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Name: Course: from to Instructor: Infoline Tel: 01805 23 56 11 Fax: 01805 23 56 12 Internet: http://www.siemens.com/sitrain Version V5.9.1

(for STEP? V5.4 SP3. WinCC flexible 2008. Starter V4.0)

SIMATIC S7

TIA-Service Training 1

2. Training Units and Addressing

3. Installation/Maintenance of the Programmable Logic Controller

4. The SIMATIC Manager

5. Symbols

6. Hardware Configuration

7. Hardware Commissioning

8. Block Architecture and Block Editor

9. Binary Operations

10. Digital Operations

11. Introduction to HMI and PROFIBUS DP

12. Rewiring a User Program

13. Introduction to Micromaster

14. Documenting, Saving, Archiving

15. Closing Exercise

16. Solutions

17. Training and Support

18.

19.

20.

SIEMENS

Information and Training

Automation and Drives

ST-SERV1 Course

AL: N ECCN: 5D992

Export Regulations

AL Number of European resp. German export list.

Goods with labels not equal to "N" are subject to export authorization. ECCN Number of US export list. (Export Control Classification Number). Goods

with labels not equal to "N" are subject to re-export authorization for export to certain countries.

Indication Goods labeled with "AL not equal to N" (here: technical documentations)

are subject to European or German export authorization when being exported out of the EU.

Goods labeled with "ECCN not equal to N" (here: technical documentations) are subject to US re-export authorization.

Even without a label, or with label "AL:N" or "ECCN:N", authorization may be required due to the final whereabouts and purpose for which the goods are to be used (here: technical documentations). Decisive are the export labels stated on order acknowledgements, delivery notes and invoices.

This document was produced for training purpose. SIEMENS assumes no responsibility for its contents.

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable to damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

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SIEMENS

Date: 18.09.2009 File: SERV1_01E.1

2.1 SITRAIN Training for

qtr Automation and Industrial Solutions

Contents Page

The SIMATIC S7 System Family ... 2

Objectives 3 SIMATIC S7 Overview ... 4

What does "Totally Integrated Automation" Mean ... 5

The SIMATIC S7/C7 and WinAC Controllers ... 6

S7-200 ... 7

S7-200 Micro Controller 8 S7-200: Modules / Expansion Modules (EM) ... 9

S7 - 300 Automation System ... 10 S7-300: Modules ... 11 S7-300: CPU Design ... 12 S7-400 Automation System ... 13 S7-400: Modules ... 14 S7-400: CPU Design ... 15

SIMATIC Embedded Automation - Overview ... 16

Device Spectrum of SIMATIC Embedded Automation ... 17

An Application Example for PC-based Automation ... 18

SIMATIC Microbox 427-B RTX "Embedded PC" ... 19

SIMATIC S7- mEC (Modular Embedded Controller) ... 20

PG/PC Requirements for Installing STEP 7 ... 21

Installing the STEP 7 Basic Package ... 22

STEP 7 Tools ... 23

STEP 7 Software Packages (Examples) ... 24

If You Want to Know More about the Topic "TIA" ... 25

More Information ... 26 SITRAIN Training for

Automation and Industrial Solutions

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Page 1 The SIMATIC S7 System Family

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Date: 18.09.2009 File: SERV1_01E.2

SITRAIN Training for V, Automation and Industnal Solutions

Contents Page

Programming Sequence Control Systems with S7- GRAPH ... 27

The State Diagram Method S7- HiGraph ... 28

Programming in the High Level Language S7- SCL ... 29

CFC - Tool for Graphic Interconnection of Si Blocks ... 30

Process Diagnosis with S7- PDIAG ... 31

Testing User Programs with S7- PLCSIM ... 32

Runtime Software for Closed-loop Control Engineering Tasks ... 33

Communicating with SIMATIC NET ... 34

Operator Control and Process Monitoring with SIMATIC HMI ... 35

Process Visualization and Operator Control with WinCC ... 36

Process Automation with SIMATIC PCS 7 ... 37

DRIVES Technology ... 38

The SINAMICS Family ... 39

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SIEMENS

Objectives

Upon completion of the chapter the participant will ...

have an overview of the SIMATIC S7 system family

be familiar with the S7-300 and S7-400 automation systems have an overview of the modules available for these automation systems

understand the concept of "Totally Integrated Automation" (T.I.A.) be familiar with the programming devices

be familiar with the PC requirements for working with STEP7 be familiar with the tools of the STEP7 basic programming package have an overview of the most important tools used in the T.I.A. concept

Date: 18.09.2009

File: SERV1_01E.3

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li SITRAIN Training for Automation and Industrial Solutions

SITRAIN Training for

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Page 3 The SIMATIC S7 System Family

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SIMATIC S7 Overview

Date: 18.09.2009 File: SERV1_01E.4

1₄₇. _{Automation and Industrial Solutions}

Introduction

Hard-wired

Controllers -> PLC

For the operation of machines, equipment and processes in almost all areas of manufacturing you require control elements in addition to energy supply. It must be possible to initiate, control, monitor and end the operation of any given machine or process.

In the hard-wired controllers of the past, the program logic was governed by the task-specific wiring of contactors and relays.

Today, programmable logic controllers are used to solve automation tasks. The logic stored in the program memory of an automation system does not depend on equipment design and wiring and can be modified at any time with the help of a programming device.

Totally Integrated Production processes are no longer seen as individual partial processes, but

Automation rather as integral components of an entire production process.

The total integration of the entire automation environment is today achieved with the help of:

• one common software environment that integrates all components and tasks into one uniform easy to use system

• a common data management (central database)

• a common communication between all participating automation components.

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SIEMENS

What does "Totally Integrated Automation" Mean

Date: 18.09.2009 File: SERV1_01E.5

111 SITRAIN Training for Automation and Industrial Solutions

Totally Integrated Automation

Advantages

The new SIMATIC family unifies all devices and systems, such as hardware and software, into a uniform, powerful system platform.

In this platform existing barriers between computer, PLC, and process control have been overcome. Operator control and monitoring are improved.

This totally integrated automation offers you, among other things, the following advantages:

• A scalable hardware platform. The optimal (price/performance)

functionality (PLC or computer) can be chosen for the task to be solved. • An open totally integrated automation environment. An existing

system can be easily extended, or future automation solutions can be integrated.

Existing investments retain their value. The transition from an existing SIMATIC, TELEPERM or TI environment can be carried out very easily. • Powerful software increases the productivity in the implementation of a

project reducing the engineering and life cycle costs. In addition, expenses for commissioning, maintenance and service are reduced.

• SIMATIC is based on Windows standards and can thus easily use their applications (standard software) and communication mechanisms.

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modular —TV l•willF■PimIll =LED SIMATIC S7 - 300 Lower and middle performance range complete SIMATIC C7 — 6xx

The SIMATIC S7/C7 and WinAC Controllers

Upper and middle performance range modular

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SIMATIC 07

WinAC

The programmable logic controller family consists of the Micro PLC (S7-200) performance range, the lower/middle performance range (S7-300) and the middle/upper performance range (S7-400).

This complete system is the combination of a PLC (S7-300) and an operator panel of the HMI operator control and process monitoring system. The integration of programmable logic controller and operator panel in one device makes

complete machine controls in the smallest space and at an economical price possible.

WinAC is a PC-based solution. It is used when various automation tasks (control, visualization, data processing) are to be solved with a PC.

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S7-22x

S7-200

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Date: 18.09.2009 File: SERV1_018.7

SITRAIN Training for lir Automation and Industrial Solutions

Features • Modular small control system for the low-end performance range, • Performance-graded range of CPUs,

• Extensive selection of modules,

• Expandable design with up to 7 modules, • Backplane bus integrated in the modules, • Can be networked with

- RS 485 communications interface or - PROFIBUS or

- connected with Industrial Ethernet,

• Central PG/PC connection with access to all modules, • No slot rules for peripheral modules,

• Own software,

• "Complete package" with power supply, CPU, I/O in one device, • "Micro PLC" with integrated functions.

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S7-200 Micro Controller

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SIEMENS SINAlIC ST-200 SF RUN STOP Status Indicators for Integrated DO Status Indicators PPI Connection .1, -I, ..5...6„.2 .0 4 11 irirliqjak 214-'RD22-0Y130 Status Indicators for Integrated DI - Potentiometer - Memory Card - Mode Selector SIMATIC S7 Siemens AG 2008. All rights reserved.

Date: 18.09.2009 File: SERV1_01E.8

iv-

Mode Selector For manual mode selection of the CPU:

STOP = Stop mode, the program is not executed.

TERM = Program execution, read/write access possible from PG.

RUN = Program execution, read-only access possible from PG.

Status Indicators SF = Group error; internal CPU fault; red

(LEDs) RUN = Run mode; green

STOP = Stop mode; yellow

DP = PROFIBUS-DP (only CPU 215)

Memory Card Slot for memory card. A memory card saves the program contents in the event of a power outage without the need for a battery.

PPI Connection The programming device / text display or another CPU is connected here. This enables you to access several controllers from a PG or text display. As well, the S7-200 CPUs use the Network Read (NETR) and Network Write (NETW) instructions to read and write to each other (peer-to-peer communication).

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S7-200: Modules / Expansion Modules (EM)

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Processors (CP) SIEMENS

SIMATIC S7 Date: 18.09.2009 SITRAIN Training for

Expansion • Digital input modules:

Modules (EM) - 24VDC

- 120/230VAC • Digital output modules:

- 24VDC - Relay

• Analog input modules: - Voltage

- Current - Resistance - Thermocouple • Analog output modules:

- Voltage - Current

Communications Using the CP 242-2, the S7-200 can be connected to an AS-Interface as the

Processors (CP) master. In that way, 31 AS-Interface slaves can control up to 248 binary

elements. This greatly increases the number of inputs/outputs of the S7-200. Other communications modules are the modem and PROFIBUS-DP expansion modules. The SIMATIC NET CP 243-1 can be used to connect to Industrial Ethernet.

Accessories Bus connector

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Date: 18.09.2009

File: SERV1_01E.10

4F

Features • Modular small control system for the lower and middle performance range • Performance-graded range of CPUs

• Extensive selection of modules

• Expandable design with up to 32 modules • Backplane bus integrated in the modules • Can be networked with

- Multipoint Interface (MPI), - PROFIBUS or

- Industrial Ethernet or - PROFINET

• Central PG/PC connection with access to all modules • No slot rules for peripheral modules,

• Configuration and parameter setting with the help of the "Hardware Configuration" tool

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SIEMENS

S7-300: Modules

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SM: SM: SM: SM: FM: DI DO Al AO - Counting - Positioning - Closed-loop control

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PS CPU IM (optional) (optional) CP: - Point-to Point - PROFIBUS - Industrial Ethernet SIMATIC S7

Date:

File: 18.09.2009 SERV1_01E.11

21 SITRAIN Training for gr. Automation and Industrial Solutions

Signal Modules (SM)

• Digital input modules: • Digital output modules: • Analog input modules: • Analog output modules:

24VDC, 120/230VAC 24VDC, Relay Voltage, Current, Resistance, Thermocouple Voltage, Current Interface Modules (IM) Dummy Modules (DM) Function Modules (FM) Communications Processors (CP) Accessories

The IM360/1M361 and 1M365 make multi-tier configurations possible. The interface modules loop the bus from one tier to the next.

The DM 370 dummy module reserves a slot for a signal module whose

parameters have not yet been assigned. A dummy module can also be used to reserve a slot for installation of an interface module at a later date.

Perform "special functions": • Counting

• Positioning

• Closed-loop control.

Provide the following networking facilities: • Point-to-Point connections

• PROFIBUS • Industrial Ethernet • PROFINET.

Bus connectors and front connectors

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S7-300: CPU Design

CPU 315-2DP until Oct. 2002 CPU 315-2DP after Oct. 2002

Date: 18.09.2009 SITRAIN Training for

File: SERV1_01E.12 Automation and Industrial Solutions

Mode Selector MRES = Memory reset function (Module Reset)

STOP = Stop mode, the program is not executed.

RUN-P = Program execution, read/write access possible from PG.

Status Indicators

(LEDs) SF Group error; internal CPU fault or fault in module with diagnostics capability.

BATF = Battery fault; battery empty or non-existent.

DC5V = Internal 5 VDC voltage indicator.

FRCE = FORCE; indicates that at least one input or output is forced.

RUN = Flashes when the CPU is starting up, then a steady light in Run

mode.

STOP = Shows a steady light in Stop mode.

Flashes slowly for a memory reset request,

Flashes quickly when a memory reset is being carried out, Flashes slowly when a memory reset is necessary because a memory card has been inserted.

Memory Card

Battery Compartment

MPI Connection DP Interface

A slot is provided for a memory card. The memory card saves the program contents in the event of a power outage without the need for a battery. For CPUs after Oct. 2002, a Micro Memory Card is always necessary for operation. It also provides the backup in the event of a power outage.

For CPUs up until Oct. 2002, there is a receptacle for a lithium battery under the cover. The battery provides backup power to save the contents of the RAM in the event of a power outage. For CPUs after Oct. 2002, no battery is necessary. Connection for a programming device or other device with an MPI interface. Interface for direct connection of distributed I/Os to the CPU.

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SIEMENS

SIMATIC S7

Date: 18.09.2009 File: SERV1_01E.13

Features • The power PLC for the mid to upper performance range,

• Performance-graded range of CPUs

• Extensive selection of modules

• Expandable design to over 300 modules

• Backplane bus integrated in the modules

• Can be networked with - Multipoint interface (MPI),

- PROFIBUS or - Industrial Ethernet or - PROFINET

• Central PG/PC connection with access to all modules

• No slot restrictions

• Configuration and parameter setting with the help of the "Hardware Configuration" tool

• Multicomputing (up to four CPUs can be used in the central rack).

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SIMATIC S7

Date: 18.09.2009

File: SERV1_01E.14

A

v„

Signal Modules • Digital input modules: 24VDC, 120/230VAC

(SM) • Digital output modules: 24VDC, Relay

• Analog input modules: Voltage, Current, Resistance, Thermocouple • Analog output modules: Voltage, Current.

Interface Modules

(IM) The IM460, IM461, IM463, IM467 interface modules provide the connection between various racks: • UR1 (Universal Rack) with up to 18 modules

• UR2 (Universal Rack) with up to 9 modules • ER1 (Expansion Rack) with up to 18 modules • ER2 (Expansion Rack) with up to 9 modules.

Function Modules Perform "special functions":

(FM) • Counting

• Positioning

• Closed-loop control.

Communications Provide the following networking facilities:

Processors (CP) • Point-to-Point connections

• PROFIBUS • Industrial Ethernet • PROFINET.

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SIEMENS

S7-400: CPU Design

Error LEDs Slot for Memory

Date: 18.09.2009 File: SERV1_01E.15

2 SITRAIN Training for Il_tr_{Automation and Industrial Solutions}

Fault LEDs LEDs for the CPU's statuses and faults, both internal and external

Memory Cards With the S7-400 CPUs you can, depending on your requirements, insert RAM or flash EPROM cards as external load memory:

• RAM cards are available with a capacity of: 64KByte, 256KByte, 1MByte, 2MByte. The CPU battery backs up the contents.

• Flash EPROM cards are available with a capacity of:

64KByte, 256KByte, 1MByte, 2MByte, 4MByte, 8MByte, 16MByte. The contents are backed-up on the integrated EEPROMs.

Mode Selector

MPI / DP Interface

MRES = Memory reset function (Module RESet)

STOP = STOP mode, that is, no program execution and output disabled

("OD" mode = Output Disabled).

RUN-P = Program execution, read/write access possible from PG.

MPI / DP interface (parameter-assignable in HW-Config) for • establishing the online connection to the programming device • connecting to distributed peripherals (DP)

• data exchange with other stations (S7 Communication)

DP Interface For connecting to distributed peripherals (DP, only for CPUs with 2 interfaces)

EXT-BATT Additional external battery socket for a 5 VDC to 15 VDC source to back up the RAM when the power supply is being replaced.

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Modular Controller

Open + Standard PC

S7-mEC RTX IPC

SIMATIC S7

• Highest ruggedness • Highest ruggedness • Modularity 111 • Modularity • Scalable • Scalable

a Commissioning through • Commissioning through "Automators" "Automators"

▪ Rugged (embedded) • Commissioning requires

PC know-how

• SIMATIC Soft-PLC and HMI options

• Standard PC operating system and interfaces

• Openness (HW + SW) • State-of-the-art PC technolog

• SIMATIC Soft-PLC and HMI options

• Standard PC operating system and interfaces • Openness (HW + SW) • Stat-of-the-art PC technology ▪ H / F functionality • 10 year replacement parts availability • Long-term availability • Data-secure

The Best of Both Worlds

SIEMENS

SIMATIC Embedded Automation - Overview

Date: 18.09.2009

File: SERV1_01E.16 AutomationT_ar_na_di'_li_nlf_so_tr_{rial Solutions}

PC-based Control SIMATIC Embedded Automation is the implementation of various automation tasks (PLC programming, visualization, data processing, HMI services) on one common PC and software platform.

Today, three fundamental directions can be derived from this:

• Modular Controllers: field-proven S7-300 and S7-400 controllers with their different versions and performance characteristics

• Embedded Controllers such as SIMATIC S7-mEC and SIMATIC Microbox 427B

• SIMATIC Panel PCs with Win AC MP and Industrial PCs

For this purpose, Siemens offers the System PC based Automation as a block out of the area of "SIMATIC Totally Integrated Automation".

Configuration, programming and parameter-assignment is handled by the familiar engineering tool STEP 7 as of Version V5.4 SP4. The WinCC flexible software package makes the HMI configuration possible.

The existing WinAC RTX 2005 software is being replaced by the 2008 version. The most significant expansion is the PROFINET functionality with PN 10 and CBA (Component Based Automation). Included in this, among other things, is the high performance operation of PROFINET 10 as well as the open communication via "Open User Communication".

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...

_• _{• •} _{• -}

SIMATIC Microbox 427B- RTX SIMATIC Microbox 427B- HMI/RTX SIMATIC Panel PC 477B- HMI SIMATIC Panel PC 477B- HMI/RTX

SIMATIC Panel MP 177/277/377 + WinAC MP

SIMATIC S7-mEC

SIMATIC WinAC 2008 RTX

Device Spectrum of SIMATIC Embedded Automation

SIEMENS

Date: 18.09.2009 File: SERV1_01E.17

• SITRAIN Training for ▪ Automation and Industrial Solutions

The slide shows an overview of the most important device components that are available for SIMATIC Embedded Automation.

Device Spectrum

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PLC HMI Field device Drive Windows Ethernet interface WINAC RTX PROFINET interface

Main application case for PC-based Automation:

PROFINET 10 local "behind" CPU to avoid dependancy on system configuration (independent assignment of IP addresses).

Data server

PG/PC HMI

WinCC flexible Thin Client

System / Cell network

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An Application Example for PC-based Automation

Date: 18.09.2009 File: SERV1_01E.18

I_{hr Automation and Industrial Solutions}

Application Example The application example above shows a possible structure for the use of a

SIMATIC Microbox 427-B in an automation solution. The connection of local PN 10 slaves takes place behind the CPU to avoid dependencies on the system configuration. PROFINET 10 RT services can be used in parallel with CBA functions on the same line. Third party devices can be addressed via the open T communication (Open user communication) (T-send and T-receive).

WinAC RTX 2008

Realtime Core

SIMATIC WinAC RTX 2008 makes use of a PROFINET 10 Controller Interface for operating distributed PROFINET peripherals. Thereby, the RT and IRT operating modes are supported. Moreover, two different interface types can be operated with WinAC RTX 2008:

• the Standard Ethernet (LAN-Interface) of the SIMATIC PC

• the CP1616/1604, integrated PROFINET interface of the S7-mEC and the SIMATIC PC

The interface integration in WinAC RTX 2008 and in the familiar STEP 7

configuration takes place similar to the PROFIBUS interfaces as submodules that are used today. They behave like the integrated PN interface of the SIMATIC S7-CPUs. Basically, the following types of data transmission are available (Standard Ethernet LAN operating mode):

• PROFINET 10 RT with up to 128 PROFINET 10 devices • PROFINET Component Based Automation (CBA) • Open User Communication (T-communication) • S7 communication and routing

WinAC RTX 2008 simplifies the installation of the Ardence RTX realtime core. Effective immediately, this is completely integrated in the setup of WinAC RTX and no longer has to be installed separately.

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System Fault RUN/STOP SIEMENS 1 PS ON • BATF CPU

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INTF O EXTF BUSE-_I • BUSF2 BUSF3 BUSF4 'Ili FR CE I RUN STOP IRUN _Oi STOP M RE S SIMATIC Microbox 427-B RTX "Embedded PC"

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SIMATIC S7

_211 SITRAIN Training for

It T' _{and Industrial}_Solutions

Microbox 427B... The SIMATIC Microbox 427B-HMI/RTX is an "embedded solution" for combined controller and operator control and visualization tasks. The ready-to-go Microbox provides the WinAC RTX, WinCC flexible RT and Windows XPe software pre-installed. Special properties with regards to retentive storing of SIMATIC WinAC RTX user data exist.

Configuration and programming is done as usual with STEP 7. Industrial Ethernet and PROFIBUS interfaces are available for download activities and data

communication. Furthermore, USB interfaces, connection possibilities for flat screens (DVINGA), as well as a serial RS232 interface and up to three PC/104-Plus cards are available.

SIMATIC WinAC RTX makes the use of an "Open Development Kit" for implementing application-specific functions in the PLC program possible.

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EM PC

USB connection for mouse etc.

Thin Client EM PCI-104

Remote Desktop Protocol (RDP) for access to all S7-mEC programs EC31 RTX STEP 7 for parameterization + diagnosis (RTX) r 2x USB 1x IE/PN 1x serial 1x DVI-I lx serial 1x CF slot Connection of S7 standard peripherals Up to 3 PCI cards

SIMATIC S7- mEC (Modular Embedded Controller)

Date: 18.09.2009 File: SERV1_01E.20

SITRAIN Training for =_ Automation and Industrial Solutions

Embedded Controller The new high-performance SIMATIC S7-mEC "modular embedded controller"

completes the product portfolio in the area of the SIMATIC Controller. The benefits of a Standard S7 Controller are combined with those of a PC-based solution.

Different automation solution tasks can be implemented on one hardware p:atform with the S7-mEC. The hardware basis consists of current PC technology with an Intel Core Duo 1.2 GHz processor, a 2GB Flash Disk and 1 GB main memory. SIMATIC WinAC RTX 2008 is used as the application program, Windows XPe functions as the operating system. Remote services, such as, remote monitoring via TCP/IP services are available. The S7-mEC also has a Multimedia Card Slot (MMC).

The design without fan and hard drive is well-suited for the industrial environment. Three Industrial Ethernet ports and up to two additional USB interfaces enable the problem-free integration in existing automation scenarios.

The S7-mEC "modular embedded controller" is installed and configured like an S7-300 PLC.

SIMATIC STEP 7 V5.4 SP4 with additional hardware patch is used as the engineering tool (RTX version on the S7-mEC necessary).

WinCC flexible can be used as an additional option for operator control and monitoring. The new SIMATIC Thin Client and other Windows XPe applications can also be used.

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SIEMENS

PG/PC Requirements for Installing STEP 7

Operating Systems: Microsoft Windows 2000 Professional

Microsoft Windows XP Professional Microsoft Windows Vista

Memory on the Hard Drive: Mouse: Interfaces:

Depending on the installation, between 400 MB and 800 MB Yes

• CP5611 (PCI) or • CP5512 (PCMCIA) or • PC adapter (USB)

• Industrial Ethernet Interface (NIC)

• Programming interface for Memory Card (optional)

/

SIMATIC S7

Date: 18.09.2009

File: SERV1_010.21

A

SITRAIN Training for Automation and Industrial Solutions

Requirements SIMATIC Programming devices (PG) provide the optimum basis for using the STEP 7 software.

You can, however, also use a PC that fulfills the above-listed requirements. So that you can make the necessary online connection between the automation system (PLC) and the PC, the PC must be equipped with one of the interfaces listed in the slide above.

If user programs are to be loaded on memory cards outside of the CPU, the PC must also be equipped with the appropriate programming interface.

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SIMATIC Manager ProTsol Pro CS

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51,7 Converting 55 Files

PI LAD, STL, FBD - Programming 57 Blocks Memory Card Parameter Assignment

rks signment

State Graphs on figuring ocess Diagnostics S7-PLCSIM Simulating Modules Setting the PG-PC Interface B

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STARTER MI TI 405-S7 Converting TI Files TI 5135-57 Converting TI Files Programs Documents ' Settings Search • Help and Support

r 0 Run...

Log Off se3997... 43 Shut Down... d Start SIMATIC Manager [c) STEP 7 S7/M7/C7 About 6,0₁

Installing the STEP 7 Basic Package

SITRAIN Training for %T Automation and Industrial Solutions

Installation

Date: 18.09.2009 File: SERV1_01E.22

2. Choose options 3. Choose language(s)

4. Insert authorization disk when prompted. 5. Re-boot when prompted

1. Activate "Setup.exe" on the Installation CD or use the automatic Setup routine activation

Software Protection

Notes

Hot fixes Result

The STEP 7 software is copy-protected and can only be used on one programming device at a time.

When you have installed the software, you cannot start using it until you have transferred the authorization to the hard disk drive from the authorization disk. • Be sure to read the notes in the README.TXT file on the authorization disk. If

you do not observe these instructions, you risk losing your authorization. • For emergency operation, the STEP 7 basic package can also be used without

authorization. As well, there is also a 14 day limited authorization available in addition to the unlimited (in time) authorization.

STEP7 software updates can be downloaded from the Internet.

The main tool in STEP 7 is the SIMATIC Manager. There are two ways in which to activate it:

1. through the Task bar 4 Start - SIMATIC SIMATIC Manager or through

2. the icon "SIMATIC Manager" on the Windows Desktop.

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SIEMENS

STEP 7 Tools

NCM 57

CFC - Interconnect blocks Configure SIMATIC Workspace

5+7 Converting 55 Files

LAD, STL, FBD - Programming 57 Blocks Memory Card Parameter Assignment

Qp _{NetPro - Configuring Networks}

PID Control Parameter Assignment 57 SCL - Programming 57 Blocks

57-GRAPH - Programming Sequential Control Systems 57-PDIAG - Configuring Process Diagnostics

57-PLCSIM Simulating Modules Setting the PG-PC Interface TI 405-57 Converting TI Files

TI 505-57 Converting TI Files

57-HiGraph - Programming State Graphs STARTER

Date: 18.09.2009 File: SERV1_01E.23

SITRAIN Training for 41

°' Automation and Industrial Solutions

SIMATIC Manager Notes LAD, STL, FBD Memory Card Parameter Assignment. Configuring Networks Setting the PG-PC Interface PID Control Parameter Assignment Converting S5 Files Configure SIMATIC Workspace

The SIMATIC Manager manages the STEP 7 projects. It is the main program and also appears on the WINDOWS desktop.

"STEP 7 - Readme" provides detailed information about the version, installation procedure, etc.

Tool for writing STEP 7 user programs in the "Ladder Diagram", "Statement List" or "Function Block Diagram" programming languages.

You can save your user programs on EPROM cards by either using the programming device or an external prommer.

Different drivers are required, depending on the application.

Network configuration with the "NetPro" tool which belongs to the STEP 7 basic package.

This tool is used for setting the local node address, the transmission speed and the highest node address in the MPI network.

The basic STEP 7 software package also includes blocks for solving PID

(closed-loop) control problems. You choose "PID Control Parameter Assignment" to start the program for assigning parameters to the closed-loop control blocks. STEP5 programs can be converted into the corresponding STEP 7 programs with the help of the S5/S7 converter.

This option provides facilities for configuring multi-user systems.

Converting TI Files SIMATIC TI programs can be converted into the corresponding STEP 7 program

with the help of the TI/S7 converter.

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Options

Standard PID Control PRODAVE MPI Tele Service SIMATIC S7-300 STEP 7 _{S7- SCL} Fuzzy Control S7- HiGraph SIMATIC 57-400 11111 Modular PID

Control DOCPRO TeleService

STEP 7 Professional STEP 7

S7- PLCSIM S7- GRAPH

Which PLC?

Necessary

STEP 7 Micro/WIN SIMATIC S7-200 STEP 7 Lite ;11 SIMATIC S7-300 S7- PDIAG S7- PLCSIM S7- SCL S7- PLCSIM S7- GRAPH STEP 7 Micro License STEP 7 Professional

STEP 7 Software Packages (Examples)

Date: 18.09.2009 File: SERV1_01E.24

MP_{A SITRAIN}_{Training for}

U.111P. _{Automation and Industrial Solutions}

STEP 7

STEP 7 Lite

STEP 7 is the basic package for configuring SIMATIC S7-300 or S7-400 systems. With STEP 7 you can:

• configure hardware and assign parameters to it; • configure communication;

• program; • test and debug; • document and archive; • carry out diagnosis.

STEP 7 Lite can be used to program the SIMATIC S7-300 (also the compact CPUs). Programs that were created with STEP 7 Lite can also be exported to STEP 7.

It is not possible to carry out a PROFIBUS (DP) or ETHERNET configuration! ET200S or ET200X configuration (standalone) is possible.

PLCSIM and Teleservice can be used as option packages. STEP 7 Micro is suitable exclusively for configuring the S7-200.

With the exception of STEP Micro/Win, a license is required for each package. STEP 7 Professional is a Software Package that contains all IEC languages: STEP 7 Basic, S7-SCL, S7-GRAPH and the simulation package S7-PLCSIM. STEP 7 Professional is available as an upgrade package (Powerpack) for STEP7. Prerequisite for acquiring the powerpack is a valid STEP 7 license.

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SIMATIC S7 Date: 18.09.2009

File: SERV1_01E.25

11 SITRAIN Training for ‘r Automation and Industrial Solutions

If You Want to Know More about the Topic "TIA"

SIEMENS

Note The following pages contain either further information or are for reference to complete a topic.

For more indepth study we offer advanced courses and self-learning mediums.

(28)

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Die CPU 315-2 DP verfugi

• Mikroprozeseor.

der Prozessor erreicht eine Bearbeitungszeit von ca 100 ns je einaranweisung und 4 us le • 128 KByte Arbedsspeicher (entspncht Owe 43 KAnweisungen):

Der umfangreiche Arbeitsspeicher fOr ablaufrelevante Programmteile bietetAnwenderprog Cards (may 8 MByte) als Ladespetcner fur Programm ermoglichen zusatiich die Projektat Kommentaren) in der CPU und kOnnen zur Datenarchivierung und Rezepturverwaltung yew • Flexible Ausbaubarkeit;

max. 32 Baugruppen (Izeiliger Aufbau) • Mehrpunkffehige Schnittstelle

Die integrierle Schnittstelle MPI kann max_ 16 Verbindungen gleichzeitig zu 07-3001400 ode Von den Verbindungen ist jeweils eine kir PG und eine (Or OP fest reserwert. Mit der MPI ist Datenkommunikation" eine einfache Vernetzung mit max. 16 CPUs aufzubauen • PROFIBUS DP-Schnittstelle

Die CPU 315-2 DP mit PROFIBUS DP-MastertSlave-Schnittstelle ermeglicht einen dezentri Geschwindigkeit und einfacher Handhabung. Die dezentrale Periphene wird aus Anwende (gieiche Projeldierung, Adressierung und Programmierung).

Es wird die PROFIBUS DP V1-Norm vollstandig unterstutzt. Dies ermbglichtverbesserte Di V1-Normslaves.

• Passwortschutz,

Ein Passwortkonzept das Anwenderprogramm vor unberechtigtem Zugriff • Diagnose-Puffer;

Die letzten 100 Fehler- und Unterbrechungsereignisse werden zu Diagnosezwecken in ein • Wartungsfrete Datensicherung;

Date: 1 8.09.2009 File: SERV1_01E.26

Ur Automation and Industrial Solutions

Information Manual

Catalog

You will find more information on the SIMATIC systems in the items below. The manuals give detailed information on the hardware and software. In addition to the paper version, you can also use the electronic manuals. They are, in part, included in the installation or STEP 7.

You can download the most recent SIMATIC manuals free of charge from the

Internet.

A collection of electronic SIMATIC manuals (HW, SW, Engineering, HMI, NET, PG) can be ordered under the order number 6ES7 998-8XC01-8YE0.

The ST 70 catalog contains all SIMATIC components with their performance and

order data.

Electronic Catalog In addition to the paper version, the (CA01) catalog is also available as a CD. This

information is also available on the Internet (www.siemens.de/Simatic).

Siemens Partner Of course, your Siemens partner is also available for further information.

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SIEMENS

Programming Sequence Control Systems with S7- GRAPH

❑ S7-GRAPH: The tool for

programming sequence cascades o Compatible with DIN EN 6.1131-3 o Designed for the requirements of

production engineering

o Graphic division of the process into steps and transitions o Steps contain actions

o Transitions check the conditions for switching to the next step ij The following phases of

automation can be

optimized with S7-GRAPH:

— T4 S1 — T1 S2 S5 S6 — T5 T2 o Planning, Configuring o Programming o Debugging o Commissioning o Maintenance, Diagnostics S4 — T3

0

SIMATIC S7 Siemens AG 2008. AU rights reserved.

Date: 18.09.2009 File: SERV1_01E.27

2/1 SITRAIN Training for

ittr Automation and Industrial Solutions

S7-GRAPH With the S7-GRAPH programming language, you can clearly and quickly

configure and program sequential sequences that you wish to control with an S7 PLC system.

The process is thus split into single steps with their own function scope. The sequence is graphically displayed and can be documented with picture and text. The actions to be performed and the transitions, which control the conditions for switching to the next step, are determined in the individual steps. Their definitions, interlocking or monitoring are determined by a subset of the

STEP 7 programming language LAD (ladder diagram).

S7-GRAPH for S7-300/400 is compatible with the sequence language established in the DIN EN 61131-3 standard.

Functionality The following functions are offered:

• Several sequencers in the same S7-GRAPH function block • Free number assignment of the steps and transitions • Simultaneous branches and alternative branches • Jumps (also to other sequence cascades)

• Starting/Stopping of sequence cascades as well as activating/holding of steps.

Test Functions • Display of active steps or faulty steps

• Status display and Modify Variable

• Switching between the operating modes: manual, automatic and jogging mode

User Interface • Overview, Single Page and Single-step display

• Graphic separation of locking controls and monitoring conditions.

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The State Diagram Method S7- HiGraph

❑

S7-HiGraph: The tool for

programming using

State Diagrams

o Division of the machine into functional units

o Creating state diagrams for every function unit o States contain actions

o State diagrams communicate using messages

❑

The following phases of

automation can be

optimized with S7-HiGraph:

o Planning, Configuring

o Programming and Debugging o Commissioning

o Maintenance, Diagnostics o Supports reusability

Position

Cam-operated Index out switch Index in Index yt, Counterbearing lock/release Counterbearing Motor Coordinator Motor

111771=1

Date: 18.09.2009 File: SERV1_01E.28

SITRAIN Training for Automation and Industrial Solutions

Overview

Function Units

State Diagram

S7-Higraph allows the asynchronous processes to be described using state diagrams. The machine or system to be automated is looked upon as a combination of independent elements, the function units.

The function units are the smallest mechanical units of a machine or system. As a rule, a function unit is made up of mechanical and electrical basic elements. In programming, a state diagram is assigned to every function unit. In it, the functional, that is, the mechanical and electrical properties of the function unit are mapped.

The state diagram describes the dynamic behavior of a function unit. It describes the states that a function unit can have, as well as the state transitions. State diagrams can be used more than once. State diagrams that were created once for a specific function unit, can be reused in other program locations.

Diagram Groups By combining parallel running state diagrams, you can describe the complete and Instances functionality of a machine or system.

Advantages This "object-oriented" method of S7-HiGraph is well suited for: • the machine and system manufacturer (mechanical engineering) • the automation specialist (electrical engineering) as common means of

description

• the commissioning engineer and the maintenance specialist

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Programming in the High Level Language S7- SCL

o S7-SCL: High level language for

creating PLC programs

o Compatible with DIN EN 6.1131-3 (ST=Structured Text))

o Certified according to "PLC open" Base Level

o Contains all the typical elements of a high level language, such as operands, terms, control statements o PLC specifics are integrated,

such as I/O access, timers, counters...)

Advantages:

o Well structured, easy to understand program

o For those knowledgeable in high level languages

o For complex algorithms

FUNCTION BLOCK Integrator VAR INPUT

!nit : BOOL; // Reset output value x : REAL; // Input value

Ta : TIME; // Sampling interval in ms Ti : TIME; // Integration time in ms olim : REAL; // Output value upper limit ulim : REAL; // Output value lower limit END_VAR

VAR_OUTPUT

y : REAL:. 0.0; // Initialize output value with 0 END_VAR

BEGIN

IF TIME_TO_DINT(Ti) = 0 THEN // Division by ? OK := FALSE; y := 0.0; RETURN; END_IF; IF Init THEN y:= 0.0; ELSE y := y+TIME_TO_DINT(Ta)*x/TIME_TO_DINT(Ti); IF y > olim THEN y := olim; END_IF;

IF y < ulim THEN y := ulim; END_IF; END_IF;

END_FUNCTION_BLOCK SIEMENS

Date: 18.09.2009 File: SERV1_01E29

SITRAIN Training for ittr Automation and Industrial Solutions

Overview S7-SCL (Structured Control Language) is a PASCAL-similar high level text language for S7 - 300/400 and C7 and simplifies the programming in control technology for mathematical algorithms, data management and organization tasks.

S7-SCL has the PLC open Base Level certificate and is in accordance with the DIN EN 61131-3 (Structured Text) standard.

With S7-SCL, you can formulate time-saving and economical solutions for automation tasks.

Functionality SCL offers the functional scope of a high level language such as: • loops

• alternatives

• branch distributors, etc.

combined with control-specific functions such as:

• bit accesses to the I/O, bit memories, timers, counters etc. • access to the symbol table

• STEP7 block accesses

Advantages of SCL • simple to learn programming language especially for beginners

• easy to read (understandable) programs are generated.

• simpler programming of complex algorithms and processing of complex data structures

• integral debugger for symbolic debugging of the source code (single-step, breakpoints, etc.)

• system integration in S7 languages such as STL and LAD.

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CFC - Tool for Graphic Interconnection of S7 Blocks

❑ CFC (Continuous Function Chart):

Tool for graphic creation of PLC programs

o Blocks are placed on function charts and interconnected o Interconnection is

possible:

- between I/O fields - also to blocks in

other charts

o Sources and destinations 1,1 RIC

are managed in the — CO CIN

margins ❑ Advantages

o Program creation for technologists

o quick creation, testing and commissioning times

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Date: 18.09.2009

File: SERV1_01E.30 Automation Ta

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rial Solutions

Overview With the engineering tool CFC (Continuous Function Chart), you can create automation tasks by drawing a technology plan - similar to a Function Block Diagram in PLC programming.

In this graphic programming method, blocks are positioned in a type of drawing sheet and are graphically interconnected with one another. You can quickly and easily convert technological aspects into complete executable automation programs with CFC.

Scope The following is supplied with CFC: • CFC Editor

• Code Generator • Debugger

• Standard block libraries

Note The CFC product, as an option package, is smoothly integrated in the STEP 7

architecture with a unified Look & Feel and with common data management. CFC is easy to use, easy to learn and provides consistent data management.

The CFC tool plays an important role in the configuration of the PCS 7 process control system. Prerequisite is a previously installed SCL option package.

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❑

S7- PDIAG: Tool for configuring

the fault definition in STL, LAD, FBD

o Integrated in the development environment o Simple formulation of fault monitoring and

message texts (during and after the program session)

o Fault detection and criteria analysis are conducted automatically

o Comprehensive information for the operator on:

• type of fault • location of fault • cause of fault

❑

Reduction of down-time

Process Diagnosis with S7- PDIAG

❑

Process diagnosis: Detection of

faults occurring outside the PLC

o Sensor/actuator defective, movement faulty,

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)

Date: 18.09.2009 File: SERV1_01E.31

%;.

Process Diagnosis

S7-PDIAG

Diagnosis is important in the operating phase of a plant or machine. Diagnosis is usually initiated when a fault leads to standstill or malfunction of the plant or machine.

Programmable logic controllers are widely used in many areas. Field experience has proven that over 98% of faults occur in the peripherals (such as magnet valves and end switches). The distribution of fault occurrences makes it

meaningful for the diagnosis to focus on process faults, since missing messages or faulty functions lead to down-times and the resulting costs.

Process diagnosis diagnoses exactly these external components (such as sensors and actuators) or sequences in the process of a plant or machine. The S7-PDIAG software package enables a uniform configuration of the process diagnosis for the SIMATIC S7-300/400 controllers in the LAD, FBD and STL programming languages.

You can already define signal monitoring routines including first-up signal acquisition and criteria analysis and input the associated message texts while or after creating the user program in the LAD, FBD or STL programming languages. PDIAG automatically generates monitoring blocks which you must call in your user program.

At every call, the fault conditions are checked and in case of an error, the relevant process values are acquired and sent to the display device for the criteria

analysis.

For the configuration of the operator panel, S7-PDIAG stores the process diagnosis data in a shared database. This data can then be accessed by the OP configuration software WinCC flexible with the option package ProAgent and be made available for display on the operator panel.

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Testing User Programs with S7- PLCSIM

❑

S7-PLCSIM: Simulation software

for offline testing of PLC programs

o Functional program test

• on a simulated CPU • with display/modify

I/O

o Testing of user blocks in

• LAD, FBD, STL, S7-_SCL,

• S7-_{GRAPH, S7}-_{HiGraph, CFC}

• S7-PDIAG, WinCC

0

Advantages

o Faults can be detected early and eliminated o Many tests are already possible in the office

without the final hardware

SIMATIC S7

Date: 18.09.2009 SITRAIN Training for

S7 - PLCSIM The SIMATIC S7-PLCSIM engineering tool (option package) emulates a complete S7-CPU including addresses and I/O on a PG/PC.

S7-PLCSIM thus enables you to test a program offline on the PG/PC. All STEP 7

programming languages (STL, LAD, FBD, S7-Graph, S7-HiGraph, S7-_{SCL and}

CFC) can be used.

S7-PLCSIM allows you to check the functionality of user programs on the PC/PG, regardless of whether the final hardware is available or not.

Functionality S7-PLCSIM offers the following functions for running a program on a simulated PLC:

• An icon in the SIMATIC Manager'_{s toolbar switches the Simulation on or off.} If the simulation is turned on, every new connection is automatically made to the simulated PLC.

If the simulation is turned off, then every new connection is made to the "_real" _PLC.

• You can create view objects that allow you to access memory areas, accu

-mulators and tabs of the simulated CPU. You can modify and display all the data in these view objects.

• You can change the CPU'_{s operating mode (STOP, RUN and RUN-P) just}

as with a "real" CPU. The simulation also provides a "_{Pause" function that} allows you to halt the program execution without affecting the state of the program.

Advantages With S7-PLCSIM, you can detect faults early in the development phase and eliminate them. The quality of the user programs is greatly improved and the commissioning costs are lowered.

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Runtime Software for Closed-loop Control Engineering Tasks

Yes Closed-loop control m. Overview Confi- gura-tion tool PID Controller No Basic SW PID Control Yes Standard PID Control Yes Modular PID Control Yes Fuzzy Control Yes Neuro Systems Yes

Basic SW or option package S7-200 C7 Basic SW Basic SW Option Option Option Option S7-300 SIEMENS

Closed-loop In a closed-loop control system process variables are controlled in such a way

Control Engineering that they reach their new preset values as quickly as possible and that they

maintain these in spite of the effect of disturbances.

Basic Software The STEP 7 basic package already contains a series of function blocks for

PID Control solving simple control engineering tasks.

Standard This additional package contains blocks and a parameter assignment tool with

PID Control integrated control setting for standard tasks such as temperature controllers, flow rate regulators, pressure regulators etc.

Modular Through the interconnection of supplied standard function blocks, you can

PID Control implement just about every closed-loop control engineering structure, even in the upper performance range of process engineering.

The package contains 27 FBs and a commissioning tool.

Fuzzy Control Fuzzy Systems are used when the mathematic description of a process is difficult or even impossible, when a process behavior is not consistent, when non-linearities occur, but, on the other hand, experience with the process exists.

NeuroSystems Neuronal Systems are used with those problems, whose structure and solution are only partly known. NeuroSystems can be used in all automation levels, from the individual closed-loop controller to the optimization of a plant.

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Date: 18.09.2009 File: SERV1_01E.34

111_4T _{Automation and Industrial Solutions}

SIMATIC NET SIMATIC NET is the name of an entire family of networks.

• Industrial Ethernet according to IEEE 802.3 - the international standard for the networking of areas and cells

• PROFIBUS according to EN 50170 - the international standard for the field area and the cell network with a limited number of nodes

• AS-Interface - for communication with sensors and actuators.

Industrial Ethernet The Industrial Ethernet network is a cell level network according to the international standard IEEE 802.3 (Ethernet) and is designed for industrial use. Extensive open network solutions are possible. A high transmission rate is guaranteed with various transmission media. Industrial Ethernet is an industry standard, world-wide tested and accepted.

PROFINET PROFINET as the standard for communication applications in the field level enables the interfacing of distributed field devices through Industrial Ethernet with the TCP/IP protocol.

PROFIBUS PROFIBUS is the bus system for cell networks with a limited number of nodes. It is based on the European standard EN 50170, Volume 2, PROFIBUS. Since the requirements according to EN 50170 are fulfilled, PROFIBUS guarantees openness for the connection of components from other manufacturers that conform to standards. The PROFIBUS accessing procedure functions according to the "Token Passing with subordinate Master-Slave" procedure. As a result, a distinction is made between active and passive network participants.

AS - Interface The AS-Interface is a networking system for binary sensors and actuators in the field area. With AS-Interface, binary actuators and sensors become capable of communication, for which a direct field bus connection was not technically possible up until now or was not economical.

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Operator Control and Process Monitoring with SIMATIC HMI

Process visualization Process visualization

system system

SIMATIC WinCC SIMATIC WinCC flexible

SIMATIC PG, PC -41_E00101616W, SIMATIC Panels, PGs, PCs

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Date: 18.09.2009 File: SERV1_01E.35

SITRAIN Training for 1_{41 Automation and Industrial Solutions}

Overview For the SIMATIC S7, there is a field-proven HMI system for user-friendly process control and monitoring available, the SIMATIC HMI. It ranges from the simple text display to the process visualization system.

SIMATIC S7 and SIMATIC HMI are completely harmonized and integrated. This simplifies the use of the human-machine interface system SIMATIC HMI

considerably.

• SIMATIC S7 has already integrated HMI services. The HMI system requests process data from the SIMATIC S7. Data transmission between SIMATIC S7 and SIMATIC HMI is carried out by the two operating systems and does not have to be taken into account in the user program.

SIMATIC HMI systems can be connected directly to PPI (S7-200) and

MPI or PROFIBUS (S7-300 and S7-400). Operation using PROFIBUS makes process control and monitoring even over greater distances possible.

• Numerous features from the uniform database and symbols up to the same user-friendly Windows-oriented user interfaces simplify the use of HMI systems.

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/

Programming

Interfaces

Process Visualization and Operator Control with WinCC

/

Alarm Logging

(Message System)

/

Standard

Interfaces

/

Report Designer

/

PLC

(Report System)

Communication

Process visualization

Tag Logging

/

(Archiving)

WinCC

Function Modules

SIMATIC WinCC (Windows Control Center) is the open process visualization system from Siemens. It can be integrated problem free in a new or already existing PLC system.

The heart of SIMATIC WinCC is an industry and technology independent basic system with all the important functions for operator control and monitoring, such as:

• Pixel graphic display

• Measured value acquisition (archiving functions, data compression, minimum and maximum values etc.)

• Message display, archiving and reporting

• Process communication to different PLC systems • Standard interlaces, for example, Microsoft programs

• Documentation of machine and process sequences with individual reports. Basis of WinCC WinCC is based on the 32-bit standard operating systems Windows 2000/XP

from Mircrosoft. This platform gives WinCC the following functionality: • Use of the Windows operating equipment (such as printer and driver) • Data exchange with other Windows applications via DDE, ODBC, SQL,

OLE, ActiveX and OPC. • API programming interlace

• use of hardware available in the market