu options: PLC -> Diagnostic/Setting -> Operating Mode -> Warm Restart

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After Inserting a Memory Card - Mode selector in “STOP” position - Insert Memory Card (slow flashing of "STOP" LED indicates request for memory reset)

- Switch the mode selector quickly to the "MRES" position and release (fast flashing of "STOP" LED indicates memory reset being performed) - Switch mode selector to "RUN" or "RUN-P" position


Task

You are to perform a CPU memory reset and check whether the memory reset was successful.

What to Do

1. Carry out the memory reset according to the steps in the slide above 2. Check the success of the memory reset (only if you have a CPU previous to Oct. 2002. The memory reset was successful when only system blocks (SDBs, SFCs, SFBs) are left in the CPU . In the SIMATIC Manager -> switch to the Online View using -> double-click on MPI=2 -> double-click on Blocks

Notes

When the CPU memory is reset, all user data in the CPU are deleted. To make sure that no “old” blocks are left in the CPU, a memory reset of the CPU should be performed. The following takes place during a memory reset: • All user data are deleted (with the exception of the MPI parameter assignments). • Hardware test and initialization • If an Eprom memory card or a Micro Memory Card is installed, the CPU copies the memory card contents back into the internal RAM after the memory reset. • If no memory card or Micro Memory Card is installed, the preset MPI address is retained. If, however, a memory card is installed, the MPI address stored on it is loaded. • The contents of the diagnostic buffer (which can be displayed with the PG) are retained


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Exercise 2: Retrieving a Project and Save As


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Task

You are to retrieve a project and save it under the name "My_Project".

What to Do

1. Start the SIMATIC Manager 2. Delete the old project "My_Project" (should it exist): File -> Delete -> User Projects -> select "My_Project" from the list -> confirm 3. Retrieve the project “SERV2_A": File -> Retrieve -> select "SERV2_A.ZIP" from the list -> acknowledge with "OK" -> select "S7-Courses" from the list of target directories -> acknowledge message with "YES" 4. Save the project under the name "My_Project" File -> Save as... -> User projects -> enter "My_Project" as the name -> confirm

Notes

The project contains the program for the conveyor model as you edited it in the previous course - ST-SERV1, a hardware station and a ProTool/Pro project for the TP170B.


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Exercise 3: Adapting the Setpoint Configuration

SIMATIC S7

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02.12.2005 SERV2_02E.25


Task

Since different training units and CPUs are used for the courses, the available CPU has to be integrated into the setpoint configuration. During the course, corrections to the hardware configuration also have to be made.

Note

If you have an S7-400 training unit, use the HW Station "S7-400".

What to Do

1. 2. 3. 4. 5.


Start the "HW Conf" tool Adapt the hardware configuration for the training unit Exchange the CPU for correct one Save and compile the configuration Download the configuration into the CPU

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Exercise Preparation: Attaching the Fault Simulation Connector

Fault simulation connector


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Task

In the following two exercises, you are to check the wiring of the sensors and actuators of the conveyor model to the digital input and output modules. The errors that you are to determine are simulated using a fault simulation connector. This connector must first be attached to the conveyor model.

What to Do

1. Remove the 32-pin Sub-D plug on the conveyor model 2. Attach the fault simulation connector to the conveyor model 3. Attach the 32-pin Sub-D plug to the fault simulation connector


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Exercise 4: Testing the Sensor‘s Wiring on the Conveyor Model

SIMATIC S7

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02.12.2005 SERV2_02E.27


Task

In this exercise, you are to check the wiring of the conveyor model‘s sensors to the digital input modules according to the symbol table (see slide). You will check the wiring of the actuators in the next exercise.

Note

The errors that occur are simulated by the fault simulation unit that you just attached. Your task is to determine the errors, not to eliminate them!

What to Do

1. Start the "Monitor/Modify Variable" function SIMATIC® Manager -> PLC -> Monitor/Modify Variable 2. Enter the inputs shown in the slide into the variable table. Activate variable monitoring using Insert -> Range of Variables -> as of Address: I 4.0, Number: 8, Display Format: BIN 3. To check the input wiring, press the sensors on the conveyor model one after the other and observe whether the associated input states are displayed on the screen 4. After you have completed the input wiring test, save the variable table under the name "I/O Conveyor Model" Table -> Save as... -> in the dialog, open the Blocks folder of the HW Station "S7_300 _Station" -> enter the object name "I/O Conveyor Model" -> OK 5. Exit the Monitor / Modify Variable function

Result


.

1st. error:

................................................................................................

Possible Cause:

................................................................................................

2nd. error:

................................................................................................

Possible Cause:

................................................................................................

Page 27


Exercise 5: Testing the Actuator‘s Wiring on the Conveyor Model

Example: Conveyor to the right

SIMATIC S7

Date: File:



02.12.2005 SERV2_02E.28


Task

Now check the wiring of the conveyor model‘s actuators to the digital output modules using the function "Enable Peripheral Outputs" .

What to Do

1. Open the "I/O Conveyor Model" variable table from the previous exercise SIMATIC® Manager -> open the Blocks folder of the HW Station "S7_300_Station" -> double-click on "I/O Conveyor Model" 2. Add the peripheral output byte PAB 0 Display format "binary" to the variable table 3. Even if it isn‘t necessary here: Establish a connection to the directly connected CPU PLC -> Connect to -> Direct CPU 4. Activate the function "Enable Peripheral Outputs" Variable -> Enable Peripheral Outputs 5. To test the output wiring, enter the state 1 for the respective output in the column "Modify Value", activate it using and observe whether the associated actuator on the conveyor model is energized. 6. Exit the Monitor / Modify Variable function.

Result


1st. error:

................................................................................................

Possible cause:

................................................................................................

2nd. error:

................................................................................................

Possible cause:

................................................................................................

3rd. error:

................................................................................................

Possible cause:

................................................................................................

Page 28


Exercise 6: Checking the Interface of the TP170B Loader B6.0.2.16 Transfer

Start Control Panel

OK X

MPI Panel is the only master on bus Station Parameters Address: Time-out:

OK X

Transfer Settings Channel

Directories

MPI Profibus

Channel 1: Serial:

S7-Transfer Settings

Enable Channel

1 1s

NetworkParameters OK X Rate: Transmission

187,5 kbits\s

Highest Station:

31

Remote Control Channel 2: MPI

Properties...

Enable Channel Remote Control

SIMATIC S7

Advanced

Date: File:


02.12.2005 SERV2_02E.29


Task

The interface of the TP170B is to be set up as in the slide, so that the ProTool/Pro project can then be downloaded from the PG.

What to Do

1. 2. 3. 4. 5. 6. 7. 8.


Exit Runtime on the TP170B Press the "Control Panel" button Double-click on the "Transfer" icon Define the settings as in the slide With "OK", accept the settings until you get back to the "Control Panel" Double-click on the "OP" icon Press the "Save Registry" button With "OK", accept the settings until you get back to the screen with the "Transfer", "Start" and "Control Panel" buttons 9. Press the "Transfer" button. The TP 170B then waits for a connection from the PG.

Page 29


Exercise 7: Downloading a ProTool Project


Date: File:

02.12.2005 SERV2_02E.30


Task

You are to download the ProTool/Pro project to the TP170B.

What to Do

1. Open the ProTool/Pro project by double-clicking on the object "TP170B_Colour" 2. Click on the "Download" icon 3. Acknowledge the messages that follow 4. Exit ProTool/Pro.


Page 30


Exercise 8: Downloading the Program


Date: File:

02.12.2005 SERV2_02E.31


Task

The "Demo_1" S7 program contains the program for the conveyor model from the previous course - ST-SERV1. This program is to be downloaded and in the next exercise the function is to be tested.

What to Do

1. Select the "Blocks" object from the "Demo_1" S7 program 2. Click on the icon 3. Acknowledge the message "Do you want to load the system data?" with "No". 4. Switch on the conveyor model with S5 = ON 5. Connect the TP 170B and the PG to the MPI interface and the ET 200S and the Micromaster to the Profibus interface 6. Carry out a warm restart on the CPU.


Page 31


Exercise 9: Function Test of the Conveyor Model


Date: File:

02.12.2005 SERV2_02E.32


System Function

The conveyor model is to be operated through a screen on the TP170B as follows.

System ON/OFF

The system is switched on through the "System On" button and off through the "System Off" button. When the system is on, you can then set the manual mode or the automatic mode.

Manual Mode

The manual mode is selected with the "Auto/Manual" switch and is accepted with the "Accept" button. In manual mode, a part can be moved in the direction of the light barrier with "Jog right" or in the other direction with "Jog left" as long as the appropriate button is pressed.

Automatic Mode

When the system is on, automatic mode can be selected with the "Auto/Manual" switch and can be accepted with the "Accept" button. In automatic mode, the parts are placed on the conveyor in front of the proximity sensor "Ini1" or "Ini2". After acknowledging with the appropriate "S1" or "S2" momentary-contact switch, the conveyor moves until the part has crossed the light barrier. If the conveyor doesn‘t reach the light barrier within 6 seconds, the conveyor stops and a fault is indicated on an LED on the simulator. This fault can be acknowledged by pressing the momentary-contact switch I1.0 ("T_Ackn_Fault). The number of completed parts are counted as they cross the light barrier and are displayed on the output field "Actual_Quantity". When the preset setpoint quantity is reached, it is indicated on the LED "H4" on the conveyor model. Until this is acknowledged with the momentary-contact switch "S4", no new transport function can be started.


Page 32


Serv2 02e Hw Sw-comm

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